scholarly journals Experimental Investigation on Surface Roughness and Metal Removal Rate of Aluminium 2024 Alloy

2021 ◽  
Vol 9 (9) ◽  
pp. 1424-1429
Author(s):  
Dr. V. S. Srinivasa Murthy
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Xrd Analysis ◽  
Milling Machine ◽  
Cnc Milling ◽  
Sintering Process ◽  
Dimensional Changes ◽  
Cnc Milling Machine ◽  
2024 Alloy

Abstract: The purpose of this work is to investigate experimentally the surface roughness and MRR while machining of aluminium 2024 alloy which is prepared by powder metallurgical technique. Aluminium 2024 alloy prepared with different composition such as Pure Al, 1.5 W% of Mg and 2-6 % of Cu powders. Powders are blended with ball milling machine according to the composition required and specimens are prepared in square shape die (25*25mm) by applying uniaxial load of 200Mpa. The sintering process was performed at 594 0C for 60 min and cooled at room temperature. SEM and XRD analysis was carried out to know various characteristics like green density, dimensional changes during sintering, sintering density, mechanical properties and microstructures. Finally the Surface roughness and MRR during machining with CNC milling machine at different depth of cuts was also evaluated. Keywords: Aluminium 2024 alloy, surface roughness, MRR, SEM and XRD analysis

scholarly journals Optimizing the Process Parameters of Drilling on Aluminium Alloy 7075 using taguchi and Anova Techniques

2020 ◽  
Vol 9 (3) ◽  
pp. 2460-2464
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Machining Operations

In many material processing and manufacturing industries quality and productivity are two important requirements but these are more antithetical criteria in any machining operations. So, it is vital to optimize the productivity and quality simultaneously. The main objective of this paper is to optimize the process parameters of drilling operations such as cutting speed, feed, and point angle on aluminum alloy 7075. Al 7075 is one of the multifunctional materials in various applications. Taguchi is mostly used for data analysis and optimization of process parameters for getting maximum material removal rate and least surface roughness factor. Machining operations were conducted on CNC milling machine. The number of drilling experiments was performed on aluminum 7075 using HSS drill bit on CNC milling machine. The investigation of variance (ANOVA) was engaged to find the most notable control factors affecting the material removal rate & surface roughness. The conclusions of present work were drawn from several experimental trails; it was found that at the 9th experimental trail, point angle was most significant x factor for surface roughness and feed is the most affecting factor for material removal rate.

Application of Taguchi and Response Surface Methodologies for Surface Roughness in Rotary Tool Polishing Hardness Mould Steels

2011 ◽  
Vol 87 ◽  
pp. 82-89
Author(s):  
Potejanasak Potejana ◽  
Chakthong Thongchattu
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Laser Scanning ◽  
Cutting Speed ◽  
Optimal Level ◽  
Confocal Laser ◽  
Milling Machine ◽  
Cnc Milling ◽  
Polishing Process ◽  
Cnc Milling Machine

This research proposes a new application of 3-axis CNC milling machine for polishing the 60 HRC hardness steels. The rotary polishing tools are designed by refer to the end-mill ball nose’s design. The diamond powder are coated in rotary polishing tools by resinoid bonding method and concentrated in 4.4 karat/cm2. The Zig-milling tool paths are used to polish the hardness steel. After polishing, the confocal laser scanning microscope is used to analyze the arithmetic mean surface roughness of the hardness steels. The L12 orthogonal array of the Taguchi’s method is selected to conduct the matrix experiment to determine the optimal polishing process parameters. The diamond grit size and cutting speed of the rotary polishing tools, feed rate and step over of the tool path, the depth of polishing process penetration, and polishing time are used to study. The combination of the optimal level for each factor of the hardness steel polishing process are used to study again in the confirmation experiment. The predicted signal to noise ratio of smaller - the better under optimal condition are calculated by using the data from the experiment. The combination of the optimal level for each factor are used to study again in the confirmation experiment and the result show that polishing time was a dominant parameter for the surface roughness and the next was depth of penetration. The response surface design is then used to build the relationship between the input parameters and output responses. The experimental results show that the integrated approach does indeed find the optimal parameters that result in very good output responses in the rotary polishing tools polished hardness mould steel using CNC milling machine. The mean surface roughness of hardness steel polishing process is improved by the diamond rotary tools with the 3-axis CNC milling machine.

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.

Optimizing the Machining Parameters in Glass Grinding Operation on the CNC Milling Machine for Best Surface Roughness

2010 ◽  
Vol 154-155 ◽  
pp. 721-726 ◽  
Author(s):  
Mohd Sayuti ◽  
Ahmed Aly Diaa Mohammed Sarhan ◽  
Mohd Hamdi Bin Abd Shukor
Keyword(s):  
Surface Roughness ◽  
Machining Process ◽  
Depth Of Cut ◽  
Response Analysis ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Cnc Milling Machine ◽  
Tool Diameter

Glass is one of the most difficult materials to be machined due to its brittle nature and unique structure such that the fracture is often occurred during machining and the surface finish produced is often poor. CNC milling machine is possible to be used with several parameters making the machining process on the glass special compared to other machining process. However, the application of grinding process on the CNC milling machine would be an ideal solution in generating special products with good surface roughness. This paper studies how to optimize the different machining parameters in glass grinding operation on CNC machine seeking for best surface roughness. These parameters include the spindle speed, feed rate, depth of cut, lubrication mode, tool type, tool diameter and tool wear. To optimize these machining parameters in which the most significant parameters affecting the surface roughness can be identified, Taguchi optimization method is used with the orthogonal array of L8(26). However, to obtain the most optimum parameters for best surface roughness, the signal to noise (S/N) response analysis and Pareto analysis of variance (ANOVA) methods are implemented. Finally, the confirmation test is carried out to investigate the improvement of the optimization. The results showed an improvement of 8.91 % in the measured surface roughness.

Application of Taguchi and Response Surface Methodologies for Surface Roughness in Rotary Tool Polishing Hardness Mould Steels

2011 ◽  
Vol 383-390 ◽  
pp. 882-886
Author(s):  
Potejanasak Potejana ◽  
Chakthong Thongchattu
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Integrated Approach ◽  
Diamond Powder ◽  
Milling Machine ◽  
Cnc Milling ◽  
Depth Of Penetration ◽  
Surface Design ◽  
Cnc Milling Machine ◽  
The Matrix

This research proposes a new application of 3-axis CNC milling machine for polishing the 60 HRC hardness steels. The rotary polishing tools are designed by refer to the end-mill ball nose’s design. And the diamond powder was coated in rotary polishing tools. The L12 orthogonal array of the Taguchi’s method is selected to conduct the matrix experiment to determine the optimal polishing process parameters. The result show that polishing time was a dominant parameter for the surface roughness and the next was depth of penetration. The response surface design is then used to build the relationship between the input parameters and output responses. The experimental results show that the integrated approach does indeed find the optimal parameters that result in very good output responses in the rotary polishing tools polished hardness mould steel using CNC milling machine.

scholarly journals Effect of feed rate and depth of cut on face milling process on surface roughness of Al-Mg alloy using CNC milling machine 3 axis

2021 ◽  
Vol 3 (11) ◽  
pp. 11-18
Author(s):  
Rachmawati Achadiah ◽  
Putu Hadi Setyarini ◽  
Mas Ayu Pambayoen ◽  
Irfan H. Djunaidi ◽  
Dan Sti Azizah
Keyword(s):  
Surface Roughness ◽  
Control System ◽  
Feed Rate ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
Rate Variation ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine

The purpose of this study was to determine the effect of feed rate and depth of cut on the surface roughness of Al-Mg aluminum using a DIY CNC Milling Machine and Krisbow Universal Milling Machine as a comparison. The open-loop control system is a control system used in the design of DIY CNC Milling machines. A PC with Mach3 software is used as a PC Based Direct Digital Controller to control the system. In this study, the feed rate variation 24 mm/minute and 42 mm/minute and depth of cut 0.25 mm, 0.5 mm, and 0.75 mm were used. After the face milling process, the surface roughness test was carried out using the Mitoyo Surface Roughness Tester to determine the level of surface roughness of the machining results the DIY Milling Machine and Krisbow Universal Milling Machine as a comparison. The results showed that as the feed rate and depth of cut increased, the surface roughness values of both tools increased.

scholarly journals Optimizing the Grinding Parameters on the CNC Milling Machine for Best Glass Edge Quality

2021 ◽  
Vol 1885 (3) ◽  
pp. 032069
Author(s):  
Xiaoyu Li ◽  
Minbo Wang ◽  
Liangbao Jiang ◽  
Jiaxi Liu ◽  
Jiaming Li ◽  
...  
Keyword(s):  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Grinding Parameters ◽  
Edge Quality ◽  
Glass Edge
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