Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Surface Integrity Studies in Ball End Milling of Thin Shaped Cantilever Inconel 718

2014 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Raju S. Pawade
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
Surface Defects ◽  
End Milling ◽  
Surface Region ◽  
Lower Surface ◽  
Machined Surface ◽  
Ball End Milling ◽  
Integrity Analysis

The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever plate of Inconel 718. It is noticed that the workpiece deflection has significantly contributed to machined surface integrity in terms of surface topography and subsurface microhardness. The ball end milling performed with 15° workpiece inclination with horizontal tool path produced higher surface integrity which varies with the location of machined surface region. In general, the mid portion of the machined plate shows lower surface roughness and microhardness with less surface defects.

Surface Roughness Prediction in End Milling of Machinable Glass Ceramic and Optimization by Response Surface Methodology

2011 ◽  
Vol 189-193 ◽  
pp. 1376-1381
Author(s):  
Moola Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou El Hossein
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Glass Ceramic ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Speed ◽  
Lower Surface ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents the prediction of a statistically analyzed model for the surface roughness,R_a of end-milled Machinable glass ceramic (MGC). Response Surface Methodology (RSM) is used to construct the models based on 3-factorial Box-Behnken Design (BBD). It is found that cutting speed is the most significant factor contributing to the surface roughness value followed by the depth of cut and feed rate. The surface roughness value decreases for higher cutting speed along with lower feed and depth of cut. Additionally, the process optimization has also been done in terms of material removal rate (MRR) to the model’s response. Ideal combinations of machining parameters are then suggested for common goal to achieve lower surface roughness value and higher MRR.

Surface quality analysis in ball end milling of Inconel 718 cantilevers by response surface methodology

2016 ◽  
Vol 231 (4) ◽  
pp. 628-640 ◽  
Author(s):  
Nandkumar N Bhopale ◽  
Raju S Pawade ◽  
Suhas S Joshi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Machining Parameters ◽  
Machined Surface ◽  
Ball End Milling ◽  
Fixed End ◽  
Side Flow

The ball end milling process is commonly used for generating complex three-dimensional sculptured surfaces with definite curvature. In such cases, variation of surface properties along with the machined surface is not well understood. Therefore, this article investigates the effect of machining parameters on the quality of surface in ball end milling of thin-shaped cantilever of Inconel 718. A distinct variation is also observed in the measured values of deflection of workpiece: surface roughness and surface damage in different regions, that is, fixed end, mid portion and free end of machined surface. The experiments were conducted according to the central composite design with four factors, namely, cutting speed, feed, workpiece thickness and workpiece inclination with tool path orientation. It is observed that the process parameters have statistically significant effect on machined surface of Inconel 718. Horizontal tool path condition during milling is most favourable in all aspects of surface quality with high speed and lower feed. The surface roughness values at the fixed end of plate are less as compared with that of mid portion and free end sides. Scanning electron microscope images show various defects such as side flow, smeared layer, microparticle, grooves and feed marks.

Optimization of Cutting Parameters during Turning of AISI-310 Using Response Surface Methodology

2016 ◽  
Vol 854 ◽  
pp. 45-51
Author(s):  
S. Nandhakumar ◽  
R. Vijayakumar ◽  
Senthil Padmavathy ◽  
N. Nagasundaram
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Feed Rate ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Parameters Optimization ◽  
Depth Of Cut ◽  
Optimization Of Cutting Parameters

Design of Experiments is employed to study the stimulus of cutting parameters such as feed rate, spindle speed, depth of cut in the turning operation of AISI-310 and optimizing the value of those parameters for getting the higher material removal rate (MRR) and minimal surface roughness. A prediction model has been developed by using the above influencing parameters. For the purpose of parameters optimization we investigate the parameters using Response Surface Methodology (RSM). It is shown that feed rate is the main parameter in influencing the surface roughness, which is being followed by spindle speed and depth of cut. It is found that surface roughness and feed rate were directly proportional to each other for some extent. The confirmation tests were carried out to with the optimum set of parameters and are verified with test results. The comparison of above two results were found to be good with maximum error within 5% on comparing it with the predicted model.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

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