scholarly journals Surface Roughness Optimization in Drilling Process Using Response Surface Method (RSM)

2014 ◽  
Vol 66 (3) ◽  
Author(s):  
Mohd Amran ◽  
Siti Salmah ◽  
Mohd Sanusi ◽  
Mohd Yuhazri ◽  
Noraiham Mohamad ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Feed Rate ◽  
Spindle Speed ◽  
Drilling Process ◽  
Surface Method ◽  
Drilling Parameters ◽  
Drill Diameter

This paper presents the effect of drilling parameters on surface roughness and surface appearance by applying response surface method (RSM). The mathematical model for correlating the interactions of drilling parameters such as spindle speed, feed rate and drill diameter on surface roughness was developed. RSM methodology was used as it is a technique that most practical and effective way to develop a mathematical model. In addition, this method also can reduce trial and error in experiment. Since the number of factors are three; spindle speed, feed rate and drill diameter, by applying RSM the total numbers of experiment involved are 20 experimental observations. From the experimental result, it is found that the minimum surface roughness on the hole was 1.06 mm from combination of 2000 rpm spindle speed, 78 mm/min feed rate and 2.5 mm drill diameter. While the maximum surface roughness 2.59 mm was the combination of 250 rpm spindle speed, 153 mm/min feed rate and 3.5 mm drill diameter. A mathematical equation was developed with percentage of error are 0% to 29%. Thus, from the result we understand that to find the smooth surface in drilling process, it needs higher spindle speed with lower feed rate and smaller diameter.

Surface Roughness Analysis of Carbon/Glass Hybrid Polymer Composites in Drilling Process Based on Taguchi and Response Surface Methodology

2015 ◽  
Vol 1119 ◽  
pp. 622-627 ◽  
Author(s):  
Chye Lih Tan ◽  
Azwan Iskandar Azmi ◽  
Noorhafiza Muhammad
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Regression Model ◽  
Response Surface ◽  
Feed Rate ◽  
Hybrid Composite ◽  
Spindle Speed ◽  
Tool Geometry ◽  
Secondary Process ◽  
Drilling Process

Drilling is an essential secondary process for near net-shape of hybrid composite as to achieve the required dimensional tolerances prior to final application. Dimensional tolerance is often influenced by the surface integrity or surface roughness of the workpart. Thus, this paper aims to employ the Taguchi and response surface methodologies in minimizing the surface roughness of drilled carbon-glass hybrid fibre reinforced polymer (CGCG) using tungsten carbide, K20 drill bits. The effects of spindle speed, feed rate and tool geometry on surface roughness were evaluated and optimum cutting conditions for minimizing the aforementioned response was determined. Subsequently, response surface methodology (RSM) was utilised in finding the empirical relationships between experimental parameters and surface roughness based on the Taguchi results. The experimental analyses reveal that surface roughness is greatly influenced by feed rate and tool geometry rather than the spindle speed. This is due to the increment of feed that attributed to the increased strain rate and hence, deteriorated the surface roughness of the hybrid composite. The predicted results (via regression model) and theoretical results (via additivity law) were in good agreement with experiment results. This indicates that the regression model from response surface methodology (RSM) can be used to predict the surface roughness in machining of CGCG hybrid composite.

scholarly journals Effects of Machine Parameters on Surface Roughness Using Response Surface Method in Drilling Process

2013 ◽  
Vol 68 ◽  
pp. 24-29 ◽  
Author(s):  
M.A. Amran ◽  
S. Salmah ◽  
N.I.S. Hussein ◽  
R. Izamshah ◽  
M. Hadzley ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Drilling Process ◽  
Surface Method

scholarly journals Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 891
Author(s):  
Numan Habib ◽  
Aamer Sharif ◽  
Aqib Hussain ◽  
Muhammad Aamir ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Drilling Process ◽  
Hole Size ◽  
Hole Quality ◽  
Dry Drilling ◽  
Drilling Parameters ◽  
The Impact

Millions of holes are produced in many industries where efficient drilling is considered the key factor in their success. High-quality holes are possible with the proper selection of drilling process parameters, appropriate tools, and machine setup. This paper deals with the effects of drilling parameters such as spindle speed and feed rate on the chips analysis and the hole quality like surface roughness, hole size, circularity, and burr formation. Al7075-T6 alloy, commonly used in the aerospace industry, was used for the drilling process, and the dry drilling experiments were performed using high-speed steel drill bits. Results have shown that surface roughness decreased with the increase in spindle speed and increased with the increase in the feed rate. The hole size increased with the high spindle speed, whereas the impact of spindle speed on circularity error was found insignificant. Furthermore, short and segmented chips were achieved at a high feed rate and low spindle speed. The percentage contribution of each input parameter on the output drilling parameters was evaluated using analysis of variance (ANOVA).

Investigation on Drilling Performance of Titanium Alloy Ti6Al4V Based on Response Surface Method

2017 ◽  
Author(s):  
Zhaoju Zhu ◽  
Shaochun Sui ◽  
Jie Sun ◽  
Jianfeng Li ◽  
Kai Liu
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Drilling Performance ◽  
Surface Method ◽  
Low Efficiency

In order to break the bottleneck of low efficiency, bad quality following drilling alloy Ti6Al4V, the effect of cutting parameters on thrust force, drilling vibration, burr height and surface roughness was studied based on response surface method. The optimized parameters were obtained. Results showed that feed rate had significant effect on thrust force and little on drilling vibration, while cutting speed had significant effect on vibration and little on thrust force. It is also observed that surface roughness decreased with cutting speed increasing, as well as increased with feed rate increasing. In addition, microstructure on the drilled hole surface showed mobility along feeding direction. Grain refinement on the drilling hole surface became serious with the increase of cutting speed and feed rate.

Optimizing Pulsed Current Micro Plasma Arc Welding Parameters to Maximize Ultimate Tensile Strength of AISI 304L Sheets Using Response Surface Method

2014 ◽  
Vol 660 ◽  
pp. 322-326
Author(s):  
Kondapalli Siva Prasad ◽  
Chalamalasetti Srinivasa Rao ◽  
Damera Nageswara Rao
Keyword(s):  
Mathematical Model ◽  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Response Surface ◽  
Response Surface Method ◽  
Welding Parameters ◽  
Pulsed Current ◽  
Plasma Arc ◽  
Aisi 304L ◽  
Surface Method

AISI 304L is an austenitic Chromium-Nickel stainless steel offering the optimum combination of corrosion resistance, strength and ductility. These attributes make it a favorite for many mechanical components. The paper focuses on developing mathematical model to predict ultimate tensile strength of pulsed current micro plasma arc welded AISI 304L joints. Four factors, five level, central composite rotatable design matrix is used to optimize the number of experiments. The mathematical model has been developed by response surface method. The adequacy of the model is checked by ANOVA technique. By using the developed mathematical model, ultimate tensile strength of the joints can be predicted with 99% confidence level. Contour plots are drawn to study the interaction effect of pulsed current micro plasma arc welding parameters ultimate tensile strength of AISI 304L steel. The developed mathematical model has been optimized using Response Surface Method to maximize the ultimate tensile strength.

scholarly journals Influence of process parameters on surface roughness and forming time of Al-1100 sheet in incremental sheet metal forming

2019 ◽  
Vol 13 (2) ◽  
pp. 4911-4927
Author(s):  
Swagatika Mohanty ◽  
Srinivasa Prakash Regalla ◽  
Yendluri Venkata Daseswara Rao
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Feed Rate ◽  
Metal Forming ◽  
Wall Angle ◽  
Surface Method ◽  
Incremental Sheet Metal Forming

Product quality and production time are critical constraints in sheet metal forming. These are normally measured in terms of surface roughness and forming time, respectively. Incremental sheet metal forming is considered as most suitable for small batch production specifically because it is a die-less manufacturing process and needs only a simple generic fixture. The surface roughness and forming time depend on several process parameters, among which the wall angle, step depth, feed rate, sheet thickness, and spindle speed have a greater impact on forming time and surface roughness. In the present work, the effect of step depth, feed rate and wall angle on the surface roughness and forming time have been investigated for constant 1.2 mm thick Al-1100 sheet and at a constant spindle speed of 1300 rpm. Since the variable effects of these parameters necessitate multi-objective optimization, the Taguchi L9 orthogonal array has been used to plan the experiments and the significance of parameters and their interactions have been determined using analysis of variance (ANOVA) technique. The optimum response has been brought out using response surfaces. Finally, the findings of response surface method have been validated by conducting additional experiments at the intermediate values of the parameters and these results were found to be in agreement with the predictions of Taguchi method and response surface method.

Experimental Study on the Surface Roughness in Mesoscopic-Scale Grinding of Nickel-Based Superalloy

2016 ◽  
Vol 1136 ◽  
pp. 9-14
Author(s):  
Yun Guang Zhou ◽  
Ya Dong Gong ◽  
Yang Sun ◽  
Zhong Xiao Zhu ◽  
Qi Gao
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Feed Rate ◽  
Theoretical Basis ◽  
Spindle Speed ◽  
Range Analysis ◽  
Mesoscopic Scale ◽  
Nickel Based Superalloy ◽  
Grinding Parameters ◽  
Grinding Tool

This paper uses micro-grinding tool with 500# grains and 0.9 mm diameter to grind nickel-based superalloy Inconel600 through three factors(grinding depth, feed rate, spindle speed ) at three levels orthogonal grinding experiment in mesoscopic scale. Then according to the range analysis of surface roughness, the primary and secondary influencial factors are found; the micro grinding parameters are optimized ,the results show: the influence of the feed rate(vf)is the biggest, followed by the spindle speed(n), the grinding depth(ap) is minimal, when n=50kr/min, vf=100μm/s, ap=6μm, the grinding surface roughness is minimum: Ra=579nm; finally , the regression mathematical model of micro grinding surface roughness is established, the relative error of the calculated value and experimental measurements is low, showing that this regression mathematical model is accurate and effective. This study provides a theoretical basis for the micro grinding parameters and surface quality control of nickel-based superally.

Optimization of Machining Parameters on Surface Roughness in EDM of Ti-6Al-4V Using Response Surface Method

2011 ◽  
Vol 213 ◽  
pp. 402-408 ◽  
Author(s):  
M.M. Rahman ◽  
Md. Ashikur Rahman Khan ◽  
M.M. Noor ◽  
K. Kadirgama ◽  
Rosli A. Bakar
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Surface Finish ◽  
Machining Parameters ◽  
Surface Method ◽  
Superior Surface ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This paper presents the influence of EDM parameters in terms of peak ampere, pulse on time and pulse off time on surface roughness of titanium alloy (Ti-6Al-4V). A mathematical model for surface finish is developed using response surface method (RSM) and optimum machining setting in favor of surface finish are evaluated. Design of experiments (DOE) techniques is implemented. Analysis of variance (ANOVA) has been performed to verify the fit and adequacy of the developed mathematical models. The acquired results yield that the increasing pulse on time causes fine surface till a certain value and then deteriorates the surface finish. It is investigated that about 200 µs pulse off time produce superior surface finish. These results lead to desirable surface roughness and economical industrial machining by optimizing the input parameters.

Sign in / Sign up

Export Citation Format

Share Document