Optimization of Machining Process Parameters Using Moora Method

2020 ◽  
Vol 402 ◽  
pp. 81-89
Author(s):  
Laxman B. Abhang ◽  
Mohd Iqbal ◽  
M. Hameedullah
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Cutting Force ◽  
Process Parameters ◽  
Machining Process ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Moora Method

A multi-response optimization is a popular tool in many economic, managerial, constructional, manufacturing, process design, product design technologies, machinery and system, devices, process parameters etc. This research paper demonstrates the application of a simple multi-objective optimization on the basis of ratio analysis (MOORA) method to solve the multi-criteria (objective) optimization problem in the machining process. In this paper, the chip-tool interface temperature, main cutting force, and tool wear rate were investigated in various machining conditions in turning operations. Various machining parameters, such as the cutting speed, feed rate, and depth of cut and effective tool inserts nose radius, were considered. Composite factorial design (24+8) was used for experimentation. Multiple response values were obtained using actual experimentation. By using these experiments, two different methods were proposed. Machining parameters were optimized by minimizing chip-tool interface temperatures, tool wear rate, and main cutting force during machining of alloy steel. The results obtained using the MOORA method almost agree with the grey relational analysis method which shows the authenticate applicability, potentiality, and flexibility of MOORA method for solving various complex decision-making problems in present-day manufacturing industries.

Machinability analysis of quartz during single point diamond turning process based on finite element method: influence of ultrasonic vibration and micro-machining parameters

2020 ◽  
Vol 61 (6) ◽  
pp. 169-178
Author(s):  
Farzad Pashmforoush ◽  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Wear Rate ◽  
Tool Wear ◽  
Cutting Force ◽  
Single Point ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Micro Machining ◽  
Tool Wear Rate

Quartz is one of the difficult-to-machine materials due to its low fracture toughness and high hardness. In this study, the machinability of this material during single point diamond turning (SPDT) was numerically investigated using finite element method (FEM). First of all, the accuracy of the FE model was verified based on the experimental data available in literature. Then, the machinability of quartz was analysed in terms of cutting force, tool/workpiece temperature and tool wear rate. Also, the influence of tool vibration on cutting force and tool wear rate was investigated. Furthermore, an empirical/mathematical model was developed to express the machining outputs as a function of the micro-machining parameters. The obtained results indicate the good performance of FEM in analysing the machinability of quartz during SPDT process.

scholarly journals Fuzzy-MOORA Based Optimization of Machining Parameters for Machinability Enhancement of Titanium

2021 ◽  
Vol 8 (2) ◽  
pp. 189-198
Author(s):  
Durwesh Jhodkar ◽  
Akhtar Khan ◽  
Kapil Gupta
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Tool Flank Wear ◽  
Moora Method ◽  
Fuzzy Moora

The aim of this study is to determine the optimal combination of process parameters when machining commercially pure titanium grade 2. The unification of Multi objective optimization based on ratio analysis (MOORA) and fuzzy approach has applied to optimize the process parameters. Three process parameters i.e. cutting speed, tool overhang, and microhardness have been varied at three levels each and a total of twenty seven experiments have been conducted based on Taguchi’s L27 design of experiment technique. Cutting force, tool flank wear, and average surface roughness have been considered a machinability indicators to measure the process performance. Feed rate and depth of cut have been kept constant. Successful optimization is done and results show that machining titanium at higher cutting speed (140 m/min) and higher tool overhang length (65 mm) with medium hardness (1934 HV) results in lower cutting force, tool flank wear, and surface roughness. Outcomes of the present work reveal that the hybrid fuzzy-MOORA method is convincing enough to obtain the best process parameter combination for the best machinability while machining titanium type difficult-to-machine materials.

scholarly journals Tool wear rate optimization in PMEDM using titanium powder by Taguchi method for die steels

2016 ◽  
Vol 19 (2) ◽  
pp. 88-97
Author(s):  
Long Tien Banh ◽  
Phan Huu Nguyen ◽  
Cuong Ngo
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Taguchi Method ◽  
Electrical Discharge ◽  
Machining Process ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Optimal Value ◽  
Pulse On Time ◽  
Pulse Off Time

Powder mixed electrical discharge maching (PMEDM) is a complex machining process which is controlled by a number of machining parameters. Each machining parameter has its own influence on performance of the process. For achieving the best performance of the electrical discharge machining (EDM) process, it is crucial to carry out parametric design responses such as Metal Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness(SR). The objective of this paper is to optimization of input parameters for the TWR in PMEDM using powder titanium are presented. The Taguchi method was applied to the processing parameters to investigate the following: workpiece material, tool material, polarity, pulse-on time, current, pulse-off time, and powder concentration. The analysis used the Taguchi method and given the optimal value for TWR with respective parameters. Electrode material affected the strongest factor, the Taguchi coefficient, S/N of TWR. And the optimal value of TWR was 3.092 mm3/min. Results from optimization calculations and experimentation have demonstrated high accuracy and efficiency.

Cutting Force and Tool Wear in Face Milling of Hardened Steel

2012 ◽  
Vol 723 ◽  
pp. 77-81 ◽  
Author(s):  
Xiao Bin Cui ◽  
Jun Zhao
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Face Milling ◽  
Depth Of Cut ◽  
Tool Wear Rate ◽  
Radial Depth ◽  
Cutting Speeds

In the present study, face milling of AISI H13 steel (46-47 HRC) with CBN tools was conducted. Cutting speeds 389 and 1592 m/min were adopted in order to identify the characteristics of cutting force and tool wear at low and high cutting speeds. For each cutting speed, the metal removal rate and axial depth of cut were set to be invariable, and different combinations of radial depth of cut and feed per tooth were selected. The optimum combination of radial depth of cut and feed per tooth for each cutting speed was distinguished. For different cutting speeds, the cutting force changed in varying ways with different combinations of cutting parameters. At the cutting speed of 389 m/min, after the initial cutting stage, the tool wear rate was low even at the end of tool life. When the cutting speed was 1592 m/min, the tool wear increased rapidly, and the tool wear rate changed little in the whole tool life span. Adhesion and abrasion were the main wear mechanisms of the tool faces at the cutting speed of 389 m/min. While at the cutting speed of 1592 m/min, fracture contributed greatly to the final tool failure.

Optimization of Tool Wear Rate during Electro Discharge Machining of NiTi Alloys Using Taguchi Method

2015 ◽  
Vol 787 ◽  
pp. 260-264
Author(s):  
Vijaykumar S. Jatti ◽  
T.P. Singh
Keyword(s):  
Electrical Conductivity ◽  
Wear Rate ◽  
Tool Wear ◽  
Process Parameters ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Niti Alloys ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time

NiTi alloys are advance materials which possess superior properties such as pseudoelasticity, shape memory effect, high wear resistance, high corrosion resistance and high strength. NiTi alloys causes serious tool wear, hardening of the machined surface and poor surface finish. Electro discharge machining (EDM) is an unconventional machining process which demonstrates high capability to machine NiTi alloys. Present work emphasis on investigating the effect of EDM process parameters on the tool wear rate. Gap current, pulse on time and pulse off time were considered at three levels as input process parameters along with electrical conductivity of workpiece and tool electrode at two levels. Taguchi L36 (22 x 33) mixed orthogonal array was utilized to design the experimental plan. Based on the statistical analysis at 95% confidence level it was found that tool electrical conductivity, gap current and pulse on time are the most significant factors that influence the tool wear rate. At optimal setting of parameters the predicted value of tool wear rate obtained was 0.00811 mm3/min.

Effect of EDM Process Parameters for Burr Removal of Drilled Holes of Inconel-718

2013 ◽  
Author(s):  
Uday A. Dabade
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Process Parameters ◽  
Inconel 718 ◽  
Gas Turbines ◽  
Visual Inspection ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Pulse On Time ◽  
Edm Process

Most of the components used in automobile and aerospace industries are replaced by advanced materials such as Metal Matrix Components (MMCs) and Inconel. So in this area, drilling is most popular method used for joining, bolting and riveting purpose. Inconel-718 is a high strength, temperature resistant (HSTR) nickel -based super alloy. It is extensively used in aerospace applications, such as gas turbines, rocket motors, and spacecraft as well as in nuclear reactors, pumps and tooling. Inconel-718 is difficult to machine, because of its poor thermal properties, high toughness, high hardness, and high work hardening rate. Therefore, many researchers have tried for an alternative source by many conventional and nonconventional machining processes. Electro discharge machining (EDM) is widely used non conventional machining process for such materials. Hence, in this paper some efforts are taken to investigate the effect of different EDM process parameters such as current, dielectric flow rate and pulse on time on the tool wear rate (TWR) and grading of deburred holes by visual inspection for burr removal in drilled holes of Inconel-718 material. In this study burr removal operation of drilled holes via EDM process is carried out. Two types of electrode materials such as Aluminum and Brass with cylindrical taper geometry at tip is used. The experiments are performed using Taguchi method of design of experiment and L27 orthogonal array. The results indicate that only current is most significant parameter affecting for tool wear rate (TWR) as well as grading of drilled holes by visual inspection. Secondarily, SEM photographs of deburred holes indicate that effective burr removal operation using Brass electrode compared to Aluminium provides better solution for Inconel-718 material.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

Modeling & Analysis of End Milling Process Parameters Using Artificial Neural Networks

2014 ◽  
Vol 592-594 ◽  
pp. 2733-2737 ◽  
Author(s):  
G. Harinath Gowd ◽  
K. Divya Theja ◽  
Peyyala Rayudu ◽  
M. Venugopal Goud ◽  
M .Subba Roa
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Artificial Neural ◽  
End Milling Process

For modeling and optimizing the process parameters of manufacturing problems in the present days, numerical and Artificial Neural Networks (ANN) methods are widely using. In manufacturing environments, main focus is given to the finding of Optimum machining parameters. Therefore the present research is aimed at finding the optimal process parameters for End milling process. The End milling process is a widely used machining process because it is used for the rough and finish machining of many features such as slots, pockets, peripheries and faces of components. The present work involves the estimation of optimal values of the process variables like, speed, feed and depth of cut, whereas the metal removal rate (MRR) and tool wear resistance were taken as the output .Experimental design is planned using DOE. Optimum machining parameters for End milling process were found out using ANN and compared to the experimental results. The obtained results provβed the ability of ANN method for End milling process modeling and optimization.

scholarly journals Machinability Of Shape Memory Alloy Using Electro Spark Erosion Process 

2021 ◽  
Author(s):  
Adam Khan M ◽  
Winowlin Jappes J T ◽  
Samuel Ratna Kumar P S ◽  
Mashinini P M
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Shape Memory ◽  
Applied Voltage ◽  
Material Removal ◽  
Machining Process ◽  
Tool Wear Rate ◽  
Pulse On Time ◽  
The Impact

Abstract In this research work, the nickel – titanium based shape memory alloys are machined using electro spark machining process. The influence of the input process for electro spark production is studied in detail. From the analysis, the tool wear rate (TWR), surface roughness, and material removal rate (MRR) are investigated. The intensity of the electro spark produced at minimum pulse on-time 10 µs and maximum applied voltage (60 V). Variation in MRR is wide for a minimum pulse on time with low applied voltage. The surface roughness of the machined surface is also directly influenced by the in – efficient spark produced. The copper electrode with increase pulse duration the alloy behaves like a strong conductor to transmit electrical energy between the electrode and work material. The contribution of pulse on-time is maximum for material removal and tool wear rate. However, the surface finish depends on the applied voltage of the process designed. The impact on machined surfaces, micro-cracks, electro-discharge carter's, and recast material due to electrical discharge were assessed using a scanning electron microscope and energy-dispersive X-ray spectroscopy (EDX) analysis. The experimental value shows that material removal depends on the pulse on process timings and applied voltage. Thus, by using mathematical analysis the influence of (electric discharge machining) EDM process parameters was evaluated.

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