scholarly journals OPTIMIZATION OF VARIABEL HELIX ANGLE PARAMETERS IN CNC MILLING OF CHATTER AND SURFACE ROUGHNES USING TAGUCHI METHOD

2021 ◽  
Vol 9 (1) ◽  
pp. 35-44
Author(s):  
Festo Andre Hardinsi ◽  
◽  
Oyong Novareza ◽  
Achmad As'ad Sonief
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Feed Rate ◽  
Helix Angle ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Excited Vibration ◽  
Optimal Value ◽  
Variable Helix

In the manufacturing industries, the main problem in process of operating CNC milling machine was chatter effect (self-excited vibration) which increases the quality of the surface roughness. In this study is to determine optimal value of parameters for chatter and surface roughness. The chatter measured using accelerometer MPU-6050 with Arduino by software LabVIEW-2019 based on peaks-FFT value and the surface roughness measured by SJ-301 tester. The research parameters like variable helix angle, spindle speed, feed rate, and depth of cut using stainless steel 304 by Taguchi method. The optimum parameters value obtained are variable helix 35/38 degrees, spindle speed 3000 RPM, feed rate 150 mm/min and depth of cut 0.4 mm. Based on ANOVA value, the variable helix angle and depth of cut are found to be significant for chatter and surface roughness. The depth of cut was high contribution by ANOVA chatter by 93.84% and surface roughness by 91.93%.

scholarly journals Pengaruh Geometri Pahat Variabel Helix Angle Pada Parameter Mesin Cnc Milling Vertikal Berbasis Mikrokontroler Terhadap Nilai Getaran Chatter

2020 ◽  
Vol 1 (2) ◽  
pp. 62-71
Author(s):  
Festo Andre Hardinsi ◽  
Oyong Novareza ◽  
Achmad As’ad Sonief
Keyword(s):  
Feed Rate ◽  
Helix Angle ◽  
Machining Process ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Chatter Vibration ◽  
Vibration Acceleration ◽  
Slot Milling ◽  
Excited Vibration ◽  
Variable Helix

Abstrak Objektif. Getaran yang sering terjadi pada pengerjaan proses produksi menggunakan permesinan CNC milling merupakan hal yang sangat penting untuk diperhitungkan. Getaran ini dapat menyebabkan perubahan dimensi dan mempengaruhi tingkat kualitas benda kerja yang dihasilkan, sehingga efek getaran chatter atau self-excited vibration  pada proses pengerjaan produksi menjadi masalah utama dalam proses permesinan milling. Nilai getaran chatter ditentukan menggunakan grafik SLD secara ekperimental untuk mengetahui batas antara chatter free dan chatter occurs. Material and Metode. Material yang digunakan dalam penelitian ini adalah Stanless steel 304, dengan menggunakan sensor MPU 6050 yang terhubung pada mikrokontroler Arduino Uno menggunakan software LabVIEW 2019 student edition yang digunakan untuk mengidentifikasi nilai acceleration getaran chatter. Besar nilai acceleration diukur menggunakan FFT menggunakan software DIAdem 2019 student. Metode yang digunakan dalam penelitian ini adalah dalam bentuk eksperimental, dengan geometri pahat Variabel Helix Angle (VHA) 2 variasi sudut yaitu 40/42 (Derajat), Spindel Speed sebesar 2000,2500,3000 (RPM) , Axial Depth Of Cut sebesar 0.5, 1.0, 1.5 (mm), dan Feed Rate sebesar 100, 125 dan 150 (mm/s). Hasil. Hasil pada Grafik Stability Lobe Diagram yang didapatkan pada proses permesinan slot milling menggunakan pahat variable helix angle 40/42 derajat dengan feed rate 150 mm/mnt memiliki  chatter free yang lebih tinggi dibandingkan dengan feed rate 100 dan 125 mm/mnt. Kesimpulan.  Dari hasil yang didapatkan bahwa semakin tinggi nilai feed rate maka nilai acceleration getaran chatter semakin rendah. Untuk pengembangan dalam penelitian selanjutkan maka perlu dilakukan pemilihan parameter geometri pahat dengan variasi 3 sudut mata pahat untuk mengetahui nilai getaran chatter yang signifikan. Abstrack Objective.Vibration that often occurs in the production process using CNC milling is very important to be taken into account. This is vibration can cause dimensional changes and affect the level of quality of the workpiece produced. Therefore, effect of chatter vibration or self-excited vibration on production process becomes a major problem in the milling machining process. Chatter vibration values ​​can be determined using experimental SLD for determine boundary between free chatter and chatter occur. Materials and Methods .The material used in this study is stanless steel 304, using the MPU 6050 sensor connected to Arduino Uno mikrokontroler using LabVIEW 2019 student edition software that is used to identify chatter vibration acceleration. Acceleration is measured using FFT using  2019 student DIAdem software. The method used is experimental, geometry Variable Helix Angle 2 angular 40/42 (Degrees), Spindel Speed ​​of 2000,2500,3000 (RPM), Axial Depth Of Cut of 0.5, 1.0, 1.5 (mm), and Feed Rate of 100, 125 and 150 (mm / s). Results. Results in the Graph Lobe Stability Diagram obtained in  slot milling machining process using a variable helix angle of 40/42 degrees with  feed rate of 150 mm / min have higher chatter free compared to feed rates of 100 and 125 mm / min. Conclusion. The results show that  higher the value of  feed rate, chatter vibration acceleration value is lower. For further development in research, it is necessary to select  tool geometry parameters with variations of 3 tool eye angle to determine  chatter vibration significant

scholarly journals Sustainable Manufacturing and Parametric Analysis of Mild Steel Grade 60 by Deploying CNC Milling Machine and Taguchi Method

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1303
Author(s):  
Shakir Azim ◽  
Sahar Noor ◽  
Qazi Salman Khalid ◽  
Aqib Mashood Khan ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Feed Rate ◽  
Sustainable Manufacturing ◽  
Steel Grade ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine

Design and manufacturing are the key steps in the sustainable manufacturing of any product to be produced. Within the perspective of injection molds production, increased competitiveness and repeated changes in the design require a complete optimized manufacturing process. Local and minor improvements in the milling process do not generally lead to an optimized manufacturing process. The goal of the new geometry and parametric analysis of the mould is to reduce the quality issues in mild steel grade 60. In this explicit research, the surface roughness (smoothness) of indigenously produced injection moulds in the local market in Pakistan is investigated. The CNC milling machine (five-axis) is used for the manufacturing of an injection mould, and the Taguchi method of the design of the experiment is applied for parameters optimization. Hence, the overall process is assisted in balancing the milling machine parameters to trim down the surface roughness issue in mild steel moulds and increase their sustainability. The spindle speed (rpm), the depth of cut (mm), and the feed rate (mm/rev) are considered as input variables for process optimization, and the experiments are performed on mild steel grade 60. It is deduced that the combination of a spindle speed of 800 rpm, feed rate of 10 mm/rev and depth of cut of 0.5 mm is the best case in case of minimum surface roughness, which leads to sustainable products. It is also deduced from ANOVA, that the spindle speed is a factor that affects the surface roughness of mild steel products, while the feed rate turns out to be insignificant.

Rapid and Versatile Micromold Fabrication Using Micromilling and Nanopolishing for Microfluidic Devices

2019 ◽  
Author(s):  
Thanh-Qua Nguyen ◽  
Jeongmin Mah ◽  
Woo-Tae Park ◽  
Sangyoup Lee
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Surface ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Milling ◽  
Tool Marks ◽  
Mold Fabrication

Abstract In an effort to make microfluidic research more attractive and cost-effective, micromilled polymethyl methacrylate (PMMA) has gained interests as an alternative method to the conventional cleanroom-based micromolds fabrication technologies. The most enabling aspects of micromilling are flexibility on the design changes and the ability to fabricate three-dimensional structures. However, the major drawback of micromilling based micromold fabrication is the presence of burrs and tool marks on the surface after machining. High surface roughness on replicated polymer results in poor bonding strength and optical clarity. The roughness of micromilled surface strongly depends on the machining parameters such as tool size, spindle speed, feed rate, width of cut, and depth of cut. Thus, it is crucial to optimize the machining parameters to obtain a good surface finish. Although the optimal fabrication parameters are used to machine the micromold, the surface roughness of micromilled mold is still relative high compared to the surface of unprocessed PMMA. In this paper, we first optimize the micromilling parameters of Computer Numerical Control (CNC) milling machine to achieve the best possible of surface roughness. We have optimized the machining parameters for a flat endmill with 100 μm, 200 μm, and 400 μm in diameter of spindle speed, feed rate, width of cut, and the depth of cut respectively at 18000 rpm, 20 mm/min, 30 μm, and 20 μm. Then, a method to polish the structured surface of the micromilled mold was developed using the rotary magnetic field. By modifying the CNC program language G-code, we were able to control the polishing path, polishing force and time precisely. Consequently, the burrs and tool marks are completely removed, such that the roughness of the surface is decreased from 350 nm Ra to 30 nm Ra, and 1200 nm Rz to 300 nm Rz while the profile of microstructures is not deteriorated. Finally, we demonstrate our mold fabrication scheme by building a microfluidic immunoassay device with four Quake’s valves and showed the sequential assay process successfully.

scholarly journals Study The Effect of Process Parameters of CNC Milling Surface Generation Using Al-alloy 7024

2019 ◽  
Vol 12 (3) ◽  
pp. 103-112
Author(s):  
Nareen Hafidh Obaeed
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Surface Finish ◽  
Feed Rate ◽  
Spindle Speed ◽  
Surface Generation ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Cnc Milling ◽  
Tool Diameter

A wonderful unique research developments in modeling surface roughness and optimization of the predominant parameters to get a surface finish of desired level since only suitable selection of cutting parameters can get a better surface finish, so the objective of this work is to study the milling process parameters which include tool diameter, feed rate, spindle speed, and depth of cut resulting in optimal values of the surface roughness during machining AL-alloy 7024. The machining operation implemented on XK7124 3-axis CNC milling machine. The effects of the selected parameters on the chosen characteristics have been accomplished using Taguchi’s parameter design approach. The parameters considered are – depth of cut with two levels (0.2, 0.5 mm), tool diameter with two levels (6, 8 mm), spindle speed with two levels (1000, 2500 rpm), and finally feed rate with two levels (200, 500 mm/min). Analysis of the results showed that the optimal settings for low values of surface roughness are large tool diameter (8 mm), high spindle speed (2500 r.p.m), low feed rate (200 mm/min) and high depth of cut (0.5 mm). Response Table for mean of surface roughness showed that tool diameter has the most effected factors (rank one) followed by feed rate (rank two) then depth of cut which is the third effected factors and finally spindle speed with the less effected factors of surface roughness (rank four).

The Optimization in Machining AISI 1030 Using Taguchi Method for Dry and Flood Cutting Condition

2013 ◽  
Vol 315 ◽  
pp. 841-845
Author(s):  
Noor Hakim Rafai ◽  
Mohd Hilmi Othman ◽  
Sulaiman Hasan ◽  
Tharmaah Rao A/L Sinnasalam
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Feed Rate ◽  
Cutting Speed ◽  
Lower Surface ◽  
Quality Characteristic ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Cnc Milling ◽  
Dry Cutting

This research is an approach to investigate the effect of cutting condition on surface roughness in dry and flood cutting of AISI 1030. The objectives of this project are to compare the plastic injection mould quality between dry and flood cutting condition, as well as to determine the best cutting condition. The parameters used were depth of cut (0.25mm, 0.5mm, and 1.0mm), feed rate (50mm/rev, 100mm/rev and 150mm/rev) and cutting speed (700m/min, 1400m/min and 2100m/min). Surface roughness value was used to determine to quality characteristic of the machined mould. The experiments were done using Mazak CNC milling machine and the material selected was AISI 1030, which is a medium tensile and low hardenability carbon steel. Twenty-seven runs were done in both dry and flood cutting, adapting Taguchi Method - Orthogonal Array. After each machining, the surface roughness was measured using Mitutoyo Surface Roughness Tester. The data obtained was then analyzed through Signal to Noise Ratio calculation. This analysis produced the best combination of parameters which gives the lowest surface roughness. The best combinations for dry cutting are 2100m/min for cutting speed, 50mm/rev for feed rate and 0.25mmfor depth of cut. As for flood cutting, the best combinations are 2100m/min for cutting speed, 50mm/rev for feed rate and 1.0mm for depth of cut. The surface roughness obtained using this parameter in dry cutting is 0.27Ám and 0.40Ám in flood cutting. From the comparison, it is proved that dry cutting produced lower surface roughness compared to flood cutting.

Prediction of Surface Roughness and Optimization of Cutting Parameters in CNC Turning of Rotational Features

2020 ◽  
Vol 38 (8A) ◽  
pp. 1143-1153
Author(s):  
Yousif K. Shounia ◽  
Tahseen F. Abbas ◽  
Raed R. Shwaish
Keyword(s):  
Surface Roughness ◽  
Linear Regression ◽  
Regression Model ◽  
Linear Regression Model ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Non Linear ◽  
Optimization Of Cutting Parameters

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

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

scholarly journals Penerapan Metode Taguchi untuk Optimasi Setting Parameter CNC Milling Terhadap Kekasaran Permukaan Material

2020 ◽  
Vol 2 (2) ◽  
pp. 49-60
Author(s):  
Farizi Rachman Farizi Rachman ◽  
Bayu Wiro K ◽  
Tri Andi Setiawan ◽  
Pradita Nurkholies
Keyword(s):  
Feed Rate ◽  
Base Plate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
End Mill

Industri manufaktur di Indonesia semakin meningkat seiring dengan tingkat kebutuhan manusia yang beraneka ragam dan memicu berkembangnya teknologi, salah satunya industri proses permesinan atau machining. Kualitas produk yang baik dapat dilihat dari tingkat kekasaran permukaannya karena kekasaran permukaan dapat mempengaruhi performa yang berkaitan dengan aspek fungsional dari produk. Pada penelitian ini telah dilakukan optimasi setting parameter CNC milling terhadap kekasaran permukaan pada material S50C dengan end mill HSS diameter 8 mm. Material S50C banyak digunakan dalam manufaktur mesin seperti mekanis base plate, roda gigi, standart punch head dan komponen mesin lainnya. Penelitian ini menggunakan metode Taguchi. Parameter yang digunakan yaitu spindle speed, Feed rate dan depth of cut dengan cairan pendingin sebagai variabel konstan. Parameter optimum untuk mendapatkan nillai kekasaran yang rendah yaitu spindle speed 1100 rpm, feed rate 46 mm/min dan depth of cut 0.5 mm. Dengan taraf signifikansi 0.1 menunjukkan bahwa spindle speed berpengaruh secara signifikan dengan kontribusi 38.42% diikuti feed rate dengan kontribusi 34.16%.

A Study on Edge Milling Operation of NEMA G11 GFRP Composites Based on Grey-Taguchi Method

2014 ◽  
Vol 592-594 ◽  
pp. 18-22
Author(s):  
Hari Vasudevan ◽  
Ramesh Rajguru ◽  
Naresh Deshpande
Keyword(s):  
Taguchi Method ◽  
Feed Rate ◽  
Spindle Speed ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Milling Parameters ◽  
Response Table ◽  
Milling Operation ◽  
Grey Relational

Milling is one of the most practical machining processes for removing excess material to produce high quality surfaces. However, milling of composite materials is a rather complex task, owing to its heterogeneity and poor surface finish, which includes fibre pullout, matrix delamination, sub-surface damage and matrix polymer interface failure. In this study, an attempt has been made to optimize milling parameters with multiple performance characteristics in the edge milling operation, based on the Grey Relational Analysis coupled with Taguchi method. Taguchi’s L18 orthogonal array was used for the milling experiment. Milling parameters such as milling strategy, spindle speed, feed rate and depth of cut are optimised along with multiple performance characteristics, such as machining forces and delamination. Response table of grey relational grade for four process parameters is used for the analysis to produce the best output; the optimal combination of the parameters. From the response table of the average GRG, it is found that the largest value of the GRG is for down milling, spindle speed of 1000 rpm, feed rate of 150 mm/min and depth of cut 0.4 mm.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

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