Optimization of Cutting Parameters for End Milling AlSi/AlN Metal Matrix Composite Using the Taguchi Method

2013 ◽  
Vol 773-774 ◽  
pp. 429-436 ◽  
Author(s):  
Siti Haryani Tomadi ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron ◽  
Abdul Razak Daud
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Matrix Composite ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Optimum Cutting ◽  
Optimization Of Cutting Parameters

In this paper, the optimization of cutting parameters is investigated to assess surface roughness and cutting force in the end milling of AlSi/AlN metal matrix composite. Eighteen experiments (L18) with five factors (cutting speed, feed rate, depth of cut, volume of particle reinforcement, and type of coated insert) were performed based on Taguchi designs of the experiment method. Two types of coating (TiB2 and TiN/TiCN/TiN) of the carbide cutting tool were employed to machine various volumes of AlN particle (5%, 7% and 10%) reinforced AlSi alloy matrix composite under dry cutting conditions. Signal-to-noise (S/N) ratio and analysis of variance (ANOVA) were applied to investigate the optimum cutting parameters and their significance. The S/N analysis of the obtained results showed that the optimum cutting conditions for the cutting force were; A2 (triple coating of the insert), B2 (cutting speed: 200m/min), C1 (feed rate: 0.6mm/tooth), D1 (axial depth: 0.6mm) and E1 (5% reinforcement). At the mean time, the optimum cutting conditions for surface roughness were; A1 (single coating of insert), B3 (cutting speed: 250m/min), C2 (feed rate: 0.75mm/tooth), D1 (axial depth: 0.6mm) and E1 (5% reinforcement).The study confirmed that, with a minimum number of experiments, the Taguchi method is capable of determining the optimum cutting conditions for the cutting force and surface roughness for this new material under investigation.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

A Prediction Model of Surface Roughness in Micro End Milling

2015 ◽  
Vol 727-728 ◽  
pp. 354-357
Author(s):  
Mei Xia Yuan ◽  
Xi Bin Wang ◽  
Li Jiao ◽  
Yan Li
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
Feed Rate ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Cutting Depth ◽  
Micro End Milling

Micro-milling orthogonal experiment of micro plane was done in mesoscale. Probability statistics and multiple regression principle were used to establish the surface roughness prediction model about cutting speed, feed rate and cutting depth, and the significant test of regression equation was done. On the basis of successfully building the prediction model of surface roughness, the diagram of surface roughness and cutting parameters was intuitively built, and then the effect of the cutting speed, feed rate and cutting depth on the small structure surface roughness was obtained.

INVESTIGATION OF SURFACE MORPHOLOGY OF DRILLED CFRP PLATES AND OPTIMIZATION OF CUTTING PARAMETERS

2020 ◽  
Vol 27 (09) ◽  
pp. 1950209
Author(s):  
ÖMER ERKAN ◽  
GÖKHAN SUR ◽  
ENGIN NAS
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Design Method ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Feed Speed ◽  
Reinforced Polymer ◽  
Cfrp Composite ◽  
Optimization Of Cutting Parameters ◽  
Full Factorial

In this study, the carbon fiber reinforced polymer (CFRP) composite material was drilled using different parameters ([Formula: see text] and [Formula: see text] Point Angle, 30, 60 and [Formula: see text] cutting speed and 0.06, 0.08 and [Formula: see text] feed rate). Experimental parameters were designed according to full factorial design method and the results were analyzed using Taguchi L18 experimental design. The results of the study show that the lowest surface roughness values are 0.1958 and [Formula: see text]m with the cutting speed of 90 [Formula: see text] and feed rate of [Formula: see text] in the Point angles of [Formula: see text] and [Formula: see text], respectively. When the results of Anova analysis were evaluated, parameters (feed speed, cutting speed and end point angle) according to the effect ratios on surface roughness were formed at the rates of 41.06%, 33.13% and 5.07%, respectively. The most suitable parameters according to S/N ratios were determined using A2B3C1 factors for the average surface roughness.

scholarly journals PREDICTION OF TANGENTIAL CUTTING FORCE IN END MILLING OF MEDIUM CARBON STEEL BY COUPLING DESIGN OF EXPERIMENT AND RESPONSE SURFACE METHODOLOGY

1970 ◽  
Vol 40 (2) ◽  
pp. 95-103 ◽  
Author(s):  
Md. Anayet Patwari ◽  
A.K.M. Nurul Amin ◽  
Waleed F. Faris
Keyword(s):  
Response Surface Methodology ◽  
Carbon Steel ◽  
Cutting Force ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Medium Carbon

The present paper discusses the development of the first and second order models for predicting the tangential cutting force produced in end-milling operation of medium carbon steel. The mathematical model for the cutting force prediction has been developed, in terms of cutting parameters cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). All the individual cutting parameters affect on cutting forces as well as their interaction are also investigated in this study. The second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth of cut and, finally, by the cutting speed. Central composite design was employed in developing the cutting force models in relation to primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The adequacy of the predictive model was verified using ANOVA at 95% confidence level. This paper presents an approach to predict cutting force model in end milling of medium carbon steel using coated TiN insert under dry conditions and full immersion cutting.Keywords: Tangential Cutting Forces; RSM; coated TiN; model.DOI: 10.3329/jme.v40i2.5350Journal of Mechanical Engineering, Vol. ME 40, No. 2, December 2009 95-103

Experimental Investigations of Cutting Conditions Influence on Main Cutting Force and Surface Roughness Based on Chip Form Types in Cast Nylon Turning

2011 ◽  
Vol 110-116 ◽  
pp. 3563-3569 ◽  
Author(s):  
Bandit Suksawat
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Causal Effect ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Path Coefficient ◽  
Cutting Depth

This paper aims to investigate cutting conditions influence on main cutting force and surface roughness based on considered chip form types in cast nylon turning operation with single-point high speed steel cutting tool. The 75 experiments were performed by average of three levels of cutting speed, five levels of cutting depth and five levels of feed rate. The results reveal that main cutting forces were increased by an increasing of cutting speed and cutting depth for all obtained chip form types for all chip form types. The surface roughness is affected by increasing of feed rate and reduction of cutting speed for 2.3 Snarled and 4.3 Snarled chip form types. The statistical path-coefficient analysis results are shown that the main cutting force affected by cutting speed, depth of cut and feed rate with total causal effect value of 0.5537, 0.4785 and 0.1718, respectively. The surface roughness is influenced by feed rate, cutting speed and depth of cut with 0.8400, -0.2419 and-0.0711 of total causal effect value, respectively. These results are useful to perform varying cutting conditions for high quality of workpiece in cast nylon turning by control the chip form type.

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.

Investigation of surface damage and roughness for nickel-based superalloy GH4169 under hard turning processing

2019 ◽  
Vol 234 (4) ◽  
pp. 679-691 ◽  
Author(s):  
Lei Pan ◽  
ZR Wu ◽  
Lei Fang ◽  
YD Song
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Surface Condition ◽  
Research Work ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Minimum Surface ◽  
Nickel Based Superalloy ◽  
Optimization Of Cutting Parameters ◽  
Optimal Cutting Parameters

Machined surface condition of nickel-based superalloys has an important influence on the functional performance of the components. Proper selection of cutting parameters could improve surface finish and increase service life of parts and components. This research work bases on an experimental and statistical study of turning GH4169 nickel-based superalloy with cemented carbide tool. Surface damages like feed marks, tips, and surface tearing were discussed. The second-order polynomial model was used to describe the surface roughness response. Variance analysis was selected to eliminate the insignificant variables in the roughness model. The response surface methodology was used to investigate the combined effect of cutting parameters on two different dimensions surface roughness parameters. The optimization of cutting parameters for minimum surface roughness was obtained using desirability function method. The results demonstrate that feed rate has the most significant effect on surface roughness. High cutting speed and low feed rate result in better surface quality, but too low feed rate exacerbates built-up edge phenomenon and deteriorates surface condition. Optimal cutting parameters leading to the minimum surface roughness were highlighted.

scholarly journals Prediction of Surface Roughness and Optimization of Cutting Parameters of Stainless Steel Turning Based on RSM

2018 ◽  
Vol 2018 ◽  
pp. 1-15 ◽  
Author(s):  
Maohua Xiao ◽  
Xiaojie Shen ◽  
You Ma ◽  
Fei Yang ◽  
Nong Gao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Response Surface ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Surface Design ◽  
Composite Surface ◽  
Optimization Of Cutting Parameters

The turning test of stainless steel was carried out by using the central composite surface design of response surface method (RSM) and Taguchi design method of central combination design. The influence of cutting parameters (cutting speed, feed rate, and cutting depth) on the surface roughness was analyzed. The surface roughness prediction model was established based on the second-order RSM. According to the test results, the regression coefficient was estimated by the least square method, and the regression equation was curve fitted. Meanwhile, the significance analysis was conducted to test the fitting degree and response surface design and analysis, in addition to establishing a response surface map and three-dimensional surface map. The life of the machining tool was analyzed based on the optimized parameters. The results show that the influence of feed rate on the surface roughness is very significant. Cutting depth is the second, and the influence of cutting speed is the least. Therefore, the cutting parameters are optimized and tool life is analyzed to realize the efficient and economical cutting of difficult-to-process materials under the premise of ensuring the processing quality.

Optimization of cutting parameters in CNC turning operation using Taguchi design of experiments

2011 ◽  
Vol 2 (2) ◽  
pp. 79-87 ◽  
Author(s):  
I. Hanafi ◽  
A. Khamlichi ◽  
F. Mata Cabrera ◽  
E. Almansa ◽  
A. Jabbouri
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Design Method ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Mechanical And Thermal Properties ◽  
Taguchi Design Of Experiments ◽  
Optimization Of Cutting Parameters

Abstract Non-reinforced and reinforced Poly-Ether-Ether-Ketone (PEEK) plastics have excellent mechanical and thermal properties. Machining is an efficient process that can be used to manufacture specific mechanical parts made from PEEK composites. Researchers have focused on improving the performance of machining operations with the aim of minimizing costs and improving quality of manufactured products, in order to get the best surface roughness and the minimum cutting force. The parameters evaluated are the cutting speed, the depth of cut and the feed rate. In this paper, the effect of the mentioned parameters on surface roughness and cutting force, in dry turning of reinforced PEEK with 30% of carbon fibers (PEEK CF30) using TiN coated cutting tools, is analyzed through using robust design techniques such as Taguchi's design method, signal-to-noise (S/N) ratio and statistical analysis tools such as Pareto-ANOVA. The obtained results have shown that Taguchi method and Pareto ANOVA are suitable for optimizing the cutting parameters with the minimum possible number of experiments, and the optimized process parameters were determined for surface roughness and cutting force criteria.

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