Comparative Performance In Hard Turning Of AISI 1015 Steel With Carbide Insert Using Orthogonal Array Design And Grey Relational Analysis Under Spray Impingement Cooling And Dry Environment

2014 ◽  
Vol 4 (3) ◽  
pp. 1-32 ◽  
Author(s):  
Purna Chandra Mishra ◽  
Dipti Kanta Das ◽  
Susant Kumar Sahu
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Temperature ◽  
Impingement Cooling ◽  
Spray Impingement ◽  
Grey Relational ◽  
Carbide Insert

This study investigates the effects of cutting parameters on surface roughness (Ra), cutting temperature (T0C) at the chip tool interface and the material removal rate (MRR mm3/min) during hard machining of AISI 1015 (43 HRC) steel using carbide insert under dry and spray impingement cooling environment. A combined technique using orthogonal array and analysis of variance (ANOVA) was employed to investigate the contribution of spindle speed, feed rate, depth of cut and air pressure on responses. Utilization of IR camera is been effective to calculate the temperature at the interface of workpiece and the tool. It is observed that with spray impingement cooling, cutting performance improves compared to dry cutting. The predicted multi response optimization setting (N3-f1-d1-P2) ensures minimization of surface roughness, cutting temperature and maximization of material removal rate. Finally optimal result was validated by confirmatory test and the improvement in grey relational grade was found to be 0.288.

Investigation of Surface Roughness and Material Removal Rate on Machining of TIB2 Reinforced Aluminum 6063 Composites: A Taguchi’s Approach

2020 ◽  
Vol 22 (4) ◽  
pp. 1319-1328
Author(s):  
L. Emmanual ◽  
T. Karthikeyan
Keyword(s):  
Surface Roughness ◽  
Analysis Of Variance ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Tib2 Particles

AbstractThe utilization of TiB2 particles reinforced aluminum (Al6063) metal matrix composite materials in many different engineering fields has undergone a tremendous increase. Accordingly, the need of accurate machining of composites has increased enormously; an attempt has been made to assess the factors influencing surface roughness and material removal rate on machining the composite. The orthogonal array, the signal-to-noise ratio, and analysis of variance were employed to study the performance characteristics in turning operations of 5 and 10 wt. % TiB2 particles reinforced aluminum (Al6063) metal matrix composites. Taguchi method was used to find the optimal cutting factors for surface roughness (Ra) and material removal rate (MRR). Three cutting factors namely speed; feed and depth of cut were optimized with considerations of Ra and MRR. The experimental plan and analysis was based on the Taguchi L27 orthogonal array with three cutting factors using carbide tool (K20). The optimal parametric combination for K20 carbide insert was found to be feed, speed and depth of cut. The analysis of variance (ANOVA) result shows that feed the most significant process parameter on surface roughness followed by speed. For MRR result show that the speed and the feed are the significant parameters followed by the composition of composite material.

Parametric Study of Pulsed CO2 Laser Surface Treatment of Alumina Ceramics

2015 ◽  
Vol 15 (3) ◽  
pp. 301-308
Author(s):  
A. Bharatish ◽  
H. N. Narasimha Murthy ◽  
Ajithkumar Radder ◽  
V. Mamatha ◽  
B. Anand ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Laser Power ◽  
Material Removal ◽  
Removal Rate ◽  
Scanning Speed ◽  
Pulse Frequency ◽  
Alumina Ceramics ◽  
Laser Surface Treatment ◽  
Grey Relational

AbstractThis paper focuses on investigating the influence of laser power, pulse frequency and scanning speed on material removal rate and surface roughness during CO2 laser surface treatment of alumina ceramics. Pulse frequency and laser power were the significant factors influencing the material removal rate and surface roughness, respectively. Adequate response surface models were established to correlate the laser parameters and the measured responses. Grey relational analysis predicted the optimal responses at 90 W laser power, 5 kHz pulse frequency and 400 mm/s scanning speed. Desirability function based Multi objective optimization results indicated that minimum material removal rate (0.5117 mm3/s) and surface roughness (0.5968 µm) are achieved at 90 W laser power, 5 kHz pulse frequency and 337.37 mm/s scanning speed which were in close agreement with Grey Relational results. Increase in homogeneity and smoothness of the laser treated alumina surface along with formation of micro recast particles away from the laser traverse path were evidenced by the SEM micrographs.

scholarly journals Optimization of Multiple Response Using Taguchi-WPCA In ST 60 Tool Steel Turning Process With Minimum Quantity Cooling Lubrication (MQCL) Method

2018 ◽  
Vol 7 (1) ◽  
pp. 44-55 ◽  
Author(s):  
Dian Ridlo Pamuji ◽  
Muhammad Abdul Wahid ◽  
Abdul Rohman ◽  
Achmad As’ad Sonief ◽  
Moch Agus Choiron
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Turning Process ◽  
Feeding Speed

A research was conducted for the optimization of the turning process st 60 tool steel with multiple performance characteristics based on the orthogonal array with Taguchi-WPCA method. Minimum Quantity Cooling Lubrication (MQCL) metode was applied as a coolant. The experimental studies were conducted under varying the cutting speed, feeding, depth of cut and type of coolant. The optimized multiple performance characteristics were surface roughness, and material removal rate. An orthogonal array, signal-to-noise ratio, grey relational analysis, weighted pricipal component analysis and analysis of variance were employed to study the multiple performance characteristics. Experimental results show that cutting speed gives the highest contribution for minimize of surface roughness and maximize of material removal rate, followed by feeding speed, type of coolant and depth of cut. The minimum of surface roughness and maximize of material removal rat could be obtained by using the values of cutting speed, feeding speed,  depth of cut and type of coolant of 172.95 m/minute, 0.053 mm/rev, 0.25 mm, and vegetable oil as a coolant respectively.

scholarly journals Application of Taguchi and RSM Parameters on Surface Roughness and Material Removal Rate of AA6082T6

2021 ◽  
Vol 2070 (1) ◽  
pp. 012211
Author(s):  
Harish Mugutkar ◽  
N. Tamiloli
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Feed Speed ◽  
Expulsion Rate ◽  
The Impact ◽  
Test Outcomes ◽  
Carbide Insert ◽  
The Ideal

Abstract Taguchi and Response Surface Methodologies (RSM) for Surface Roughness (SR), and Material Removal Rate (MRR) in end processing of AA6082T6 with tungsten carbide Insert. The Experiments have been driven using the Taguchi plan. The cutting boundaries are feed, speed, and profundity of cut. The impact of machining boundaries and to assessed the ideal cuttings condition to surface unpleasantness and material expulsion rate. A second-request model has been work between the cutting limits and the machining limits to recognize out the SR and MRR by using reaction surface strategy. The test outcomes have shown the most basic factor in the surface unpleasantness is speed (31.068%) and in the material evacuation rate is profundity of cut (51.9404%). The anticipated qualities are affirmed by utilizing affirmation tests.

Study of Surface Roughness and MRR in Turning of SiC Reinforced Al Alloy Composite Using Taguchi Design Method, ANN and PCA Approach under MQL Cutting Condition

2020 ◽  
Vol 1158 ◽  
pp. 115-131
Author(s):  
Md. Rezaul Karim ◽  
Rifat Ahasan Siddique ◽  
Farhana Dilwar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Principal Component ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Experimental Values

This paper emphases on the effect of various machining constraint on surface roughness and material removal rate in turning SiC reinforced Al alloy composite through taguchi orthogonal array based experimental analysis which has been further optimized using principal component analysis (PCA). Experimental investigation has been conducted under minimum quality lubricant (MQL) cutting environment. Palm oil has been used as lubricant where flow rate and pressure were kept at 120 ml/hr and 8 bar. The whole experiment has been designed using L25 orthogonal array having three input parameters and five different level to measure surface roughness and material removal rate. Taguchi S/N ratio-based optimization has been implemented where smaller the better criteria has been used for surface roughness whereas larger the better criteria has been used for material removal rate. From Analysis of variance, it is observed that cutting speed and feed rate are the most prominent factor for surface roughness. Nevertheless, Depth of cut and cutting speed are the most dominant factor for material removal rate. While comparing the predicted output values with experimental values, MAPE value is found in the range of 0.23 % for surface roughness and 0.045 % for material removal rate which is in very much tolerable range. Correlation coefficient value for experimental values of the resultant output is 0.98286 and 0.99869 respectively which signifies the effectiveness of the whole experiment. Subsequently, machining parameters were optimized using PCA technique. To attain satisfactory response values, depth of cut, cutting speed and feed rate need to be at 0.85 mm, 396 m/min and 0.16 mm/rev respectively. By applying the model, surface roughness of 0.7257 μm and MRR of 53856 mm3/min can be obtained. Keywords: SiC reinforced Al alloy; Turing; Minimum Quality Lubricant; Surface Roughness; MRR; Taguchi orthogonal array; Principal component analysis

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.

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