scholarly journals Application Potential of Fuzzy and Regression in Optimization of MRR and Surface Roughness during Machining of C45 Steel

2019 ◽  
Vol 63 (2) ◽  
pp. 132-139
Author(s):  
Santosh Madival ◽  
Manjunath Lingappa Halappa ◽  
Mohammed Riyaz Ahmed ◽  
Lokesha Marulaiah
Keyword(s):  
Surface Roughness ◽  
Fuzzy Logic ◽  
Regression Model ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters

In the machining industry, coolant has an important role due to their lubrication, cooling and chip removal functions. Using coolant can improve machining process efficiency, tool life, surface quality and it can reduce cutting forces and vibrations. However, health and environmental problems are encountered with the use of coolants. Hence, there has been a high demand for deep cryogenic treatment to reduce these harmful effects. For this purpose, −196 °C LN2 gas is used to improve machining performance. This study focuses on the prediction of surface roughness and material removal rate with cryogenically treated M2 HSS tool using fuzzy logic and regression model. The turning experiments are conducted according to Taguchi's L9 orthogonal array. Surface roughness and material removal rate during machining of C45 steel with HSS tool are measured. Cutting speed, feed rate, and depth of cut are considered as machining parameters. A model depended on a regression model is established and the results obtained from the regression model are compared with the results based on fuzzy logic and experiment. The effectiveness of regression models and fuzzy logic has been determined by analyzing the correlation coefficient and by comparing experimental results. Regression model gives closer values to experimentally measured values than fuzzy logic. It has been concluded that regression-based modeling can be used to predict the surface roughness successfully.

scholarly journals Optimization of Turning Parameter of Composite Materials Using Response Surface Method in Minitab

2021 ◽  
Author(s):  
S. S Kulkarni ◽  
Sarika Sharma
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Research Work ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Rsm Optimization

This paper represents the optimization method utilized in machining process for figuring out the most advantageous manner design. Typically, the technique layout parameters in machining procedures are noticeably few turning parameters inclusive of reducing velocity, feed and depth. The optimization of speed, feed depth of cut is very tough because of several other elements associated with processing situations and form complexities like surface Roughness, material removal rate (MRR) that are based Parameters. On this task a new fabric glass fibre composite is introduced through which could lessen costing of manufacturing and time and additionally it will boom the technique of productiveness. Composite substances have strength, stiffness, light weight, which gives the large scope to engineering and technology. The proposed research work targets to analyze turning parameters of composite material. The machining parameters are very important in manufacturing industries. The present research work is optimized surface roughness of composite material specifically in turning procedure with the aid of changing parameter including intensity of reduce, slicing velocity and feed price and additionally expect the mechanical houses of composite material. The RSM optimization is important because it evaluates the effects of multiple factors and their interactions on one or more responsive variables. It is observed that the material removal rate increases and surface roughness decreases as per the increase of Spindle speed and feed rate.

scholarly journals Tool Wear Rate Prediction by using Optimization Techniques

2019 ◽  
Vol 9 (2) ◽  
pp. 1271-1277
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

scholarly journals Multi-Objective Process Parameter Optimization for Surface Roughness and Material Removal Rate in Face Milling of Al 6061 T6 Alloy

2019 ◽  
Vol 9 (2) ◽  
pp. 137-142
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Al 6061

This study uses Taguchi methodology and Gray Relational Analysis approach to explore the optimization of face milling process parameters for Al 6061 T6 alloy.Surface Roughness (Ra), Material Removal Rate (MRR) has been identified as the objective of performance and productivity.The tests were performed by selecting cutting speed (mm / min), feed rate (mm / rev) and cutting depth (mm) at three settings on the basis of Taguchi's L9 orthogonal series.The grey relational approach was being used to establish a multiobjective relationship between both the parameters of machining and the characteristics of results. To find the optimum values of parameters in the milling operation, the response list and plots are used and found to be Vc2-f1-d3. To order to justify the optimum results, the confirmation tests are performed.The machining process parameters for milling were thus optimized in this research to achieve the combined goals such as low surface roughness and high material removal rate on Aluminum 6061 t6.It was concluded that depth of cut is the most influencing parameter followed by feed rate and cutting velocity.

Statistical analysis of material removal rate and surface roughness in electrical discharge turning of titanium alloy (Ti-6Al-4V)

2016 ◽  
Vol 232 (9) ◽  
pp. 1603-1614 ◽  
Author(s):  
Vikas Gohil ◽  
Yogesh M Puri
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Peak Current ◽  
Pulse On Time

Electrical discharge turning is a unique form of electrical discharge machining process, which is being especially developed to generate cylindrical forms and helical profiles on the difficult-to-machine materials at both macro and micro levels. A precise submerged rotating spindle as a work holding system was designed and added to a conventional electrical discharge machine to rotate the workpiece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating workpiece; thus, mirror image of the tool is formed on the circumference of the workpiece. The machining performance of electrical discharge turning process is defined and influenced by its machining parameters, which directly affects the quality of the machined component. This study presents an investigation on the effects of the machining parameters, namely, pulse-on time, peak current, gap voltage, spindle speed and flushing pressure, on the material removal rate (MRR) and surface roughness (Ra) in electrical discharge turning of titanium alloy Ti-6Al-4V. This has been done by means of Taguchi’s design of experiment technique. Analysis of variance as well as regression analysis is performed on the experimental data. The signal-to-noise ratio analysis is employed to find the optimal condition. The experimental results indicate that peak current, gap voltage and pulse-on time are the most significant influencing parameters that contribute more than 90% to material removal rate. In the context of Ra, peak current and pulse-on time come up with more than 82% of contribution. Finally, the obtained predicted optimal results were verified experimentally. It was shown that the error values are all less than 6%, confirming the feasibility and effectiveness of the adopted approach.

Optimization of Process Parameters Using Taguchi Coupled Genetic Algorithm

2017 ◽  
pp. 67-93 ◽  
Author(s):  
Supriyo Roy ◽  
J. Paulo Davim ◽  
Kaushik Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Nsga Ii ◽  
Optimization Of Process Parameters ◽  
Cnc Lathe

In the era of mass manufacturing, Material removal rate and Surface Roughness are of primary concern even in manufacturing using contemporary CNC machines. In this work, L27 Orthogonal Array of Taguchi method is selected for three parameters (Depth of cut, Feed and Speed) with three different levels to optimize the turning parameters for Material Removal Rate and Surface Roughness on an EMCO Concept Turn 105 CNC lathe for machining SAE 1020 material with carbide tool. The MRR and SR are observed as the objective to develop the combination of optimum cutting parameters. The objectives were optimized using Taguchi, Grey Taguchi and NSGA-II. The result from these techniques was compared to identify the optimal values of cutting parameters for maximum MRR, minimum SR and best combination of both. This study also produced a predictive equation for determining MRR and SR for a given set of parameters outside the considered values. Thus, with the proposed optimal parameters it is possible to increase the efficiency of machining process and decrease production cost in CNC Lathe.

Study of Uncoated and Coated Carbide Insert on Tool Life, Surface Roughness and Material Removal Rate in Machining of EN27 steel

2015 ◽  
Vol 15 (2) ◽  
pp. 205-214
Author(s):  
Anil Ghubade ◽  
Ajay Gupta ◽  
Abhishek Abrol ◽  
Satsimran Singh
Keyword(s):  
Surface Roughness ◽  
Production Rate ◽  
Tool Life ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Coated Carbide ◽  
Carbide Insert

AbstractMetal cutting industries are facing challenges to increase production rate at minimum cost with improvement in quality in the final product. The increasing need of productivity, closed tolerance, dimensional stability and cost put tremendous pressure on manufacturing industries to design and develop new technologies to meet the required goal. Hence, coating over the existing tool plays an important role in achieving higher production rate, better tool life and minimization in cost. In this paper, we analyzed the effect of uncoated and coated carbide (triple and six layer coated) tool on tool life, surface roughness and material removal rate during dry turning of EN27 steel. Taguchi approach is used to find the best optimum parameter setting for turning of EN27 steel. A L9 orthogonal array, signal-to-noise ratio and ANOVA are applied to study machining parameters (Spindle speed, Feed rate and Depth of cut) in consideration of tool life (VB), material removal rate (MRR) and surface finish (Ra). The experimental investigation shows that the best machining performance is achieved by six layer coated carbide insert compared to uncoated and triple coated carbide insert under the selected machining conditions.

scholarly journals Optimization of Machining Parameters for MRR and Surface Roughness for 7024 AL-alloy in Pocket Milling Process

2019 ◽  
Vol 26 (1) ◽  
pp. 10-16
Author(s):  
Mustafa Mohammed Abdulrazaq ◽  
Adil Shabeeb Jaber ◽  
Ahmed Salman Hammood ◽  
Ahmed Ghazi Abdulameer
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Milling Process ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Machining Parameters ◽  
Good Surface ◽  
Good Surface Roughness

The objective of this work is the investigation of milling process variables which resulting in optimal values of the surface roughness and material removal rate during machining of 7024 Al-alloy. The machining operation implemented on C-TEK CNC milling machine. The effects of the selected parameters on the chosen characteristics have been accomplished using Taguchi’s parameter design approach; also ANOVA had been used to evaluate the contribution of each parameter on the process outputs. Different feed rates are used ranging from (60, 80 and 100) mm/min, found that high feed rates gives a high material removal rates and good surface roughness. On the other hand, using three levels of spindle speeds found that a higher spindle speeds gives better surface roughness with a little effect on MRR. The process results showed that maximum MRR achieved (2.40) mm3/min when machining feed rate (100) mm/min, spindle speed (1000) r.p.m, and depth of cut (0.6) mm while good surface roughness (0.41 µm) when machining feed rate (100) mm/min, spindle speed (1000) r.p.m, and depth of cut (0.2) mm. The level of importance of the machining parameters for material removal rate and surface roughness and is determined by using Taguchi designing experiments and the variance analysis (ANOVA).

scholarly journals A Comprehensive Study on Processing Ti–6Al–4V ELI with High Power EDM

Materials ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 303
Author(s):  
Panagiotis Karmiris-Obratański ◽  
Emmanouil L. Papazoglou ◽  
Beata Leszczyńska-Madej ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
High Power ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
White Layer ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Performance

Electrical Discharge Machining (EDM) consists of a non-conventional machining process, which is widely used in modern industry, and especially in machining hard-to-cut materials. By employing EDM, complex shapes and geometries can be produced, with high dimensional accuracy. Titanium alloys, due to their unique inherent properties, are extensively utilized in high end applications. Nevertheless, they suffer from poor machinability, and thus, EDM is commonly employed for their machining. The current study presents an experimental investigation regarding the process of Ti–6Al–4V ELI with high power EDM, using a graphite electrode. Control parameters were the pulse-on current (Ip) and time (Ton), while Machining performances were estimated in terms of Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR). The machined Surface Roughness was calculated according to the Ra and the Rt values, by following the ISO 25178-2 standards. Furthermore, the EDMed surfaces were observed under optical and SEM microscopy, while their cross sections were also studied in order the Average White Layer Thickness (AWLT) and the Heat Affected Zone (HAZ) to be measured. Finally, for the aforementioned indexes, Analysis Of Variance was performed, whilst for the MRR and TMRR, based on the Response Surface Method (RSM), semi-empirical correlations were presented. The scope of the current paper is, through a series of experiments and by employing statistical tools, to present how two main machining parameters, i.e., pulse-on current and time, affect major machining performance indexes and the surface roughness.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

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