Enhancement of Surface Finish by Optimization Technique Employed for Al 6061 Considering Different Parameters Using RSM

2019 ◽  
Author(s):  
Ajay Pal Singh ◽  
Abdul Samad ◽  
Amit Kumar Saraf
Keyword(s):  
Surface Finish ◽  
Optimization Technique ◽  
Al 6061

EDM Process Parameters Optimization Using Taguchi Method

2015 ◽  
Vol 766-767 ◽  
pp. 867-872
Author(s):  
P. Sengottuvel ◽  
V. Palanisamy ◽  
J. Arun ◽  
N.R.R. Anbusagar ◽  
J. Hameed Hussain
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Surface Finish ◽  
Inconel 718 ◽  
Optimization Technique ◽  
Experimental Result ◽  
Aluminum Electrode ◽  
Optimum Level ◽  
Machining Parameters ◽  
Inconel Alloys

In this paper , the parameters of Electrical Discharge Machine (EDM) are investigated during the machining of Inconel 718 by using different sizes of circular Aluminum electrode. Demand for better surface finishes are increasing recently for all materials, the low rigidity and high material removal rate of Inconel alloys offers a challenging task in obtaining better Surface Finish. The analysis of surface characteristics like Surface Roughness (SR) of Inconel 718 material is carried out an excellent surface finish can be obtained by setting the machining parameters at optimum level. Experimentation was carried out by using Taguchi’s L9 orthogonal array under different conditions of parameters. The response of SR is considered for improving the machining efficiency. Optimal combination of parameters was obtained Taguchi Optimization technique. The confirmation experiments results shows that the significant improvement in Surface Finish was obtained. ANOVA have been used to analyze the contribution of individual parameters on Surface Roughness. The experimental result demonstrates that the Taguchi method satisfies the practical requirements.

scholarly journals Optimization of Cutting Conditions in End Milling Process with the Approach of Particle Swarm Optimization

2011 ◽  
pp. 120-124
Author(s):  
Vikas Pare ◽  
Geeta Agnihotri ◽  
C.M. Krishna
Keyword(s):  
Surface Roughness ◽  
Particle Swarm Optimization ◽  
Surface Finish ◽  
Metal Cutting ◽  
End Milling ◽  
Optimization Technique ◽  
Particle Swarm ◽  
Swarm Optimization ◽  
Wide Range ◽  
Input Variables

Milling is one of the progressive enhancements of miniaturized technologies which has wide range of application in industries and other related areas. Milling like any metal cutting operation is used with an objective of optimizing surface roughness at micro level and economic performance at macro level. In addition to surface finish, modern manufacturers do not want any compromise on the achievement of high quality, dimensional accuracy, high production rate, minimum wear on the cutting tools, cost saving and increase of the performance of the product with minimum environmental hazards. In order to optimize the surface finish, the empirical relationships between input and output variables should be established in order to predict the output. Optimization of these predictive models helps us to select appropriate input variables for achieving the best output performance. In this paper, four input variables are selected and surface roughness is taken as output variable. Particle swarm optimization technique is used for finding the optimum set of values of input variables and the results are compared with those obtained by GA optimization in the literature.

Multi Response Optimization and Process Capability Analysis of Fused Filament Fabrication and Chemical Vapor Smoothing Operations for Rapid Casting of Biomedical Implants

2019 ◽  
Author(s):  
Jasgurpreet Singh Chohan ◽  
Rupinder Singh ◽  
Kamaljit Singh Boparai
Keyword(s):  
Surface Finish ◽  
Optimization Technique ◽  
Orientation Angle ◽  
Process Capability ◽  
Chemical Vapor ◽  
Dimensional Accuracy ◽  
Biomedical Implants ◽  
Fused Filament Fabrication ◽  
Rapid Casting ◽  
Response Optimization

Abstract Despite numerous applications of Fused Filament Fabrication (FFF), the poor surface finish, being an inherent defect, is major obstruction against utilization of prototypes for rapid casting applications. The conventional finishing methods are effective, however, the dimensional stability is compromised which is completely unacceptable in case of biomedical implants as minute dimension variations may lead to post-operative complications. The paper explores possibilities to produce chemically finished plastic replicas of hip implant through FFF which can be further used as patterns for investment casting. An advanced post-processing technique i.e. Chemical Vapor Smoothing (CVS) is tested to improve surface characteristics and dimensional accuracy of ABS replicas. The repeatability and consistency of coupled CVS and FFF processes is tested through experimentation and statistical analysis in order to endorse an alternative process for mass production of biomedical implants. The Taguchi L18 DOE was used to perform experiments which measures impact of two input parameters of FFF i.e. orientation angle and density, and four parameters of Chemical Vapor Smoothing i.e. pre-cooling time, smoothing time, smoothing time and number of cycles. The multi response optimization technique was employed to acquire optimum set of parameters yielding best surface finish, dimensional accuracy and surface hardness and hence, the overall desirability of 0.7891 was achieved. The process capability and reliability was tested at optimum settings by manufacturing twenty replicas by measuring surface roughness, hardness and dimensional accuracy at different locations of parts. It was observed that values of Cp for all the response parameters was greater than 1.33 while Cpk was greater than 1. The analysis of histograms and capability indices reveal that the FFF-CVS process carried out at optimized conditions can be defined as “statistically controlled” for fabrication of ABS replicas for biomedical applications.

Mechanical and Metallurgical Characterization of Al-6061 HMMC with SiCp and Graphitep as a Reinforcement

2021 ◽  
Vol 1034 ◽  
pp. 87-100
Author(s):  
G. Srinivas Kumar ◽  
Y. Venkata Mohana Reddy ◽  
B. Chandra Mohana Reddy
Keyword(s):  
Regression Analysis ◽  
Linear Regression ◽  
Wear Rate ◽  
Linear Regression Analysis ◽  
Optimization Technique ◽  
Wear Testing ◽  
Wear Behaviour ◽  
Al 6061 ◽  
Uniform Dispersion ◽  
Confirmation Test

The present investigation considers an experimental study of wear analysis of Al-6061 HMMC with SiCp & Graphitep as a reinforcement & optimization of wear testing parameters based on the Taguchi technique coupled with Linear Regression analysis. A Linear Regression Equation obtained from regression analysis is used as a confirmation test, for the optimum testing parameters that are obtained to get the minimum wear rate and maximum Co-efficient of Friction of Al-6061 HMMC. The wear rate experiments are carried out by utilizing the combinations of tribological testing parameters based on the L9 Taguchi OA with four testing parameters of namely applied load, Speed, Track diameter and % of reinforcement. The three materials, Al-6061 HMMC are developed by reinforcing Al-6061 aluminium alloy with different (3, 5 & 7) % of weight fraction (SiCp+Graphitep), particulates of size (<30m) in an electric crucible melting furnace. It is observed that sliding velocity has a significant contribution in controlling the friction and wear behaviour of Al-6061 HMMC (SiCp+Graphitep). A confirmation test is carried out to verify the results obtained through the optimization technique. In addition to above tests, Scanning Electron Microscopy (SEM) analysis, Elemental Characterization can be achieved by using of EDAX (Energy Dispersive X-ray Spectroscope), Surface Roughness is performed on the specimens to study the uniform dispersion of particulate matter, along with hardness test.

Optimization of Precision Grinding Parameters of Silicon for Surface Roughness Based on Taguchi Method

2011 ◽  
Vol 264-265 ◽  
pp. 997-1002 ◽  
Author(s):  
Alao Abdur-Rasheed ◽  
Mohamed Konneh
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Surface Finish ◽  
Machine Tools ◽  
Optimization Technique ◽  
Experimental Studies ◽  
Precision Grinding ◽  
Taguchi Optimization ◽  
Good Surface ◽  
Grinding Parameters

Silicon being a typical hard-brittle material is difficult to machine to a good surface finish. Although ductile-mode machining (DMM) is often employed to machine this advanced material but this technique requires the use of expensive ultra-precision machine tools therefore limiting its applicability. However, by proper selection of grinding parameters, precision grinding which can be performed on conventional machine tools can be used to generate massive ductile surfaces thereby reducing the polishing time and improving the surface quality. Precision grinding should be planned with reliability in advance and the process has to be performed with high rates of reproducibility. Therefore, this study investigated the effect and optimization of grinding parameters using Taguchi optimization technique during precision grinding of silicon. Experimental studies were conducted under varying depths of cut, feed rates and spindle speeds. An orthogonal array (OA), signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) were employed to find the minimum surface roughness value and to analyze the effect of the grinding parameters on the surface roughness. Confirmation tests were carried out in order to illustrate the effectiveness of the Taguchi method. The results show that feed rate mostly affected the surface roughness. The predicted roughness (Ra) of 34 nm was in agreement with the confirmation tests. Massive ductilestreaked surface was also found corresponding to the minimal surface finish determined from the optimal levels.

Characterization of machined polystyrene foam

1989 ◽  
Vol 47 ◽  
pp. 372-373
Author(s):  
C. W. Price ◽  
E. F. Lindsey ◽  
R. M. Franks ◽  
M. A. Lane
Keyword(s):  
Surface Finish ◽  
Cell Walls ◽  
Surface Structures ◽  
Efficient Technique ◽  
Low Density ◽  
Polystyrene Foam ◽  
Planar Surfaces ◽  
Machining Characteristics

Diamond-point turning is an efficient technique for machining low-density polystyrene foam, and the surface finish can be substantially improved by grinding. However, both diamond-point turning and grinding tend to tear and fracture cell walls and leave asperities formed by agglomerations of fragmented cell walls. Vibratoming is proving to be an excellent technique to form planar surfaces in polystyrene, and the machining characteristics of vibratoming and diamond-point turning are compared.Our work has demonstrated that proper evaluation of surface structures in low density polystyrene foam requires stereoscopic examinations; tilts of + and − 3 1/2 degrees were used for the stereo pairs. Coating does not seriously distort low-density polystyrene foam. Therefore, the specimens were gold-palladium coated and examined in a Hitachi S-800 FESEM at 5 kV.

Effect of denture cleansers, surface finish, and temperature on Molloplast B resilient liner color, hardness, and texture

2000 ◽  
Vol 9 (3) ◽  
pp. 148-155 ◽  
Author(s):  
Han-Kuang Tan ◽  
Andrew Woo ◽  
Silvia Kim ◽  
Michael Lamoureux ◽  
Michael Grace
Keyword(s):  
Surface Finish ◽  
Denture Cleansers

An appraisal of characteristic mechanical properties and microstructure of friction stir welding for Aluminium 6061 alloy – Silicon Carbide (SiCp) metal matrix composite

2019 ◽  
Vol 13 (4) ◽  
pp. 5804-5817
Author(s):  
Ibrahim Sabry
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Welded Joint ◽  
Rotation Speed ◽  
Fusion Welding ◽  
Friction Stir ◽  
Al 6061

It is expected that the demand for Metal Matrix Composite (MMCs) will increase in these applications in the aerospace and automotive industries sectors, strengthened AMC has different advantages over monolithic aluminium alloy as it has characteristics between matrix metal and reinforcement particles.  However, adequate joining technique, which is important for structural materials, has not been established for (MMCs) yet. Conventional fusion welding is difficult because of the irregular redistribution or reinforcement particles.  Also, the reaction between reinforcement particles and aluminium matrix as weld defects such as porosity in the fusion zone make fusion welding more difficult. The aim of this work was to show friction stir welding (FSW) feasibility for entering Al 6061/5 to Al 6061/18 wt. % SiCp composites has been produced by using stir casting technique. SiCp is added as reinforcement in to Aluminium alloy (Al 6061) for preparing metal matrix composite. This method is less expensive and very effective. Different rotational speeds,1000 and 1800 rpm and traverse speed 10 mm \ min was examined. Specimen composite plates having thick 10 mm were FS welded successfully. A high-speed steel (HSS) cylindrical instrument with conical pin form was used for FSW. The outcome revealed that the ultimate tensile strength of the welded joint (Al 6061/18 wt. %) was 195 MPa at rotation speed 1800 rpm, the outcome revealed that the ultimate tensile strength of the welded joint (Al 6061/18 wt.%) was 165 MPa at rotation speed 1000 rpm, that was very near to the composite matrix as-cast strength. The research of microstructure showed the reason for increased joint strength and microhardness. The microstructural study showed the reason (4 %) for higher joint strength and microhardness.  due to Significant   of SiCp close to the boundary of the dynamically recrystallized and thermo mechanically affected zone (TMAZ) was observed through rotation speed 1800 rpm. The friction stir welded ultimate tensile strength Decreases as the volume fraction increases of SiCp (18 wt.%).

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