Optimization of Process Parameters during Milling of Friction Stir Processed GFRP Composites

2014 ◽  
Vol 984-985 ◽  
pp. 297-303
Author(s):  
Bakthavachalu Balamugundan ◽  
Loganathan Karthikeyan
Keyword(s):  
Process Parameters ◽  
Statistical Significance ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
End Mill ◽  
Gfrp Composites ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Solid Carbide ◽  
Overall Performance

In this study, GFRP plates were friction stir processed at three different feed rates (15 mm/min, 20 mm/min and 25 mm/min) and at a constant spindle speed of 1500 rpm with an aim to enhance their microstructural properties. The friction stir processed plates were then subjected to milling with solid carbide K6 end mill tools. Millings trials were carried out using a Taguchi’s L9 orthogonal array under three input parameters such as cutting speed, feed and depth of cut each having three levels. The statistical significance of the process parameters was estimated using signal to noise (S/N) ratio and Analysis of Variance (ANOVA). The study showed that cutting speed during milling and feed rate during FSP contributed to the overall performance which was assessed in terms of surface roughness and delamination factor.

Mathematical modeling of delamination factor on end milling of hybrid GFRP composites through RSM

2016 ◽  
Vol 45 (5) ◽  
pp. 371-379 ◽  
Author(s):  
M.P. Jenarthanan ◽  
A. Lakshman Prakash ◽  
R. Jeyapaul
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
End Mill ◽  
Gfrp Composites ◽  
Content Type ◽  
Gfrp Composite ◽  
Solid Carbide ◽  
Mill Cutter

Purpose This paper aims to develop a mathematical model for delamination during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut and feed rate) influence the output response (delamination) in machining of hybrid glass fibre reinforced plastic (GFRP; abaca and glass) composite using solid carbide end mill cutter. Design/methodology/approach Three factors, three levels Box–Behnken design in RSM is used to carry out the experimental investigation. Shop microscope Mitutoyo TM-500 is used to measure the width of maximum damage of the machined hybrid GFRP composites. The “Design Expert 8.0” is used to analyse the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter. Findings The RSM is used to predict the input factors influencing the delamination on the machined surfaces of hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination has been carried out using RSM. Originality/value Effect of milling of hybrid GFRP composite on delamination with solid carbide end mill has not been analysed yet using RSM.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

scholarly journals Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

2021 ◽  
Vol 27 (4) ◽  
pp. 296-305
Author(s):  
Arpit Srivastava ◽  
Mukesh Kumar Verma ◽  
Ramendra Singh Niranjan ◽  
Abhishek Chandra ◽  
Praveen Bhai Patel
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Cutting Speed ◽  
Radial Force ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimization Of Process Parameters ◽  
Feed Force ◽  
Aluminum 7075 ◽  
Aluminum Alloy 7075

Abstract Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors. The wide application marks the importance of this material’s research in the manufacturing field. This research focuses on optimizing input process parameters of the turning process in the machining of Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force, material removal, and surface roughness of the workpiece. For optimization of process parameters, the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain signifi-cant factors and optimal combinations of process parameters.

scholarly journals A Combined Experimental and Optimization Model to Improve the Machinability of Nimonic C-263 Superalloy

2020 ◽  
Author(s):  
Prashant Jadhav ◽  
Chinmaya Prasad Mohanty
Keyword(s):  
Process Parameters ◽  
Cutting Speed ◽  
Sem Analysis ◽  
Depth Of Cut ◽  
Process Conditions ◽  
Optimization Of Process Parameters ◽  
Excellent Mechanical Property ◽  
Single Response ◽  
Optimal Set ◽  
Super Alloy

Nickel based superalloys finds extensive usage in manufacturing of intricate part shapes in gas turbine, aircraft, submarine, and chemical industries owing their excellent mechanical property and heat resistant abilities. However, machining of such difficult-to-machine alloys up to the desired accuracy and preciseness is a complex task owing to a rapid tool wear and failure. In view of this, present work proposes an experimental investigation and optimization of process parameters of the cryogenic assisted turning process during machining of Nimonic C-263 super alloy with a multilayer CVD insert. Taguchi’s L-27 orthogonal array is used plan the experiments. Effect of input parameters viz. cutting speed (N), cutting feed (f), depth of cut (d) are studied on responses viz. surface roughness (SR), nose wear (NW) and cutting forces (F) under hybrid cryogenic (direct+indirect) machining environment. A scanning electron microscope (SEM) analysis is carried out to explore the post-machining outcomes on the performance measures. The multiple responses are converted in to single response and ranked according to Taguchi based gray relational grade (TGRG). Feed rate (f) is found to be the most influential parameter from the analysis of variance of GRG. The means of GRG for each level of process parameters are used to improve the optimal process parameters further. Finally, the confirmative experiment is performed with these optimal set of process parameters which showed an improvement of 9.34% in the value of GRG. The proposed work can be beneficial to choose ideal process conditions to enhance the performance of turning operation.

Optimization of process parameters on machining force and MRR during end milling of GFRP composites using GRA

2018 ◽  
Vol 15 (3) ◽  
pp. 407-413
Author(s):  
Jenarthanan MP ◽  
Prasanna Kumar Reddy Gavireddy ◽  
Chetan Sai Gummadi ◽  
Surya Ramesh Mandapaka
Keyword(s):  
Process Parameters ◽  
Fibre Orientation ◽  
Orientation Angle ◽  
Helix Angle ◽  
Depth Of Cut ◽  
Gfrp Composites ◽  
Content Type ◽  
Optimization Of Process Parameters ◽  
Machining Force ◽  
Fibre Orientation Angle

Purpose This paper aims to investigate the effect and parametric optimization of process parameters during milling of glass fibre-reinforced plastics (GFRP) composites using grey relational analysis (GRA). Design/methodology/approach Experiments are conducted using helix angle, spindle speed, feed rate, depth of cut and fibre orientation angle as typical process parameters. GRA is adopted to obtain grey relational grade for the milling process with multiple characteristics, namely, machining force and material removal rate (MRR). Analysis of variance is performed to get the contribution of each parameter on the performance characteristics. Findings It is observed that helix angle and fibre orientation angle are the most significant process parameters that affect the milling of GFRP composites. The experimental results reveal that the helix angle of 45°, spindle speed of 3000 rpm, feed rate of 1000 mm/min, depth of cut of 2 mm and fibre orientation angle of 15° is the optimum combination of lower machining force and higher MRR. The experimental results for the optimal setting show that there is considerable improvement in the process. Originality/value Optimization of process parameters on machining force and MRR during endmilling of GFRP composites using GRA has not been attempted previously.

Surface Roughness Model when Machining Aluminum Nitride Ceramic with Two Flute Square End Micro Grain Solid Carbide End Mill

2013 ◽  
Vol 747 ◽  
pp. 282-286 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Alexander Gorin ◽  
K.A. Abou-El-Hossein ◽  
D. Sujan
Keyword(s):  
Surface Roughness ◽  
Aluminum Nitride ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
End Mill ◽  
Roughness Model ◽  
Solid Carbide

This research presents the performance of Aluminum Nitride ceramic in end milling using two flute square end micro grain solid carbide end mill under dry cutting. Surface finish is one of the important requirements in the machining process. This paper describes mathematically the effect of cutting parameters on surface roughness in end milling process. The quadratic model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using the response surface methodology (RSM). Design of experiments approach was employed in developing the surface roughness model in relation to cutting parameters. The predicted results are in good agreement with the experimental results within the specified range of cutting conditions. Experimental results showed surface roughness increases with increase in the cutting speed, feed rate, and the axial depth of cut.

Experimental investigation and analysis of factors influencing delamination and surface roughness of hybrid GFRP laminates using Taguchi technique

2016 ◽  
Vol 45 (6) ◽  
pp. 463-475 ◽  
Author(s):  
M.P. Jenarthanan ◽  
A. Lakshman Prakash ◽  
R. Jeyapaul
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
End Mill ◽  
Content Type ◽  
Cutting Parameter ◽  
Gfrp Composite ◽  
Solid Carbide

Purpose The paper aims to develop a mathematical model for delamination and surface roughness during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre reinforced plastic (GFRP; Abaca and Glass) composite using solid carbide end mill cutter. Design/methodology/approach Four-factor, three-level Taguchi orthogonal array design in RSM is used to carry out the experimental investigation. The “Design Expert 8.0” is used to analyse the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter. Findings The feed rate is the cutting parameter which has greater influence on delamination (88.39 per cent), and cutting speed is the cutting parameter which has greater influence on surface roughness (53.42 per cent) for hybrid GFRP composite materials. Both surface roughness and delamination increase as feed rate increases, which means that the composite damage is larger for higher feed rates. Originality/value Effect of milling of hybrid GFRP composite on delamination and surface roughness with various helix angles of solid carbide end mill has not been analysed yet using RSM.

scholarly journals Experimental Optimization of Process Parameters in CuNi18Zn20 Micromachining

Micromachines ◽  
2021 ◽  
Vol 12 (11) ◽  
pp. 1293
Author(s):  
Andrea Abeni ◽  
Alessandro Metelli ◽  
Cristian Cappellini ◽  
Aldo Attanasio
Keyword(s):  
Process Parameters ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Surface Finishing ◽  
Depth Of Cut ◽  
Micro Machining ◽  
Industrial Sectors ◽  
Optimization Of Process Parameters ◽  
The Cost ◽  
Machining Optimization

Ultraprecision micromachining is a technology suitable to fabricate miniaturized and complicated 3-dimensional microstructures and micromechanisms. High geometrical precision and elevated surface finishing are both key requirements in several manufacturing sectors. Electronics, biomedicals, optics and watchmaking industries are some of the fields where micromachining finds applications. In the last years, the integration between product functions, the miniaturization of the features and the increasing of geometrical complexity are trends which are shared by all the cited industrial sectors. These tendencies implicate higher requirements and stricter geometrical and dimensional tolerances in machining. From this perspective, the optimization of the micromachining process parameters assumes a crucial role in order to increase the efficiency and effectiveness of the process. An interesting example is offered by the high-end horology field. The optimization of micro machining is indispensable to achieve excellent surface finishing combined with high precision. The cost-saving objective can be pursued by limiting manual post-finishing and by complying the very strict quality standards directly in micromachining. A micro-machining optimization technique is presented in this a paper. The procedure was applied to manufacturing of main-plates and bridges of a wristwatch movement. Cutting speed, feed rate and depth of cut were varied in an experimental factorial plan in order to investigate their correlation with some fundamental properties of the machined features. The dimensions, the geometry and the surface finishing of holes, pins and pockets were evaluated as results of the micromachining optimization. The identified correlations allow to manufacture a wristwatch movement in conformity with the required technical characteristics and by considering the cost and time constraints.

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