scholarly journals An Estimating the Effect of Process Parameters on Metal Removal Rate and Surface Roughness in WEDM of Composite Al6063/SiC/Al2O3 by Taguchi Method

2017 ◽  
Vol 67 (2) ◽  
pp. 25-36
Author(s):  
Prasad Raturi Himanshu ◽  
Prasad Lalta ◽  
Pokhriyal Mayank ◽  
Tirth Vineet
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Metal Matrix ◽  
Metal Removal ◽  
Removal Rate ◽  
Roughness Parameter ◽  
Base Material ◽  
Weight Fraction ◽  
Percentage Weight

AbstractThe present study was focused on the fabrication of metal matrix and hybrid metal matrix composites through stir casting process. The Aluminium 6063 was used as base material and SiC/Al2O3 were used as reinforcement with varying weight %. The parametric study on a wire-cut electro discharge machine was carried out by using Taguchi Method. A statistical analysis of variance (ANOVA) was performed to identify the process parameters that were statistically significant. It was observed that the MRR decreases with increase in the percentage weight fraction of SiC and Al2O3 particles in the MMCs and HMMCs. Whereas, the surface roughness parameter increases with increase in the percentage weight fraction of SiC and Al2O3 particles due to the hardness of MMCs and HMMCs composites.

Optimization of MRR and Surface Roughness of AlMg3 (AA5754) Alloy in CNC Lathe Machine by Using Taguchi Method

2018 ◽  
Vol 877 ◽  
pp. 110-117 ◽  
Author(s):  
Poornesh Kumar Chaturvedi ◽  
Harendra Kumar Narang ◽  
Atul Kumar Sahu
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Metal Removal ◽  
Removal Rate ◽  
Surface Condition ◽  
Point Of View ◽  
Depth Of Cut ◽  
Metal Removal Rate ◽  
Cnc Lathe ◽  
Lathe Machine

Quality of the product is the major concern in manufacturing industries from customers as well as producers point of view. There are number of factors in the product such as surface condition, height, weight, length, width etc., which may be consider for the measurement of the quality. Surface roughness and Metal Removal Rate (MRR) are the two main outcomes on which numerous researchers have applied different approaches for several years to get optimum results. In this study, Taguchi Method is applied for getting optimum parameters settings for Surface roughness and Metal Removal Rate (MRR) in case of turning AlMg3 (AA5754) in CNC Lathe machine, which is an aluminum alloy having diameter 20 mm and length 100 mm. The three parameters i.e. spindle speed, feed rate and depth of cut with 3 levels are taken as the process variables and the working ranges of these parameters for conducting experiments are selected based on Taguchi’s L9 Orthogonal Array (OA) design. To analyze the significant process parameters; main effect plots for data means and for S/N ratio are generated using Minitab statistical software.

scholarly journals Optimization of Process Parameters in CNC Turning of Aluminum 7075 Alloy Using L27 Array-Based Taguchi Method

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4470
Author(s):  
Mohammad Nishat Akhtar ◽  
T. Sathish ◽  
V. Mohanavel ◽  
Asif Afzal ◽  
K. Arul ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
Metal Removal ◽  
Removal Rate ◽  
Numerical Control ◽  
Cnc Machine ◽  
Machined Surface ◽  
Aluminum 7075 ◽  
7075 Alloy

With the advent of the industrial revolution 4.0, the goal of the manufacturing industry is to produce a large number of products in relatively less time. This study applies the Taguchi L27 orthogonal array methodological paradigm along with response surface design. This work optimizes the process parameters in the turning of Aluminum Alloy 7075 using a Computer Numerical Control (CNC) machine. The optimal parameters influenced the rate of metal removal, the roughness of the machined surface, and the force of cutting. This experimental investigation deals with the optimization of speed (800 rpm, 1200 rpm, and 1600 rpm) and feed (0.15, 0.20, and 0.25 mm/rev) in addition to cutting depth (1.0, 1.5, and 2.0 mm) on the turning of Aluminum 7075 alloy in a CNC machine. The outcome in terms of results such as the removal rate of material (maximum), roughness on the machined surface (minimum), along with cutting force (least amount) were improved by the L27 array Taguchi method. There were 27 specimens of Al7075 alloy produced as per the array, and the corresponding responses were measured with the help of various direct contact and indirect contact sensors. Results were concluded all the way through diagrams of main effects in favor of signal-to-noise ratios and diagrams of surfaces with contour diagrams for various combinations of responses.

Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel

2018 ◽  
Vol 28 ◽  
pp. 55-66 ◽  
Author(s):  
Kuldeep Singh ◽  
Khushdeep Goyal ◽  
Deepak Kumar Goyal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Tool Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time

In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

Experimental investigation of machinability characteristics in Al-TiB2 metal matrix composite (MMC) based on the Taguchi method with fuzzy logics

2016 ◽  
Vol 12 (1) ◽  
pp. 177-193 ◽  
Author(s):  
M.P. Jenarthanan ◽  
A. Ram Prakash ◽  
R. Jeyapaul
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Taguchi Method ◽  
Metal Matrix ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fuzzy Logics ◽  
Content Type ◽  
Five Factors

Purpose – The purpose of this paper is to develop a mathematical model for metal removal rate and surface roughness through Taguchi method and analyse the influence of the individual input machining parameters (cutting speed, feed rate, helix angle, depth of cut and wt% on the responses in milling of aluminium-titanium diboride metal matrix composite (MMC) with solid carbide end mill cutter coated with nano-crystals. Design/methodology/approach – Taguchi OA is used to optimise the material removal rate (MRR) and Surface Roughness by developing a mathematical model. End Milling is used to create slots by combining various input parameters. Five factors, three-level Taguchi method is employed to carry out the experimental investigation. Fuzzy logic is used to find the optimal cutting factors for surface roughness (Ra) and MRR. The factors considered were weight percentage of TiB2, cutting speed, depth of cut and feed rate. The plan for the experiments and analysis was based on the Taguchi L27 orthogonal array with five factors and three levels. MINITAB 17 software is used for regression, S/N ratio and analysis of variance. MATLAB 7.10.0 is used to perform the fuzzy logics systems. Findings – Using fuzzy logics, multi-response performance index is generated, with which the authors can identify the correct combination of input parameters to get higher MRR and lower surface roughness value with the chosen range with 95 per cent confidence intervals. Using such a model, remarkable savings in time and cost can be obtained. Originality/value – Machinability characteristics in Al-TiB2 MMC based on the Taguchi method with fuzzy logic has not been analysed previously.

scholarly journals Effects of Electrical Parameters during Non conventional Machining of Al/Sic Metal Matrix Composites by Electrical Discharge Machine

2021 ◽  
Vol 23 (07) ◽  
pp. 690-699
Author(s):  
Laxman Laxman ◽  
◽  
Dr. Kishan Lal ◽  
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Metal Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Weight Ratio ◽  
High Hardness ◽  
Weight Fraction ◽  
Dielectric Fluid ◽  
Matrix Composites

Particulate Reinforced Al/SiC Metal Matrix Composites (PRALSICMMC) is gradually becoming very important materials in manufacturing industries e.g. aerospace, automotive, and automobile industries due to their superior properties such as lightweight, low density, high strength to weight ratio, high hardness, high temperature, and thermal shock resistance, superior wear and corrosive resistance, high specific modulus, high fatigue strength, etc. In this study aluminum (Al- 6063)/SiC Silicon carbide reinforced particles metal-matrix composites (MMCs) are fabricated by melt-stirring technique. The MMCs bars and circular plates are prepared with varying the reinforced particles of SiC by weight fraction ranging from 5%, 10%, 15%, and 20%. The average reinforced particles sizes of SiC are 220 mesh, 300 mesh, and 400 mesh respectively. The stirring process is carried out at 150 revs/min rotating speed by graphite impeller for 15 min. A series of machining tests are performed on EDM. Copper electrodes are used as tools (cathode), Prepared specimens of Al/SiC MMCs are used as workpiece (anode) and kerosene is used as the dielectric fluid. The Performance parameters measured during experimentation were Tool Wear Rate (g/min), Metal Removal Rate (g/min), Over Cut on diameter (mm), and Average Surface Roughness Ra (μm) for each experiment by varying Pulse Peak Current IP (2 Amp, 6 Amp, 10 Amp,14 Amp) and gap voltage Vg ( 25 Volts, 30 Volts, 35 Volts, and 40 Volts). The investigations of results are done graphically.

scholarly journals Investigation and optimization of the electro-discharge machining parameters of 2024 aluminum alloy and Al/7.5% Al2O3 particulate-reinforced metal matrix composite

2018 ◽  
Vol 25 (1) ◽  
pp. 159-172 ◽  
Author(s):  
Saeed Daneshmand ◽  
Behnam Masoudi
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Electro Discharge Machining ◽  
Pulse Off Time ◽  
Off Time

AbstractBeing newly advanced materials, metal matrix composites enjoy the properties of high service temperature, light weight, high specific strength, good wear resistance, high stiffness, and a low thermal expansion coefficient. However, machining these materials by conventional methods is difficult. A key machining process for difficult-to-machine materials like composites is electro-discharge machining, which is widely used in non-conventional material removal processes. The current work aims to identify different parameters, such as voltage, current, pulse on-time, and pulse off-time, which influence the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). By applying regression equations, a mathematical model is adopted to estimate MRR, TWR, and SR. The optimum machining parameters are investigated using the Taguchi method with L9 orthogonal array. The optimum values are also analyzed by multi-objective Taguchi method with calculation of total normalized quality loss (TNQL) and multi-signal to noise ratio (MSNR) included. Analysis of the Taguchi method introduced voltage and pulse off-time as the two main significant factors that influence the value of the material removal rate. The discharge current and pulse off-time also have a statistically significant impact on both tool wear rate and surface roughness.

Experimental Investigation during Micro-Milling of Hybrid Al6063 MMC Reinforced with SiC and ZrO2

2019 ◽  
Vol 33 ◽  
pp. 1-9
Author(s):  
P. Tripathy ◽  
K.P. Maity
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Micro Milling

The experimental investigation of process characteristics while performing micro-milling on hybrid aluminium metal matrix composite is discussed in this article. High Speed Steel micro end mill cutters are used for machining of micro-slots on Al6063 metal matrix composite reinforced with zirconia and silicon carbide. The tools are also treated cryogenically at -196°C using liquid nitrogen with a holding time of 24 hours. For this investigation, machining parameters like feed rate, cutting speed and depth of cut are considered as the process parameters. The effect of the process parameters on the material removal rate and surface roughness for hybrid metal matrix composite are analyzed. In addition, tools wear for untreated and cryo-treated single tempered tools are also investigated. The output responses i.e., material removal rate and surface roughness of cryo-treated tools exhibit better results than untreated tool due to increase in strength, hardness and wear resistance.

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