scholarly journals Effect of Process Parameters on the Surface Roughness and Kerf Width of Mild Steel during Plasma Arc Cutting Using Response Surface Methodology

2020 ◽  
Vol 5 (1) ◽  
Author(s):  
Ekhaesomi A Agbonoga ◽  
Oyewole Adedipe ◽  
Uzoma G Okoro ◽  
Fidelis J Usman ◽  
Kafayat T Obanimomo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Analysis Of Variance ◽  
Process Parameters ◽  
Cutting Speed ◽  
Gas Pressure ◽  
Kerf Width ◽  
Plasma Arc ◽  
Plasma Arc Cutting

This study investigated the effects of process parameters of plasma arc cutting (PAC) of low carbon steel material using analysis of variance. Three process parameters, cutting speed, cutting current and gas pressure were considered and experiments were conducted based on response surface methodology (RSM) via the box-Behnken approach. Process responses viz. surface roughness (Ra) and kerf width of cut surface were measured for each experimental run. Analysis of Variance (ANOVA) was performed to get the contribution of process parameters on responses. Cutting current has the most significant effect of 33.43% on the surface roughness and gas pressure has the most significant effect on  kerf width of  41.99% . For minimum surface roughness and minimum kerf width, process parameters were optimized using the RSM. Keywords: Cutting speed, cutting current, gas pressure,   surface roughness, kerf width

Fiber laser processing of GFRP composites and multi-objective optimization of the process using response surface methodology

2018 ◽  
Vol 53 (11) ◽  
pp. 1459-1473 ◽  
Author(s):  
Shiva Dayal Rao B ◽  
Abhijeet Sethi ◽  
Alok Kumar Das
Keyword(s):  
Response Surface Methodology ◽  
Fiber Laser ◽  
Response Surface ◽  
Process Parameters ◽  
Heat Affected Zone ◽  
Cutting Speed ◽  
Kerf Width ◽  
Laser Irradiance ◽  
Input Process ◽  
Cut Surface

In the present investigation, a continuous wave fiber laser with maximum power of 400 W was used to cut a glass fiber reinforced plastic sheet of 4.56 mm thickness using Nitrogen as assisting gas. The influence processing parameters such as laser irradiance, gas pressure, and cutting speed on the cut surface quality were investigated by using response surface methodology. The different responses of laser cut surface such as upper kerf width, taper percentage along the cut depth, and heat-affected zone on the top surface were measured to analyze the influence of input process parameters on the responses. A statistical analysis on the obtained results was conducted and found that the optimum values of different input process parameters were laser irradiance: 8.28 × 105 watt/cm2, cutting speed: 600 mm/min and assisting gas pressure: 7.84 bar. The corresponding values of responses were upper kerf width: 177.4 µm, taper 0.73%, and heat-affected zone on top surface: 109.23 µm. The confirmation experiments were conducted with the obtained optimum parameter setting and observed that the predicted values and experimental values for upper kerf width, taper percentage and top surface heat-affected zone were within the error limits of 2.52%, 1.84%, and 0.45%, respectively. Furthermore, damages like loose fibers, interlayer fractures, evaporation of matrix material and fiber breakages were observed.

Laser Machining of Die Steel (EN-31): An Experimental Approach to Optimise Process Parameters using Response Surface Methodology

2021 ◽  
Vol 18 (1) ◽  
Author(s):  
A. R. Patel ◽  
S. N. Bhavsar
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Laser Power ◽  
Cutting Speed ◽  
Gas Pressure ◽  
Confirmatory Test ◽  
Taper Angle ◽  
Die Steel ◽  
En 31

Experiments were performed based on response surface methodology (RSM) to investigate the process parameters effect on the features of hole geometry. Cutting speed (of 500-1000 mm/min), laser power (of 2000-4000 W), frequency (of 800-2000 Hz), duty cycle (of 75-95%), and gas pressure (of 0.05-0.15 bar) were considered as variable parameters. Deviation in the dimension of entrance and exit holes, heat affected zone (HAZ) on the upper & lower edge, and roughness were the output to analyse the cutting quality of 14 mm thick normal and heat-treated (HT) EN-31 die steel using 4 kW CO2 laser. For untreated plate, minimum taper angle was achieved with low cutting speed, higher laser power, and gas pressure. Higher cutting speed, low laser power, and higher gas pressure result in the minimum HAZ. For the HT plate, the mid-range of parameters results in the minimum taper angle and HAZ. An optimised model was developed, and the confirmatory test gives roughness up to 0.27 microns and it shows good agreement with the mathematical model. At the cross-section of holes, striation pattern, resolidified layer, and corner qualities were visually inspected. Surface damage near the cutting edge was observed using scanning electron microscopy.

scholarly journals Prediction of surface roughness and cutting force under MQL turning of AISI 4340 with nano fluid by using response surface methodology

2018 ◽  
Vol 5 ◽  
pp. 5 ◽  
Author(s):  
Pralhad B. Patole ◽  
Vivek V. Kulkarni
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Nano Fluid ◽  
Aisi 4340

This paper presents an investigation into the minimum quantity lubrication mode with nano fluid during turning of alloy steel AISI 4340 work piece material with the objective of experimental model in order to predict surface roughness and cutting force and analyze effect of process parameters on machinability. Full factorial design matrix was used for experimental plan. According to design of experiment surface roughness and cutting force were measured. The relationship between the response variables and the process parameters is determined through the response surface methodology, using a quadratic regression model. Results show how much surface roughness is mainly influenced by feed rate and cutting speed. The depth of cut exhibits maximum influence on cutting force components as compared to the feed rate and cutting speed. The values predicted from the model and experimental values are very close to each other.

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

2021 ◽  
pp. 095440892110414
Author(s):  
TS Senthilkumar ◽  
R Muralikannan ◽  
T Ramkumar ◽  
S Senthil Kumar
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Box Behnken Design ◽  
Pulse On Time

A substantially developed machining process, namely wire electrical discharge machining (WEDM), is used to machine complex shapes with high accuracy. This existent work investigates the optimization of the process parameters of wire electrical discharge machining, such as pulse on time ( Ton), peak current ( I), and gap voltage ( V), to analyze the output performance, such as kerf width and surface roughness, of AA 4032–TiC metal matrix composite using response surface methodology. The metal matrix composite was developed by handling the stir casting system. Response surface methodology is implemented through the Box–Behnken design to reduce experiments and design a mathematical model for the responses. The Box–Behnken design was conducted at a confident level of 99.5%, and a mathematical model was established for the responses, especially kerf width and surface roughness. Analysis of variance table was demarcated to check the cogency of the established model and determine the significant process. Surface roughness attains a maximum value at a high peak current value because high thermal energy was released, leading to poor surface finish. A validation test was directed between the predicted value and the actual value; however, the deviation is insignificant. Moreover, a confirmation test was handled for predicted and experimental values, and a minimal error was 2.3% and 2.12% for kerf width and surface roughness, respectively. Furthermore, the size of the crater, globules, microvoids, and microcracks were increased by amplifying the pulse on time.

Optimization of Process Parameters in Plasma Arc Cutting Applying Genetic Algorithm and Fuzzy Logic

2018 ◽  
pp. 123-139
Author(s):  
Nehal Dash ◽  
Apurba Kumar Roy ◽  
Sanghamitra Debta ◽  
Kaushik Kumar
Keyword(s):  
Genetic Algorithm ◽  
Surface Roughness ◽  
Fuzzy Logic ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Plasma Arc ◽  
Plasma Arc Cutting ◽  
Optimization Of Process Parameters

Plasma Arc Cutting (PAC) process is a widely used machining process in several fabrication, construction and repair work applications. Considering gas pressure, arc current and torch height as the inputs and among all possible outputs, in the present work Material Removal Rate and Surface Roughness would be considered as factors that determines the quality, machining time and machining cost. In order to reduce the number of experiments Design of Experiments (DOE) would be carried out. In later stages applications of Genetic Algorithm (GA) and Fuzzy Logic would be used for Optimization of process parameters in Plasma Arc Cutting (PAC). The output obtained would be minimized and maximized for Surface Roughness and Material Removal Rate respectively using Genetic Algorithm (GA) and Fuzzy Logic.

EXPERIMENTAL STUDY OF SURFACE ROUGHNESS AND TAPER ANGLE IN ABRASIVE WATER JET MACHINING OF 7075 ALUMINUM COMPOSITE USING RESPONSE SURFACE METHODOLOGY

2019 ◽  
Vol 27 (03) ◽  
pp. 1950112 ◽  
Author(s):  
A. SHANMUGAM ◽  
K. KRISHNAMURTHY ◽  
T. MOHANRAJ
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Water Pressure ◽  
Traverse Speed ◽  
Standoff Distance ◽  
Abrasive Waterjet ◽  
Machined Surface ◽  
Taper Angle

Surface roughness and taper angle of an abrasive waterjet machined surface of 7075 Aluminum metal matrix composite were deliberately studied. Response surface methodology design of experiments and analysis of variance were used to design the experiments and to identify the effect of process parameters on surface roughness and taper angle. The jet traverse speed and jet pressure were the most significant process parameters which influence the surface roughness and taper angle, respectively. Increasing the pressure and jet traverse speed results in increasing the surface roughness and taper angle. At the same time, decreasing the standoff distance and jet traverse speed possibly enhances both the responses. The optimal process parameters of 1[Formula: see text]mm as standoff distance, 192[Formula: see text]MPa as water pressure and 30[Formula: see text]mm[Formula: see text]min[Formula: see text] as jet traverse speed were identified to obtain the minimum value of surface roughness and taper angle. Based on the optimal parameters, the confirmation test was conducted. The mathematical equation was obtained from the experimental data using regression analysis; it was observed that the error was less than 5% of the experimentally measured values.

Optimization of Surface Grinding Process Parameters for Minimum Surface Roughness in AISI 1080 Using Response Surface Methodology

2014 ◽  
Vol 984-985 ◽  
pp. 118-123 ◽  
Author(s):  
S. Periyasamy ◽  
M. Aravind ◽  
D. Vivek ◽  
K.S. Amirthagadeswaran
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Surface Grinding ◽  
Steel Plates ◽  
Medium Effect ◽  
Depth Of Cut ◽  
Design Expert ◽  
Minimum Surface

In this study, the response surface methodology was used to optimize the process parameters of constant speed horizontal spindle surface grinding. The experiments were conducted based on the design expert software. The surface roughness characteristics were investigated in AISI 1080 steel plates using A60V5V grinding wheels. The optimum parameters for minimum surface roughness were found using Design Expert software. The parameters for a particular surface roughness value can also be determined using the results of this experiment. This results shows that feed has a greater effect on surface roughness and feed has medium effect on surface roughness. While dressing depth of cut has a very minimal effect on surface roughness.

Optimization of Surface Roughness in Turning of Ti-6Al-4V Using Response Surface Methodology and TLBO

2015 ◽  
Author(s):  
Neelesh Ku. Sahu ◽  
A. B. Andhare
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Titanium Alloys ◽  
Response Surface ◽  
Feed Rate ◽  
Cutting Speed ◽  
Maximum Error ◽  
Depth Of Cut ◽  
Interaction Variables ◽  
Teaching Learning

Surface roughness is an important surface integrity parameter for difficult to cut alloys such as Titanium alloys (Ti-6Al-4V). In the present work, initially a mathematical model is developed for predicting surface roughness for turning operation using Response Surface Methodology (RSM). Later, a recently developed advanced optimization algorithm named as Teaching Learning Based Optimization (TLBO) is used for further parameter optimization of the equation developed using RSM. The design of experiments was performed using central composite design (CCD). Analysis of variance (ANOVA) demonstrated the significant and non-significant parameters as well as validity of predicted model. RSM describes the effect of main and mixed (interaction) variables on the surface roughness of titanium alloys. RSM analysis over experimental results showed that surface roughness decreased as cutting speed increased whereas it increased with increase in feed rate. Depth of cut had no effect on surface roughness. By comparing the predicted and measured values of surface roughness the maximum error was found to be 7.447 %. It indicates that the developed model can be effectively used to predict the surface roughness. Further optimization of the roughness equation was carried out by TLBO method. It gave minimum surface roughness as 0.3120 μm at the cutting speed of 1704 RPM (171.217 m/min), feed rate of 55.6 mm/min (.033 mm/rev) and depth of cut of 0.7 mm. These results were confirmed by confirmation experiment and were better than that of RSM.

Optimization of Machining Condition in WEDM for Titanium Grade 6 Using MOORA Coupled with PCA — A Multivariate Hybrid Approach

2017 ◽  
Vol 16 (02) ◽  
pp. 81-99 ◽  
Author(s):  
Himadri Majumder ◽  
Kalipada Maity
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Hybrid Approach ◽  
Cutting Speed ◽  
Kerf Width ◽  
Average Surface Roughness ◽  
Average Surface ◽  
Titanium Grade ◽  
Pulse On Time ◽  
Pulse Off Time

This paper represents a multivariate hybrid approach, combining Multi-Objective Optimization on the basis of Ratio Analysis (MOORA) and Principal Component Analysis (PCA) to optimize different correlated responses during Wire Electrical Discharge Machining (WEDM) process of titanium grade 6. The response parameters selected are the average cutting speed, average Kerf width and average surface roughness (Ra). All of them have been studied in terms of pulse-ON time, pulse-OFF time, wire feed and wire tension. As indicated by Taguchi’s signal-to-noise ratio, the optimum process parameters were achieved for the desired average cutting speed, average Kerf width and average surface roughness, respectively. At last, the optimum combination of process parameters was validated by affirmation test which gave considerably improved various quality characteristics. Confirmation test outcome revealed that multivariate hybrid approach MOORA coupled with PCA was a competent strategy to decide available cutting parameters for a desired response quality for WEDM of titanium grade 6.

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