Process Design and Optimization of end Milling Parameters of Al 7075 Metal Matrix Composite

2021 ◽  
pp. 929-937
Author(s):  
D. S. Sai Ravi Kiran ◽  
Alavilli Sai Apparao ◽  
Vempala GowriSankar ◽  
Shaik Faheem ◽  
Sheik Abdul Mateen ◽  
...  
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Hybrid Composites ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Weight Percentage

This paper investigates the machinability characteristics of end milling operation to yield minimum tool wear with the maximum material removal rate using RSM. Twenty-seven experimental runs based on Box-Behnken Design of Response Surface Methodology (RSM) were performed by varying the parameters of spindle speed, feed and depth of cut in different weight percentage of reinforcements such as Silicon Carbide (SiC-5%, 10%,15%) and Alumina (Al2O3-5%) in alluminium 7075 metal matrix. Grey relational analysis was used to solve the multi-response optimization problem by changing the weightages for different responses as per the process requirements of quality or productivity. Optimal parameter settings obtained were verified through confirmatory experiments. Analysis of variance was performed to obtain the contribution of each parameter on the machinability characteristics. The result shows that spindle speed and weight percentage of SiC are the most significant factors which affect the machinability characteristics of hybrid composites. An appropriate selection of the input parameters such as spindle speed of 1000 rpm, feed of 0.02 mm/rev, depth of cut of 1 mm and 5% of SiC produce best tool wear outcome and a spindle speed of 1838 rpm, feed of 0.04 mm/rev, depth of cut of 1.81 mm and 6.81 % of SiC for material removal rate.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

Modelling and Optimization of End Milling Process Using TLBO and TOPSIS Algorithm

2017 ◽  
pp. 54-81 ◽  
Author(s):  
Atul Tiwari ◽  
Mohan Kumar Pradhan
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Metal Cutting ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Optimization Method ◽  
Depth Of Cut ◽  
Multi Objective ◽  
Order Preference

To assure desire quality of machined products at minimum machining costs and maximum material removal rate, it is very important to select optimum parameters when metal cutting machine tool are used. Minimum Surface Roughness (Ra) is commonly desirable for the component; however Material Removal Rate (MRR) should be maximized. This chapter presents an approach for determination of the best cutting parameters precede to minimum Ra and maximum MRR simultaneously by integrating Response Surface Methodology with Multi-Objective Technique for Order Preference by Similarity to Ideal Solution and Teaching and learning based optimization algorithm in face milling of Al-6061 alloy. 30 experiments have been conducted based on RSM with 4 parameters, namely Speed, Feed, Depth of Cut and Coolant Speed and three levels each. ANOVA is performed to find the most influential input parameters for both MRR and Ra. Later the multi-objective attribution selection method TOPSIS and multi objective optimization method TLBO is used to optimize the responses.

Investigation of Trochoidal Milling in Nickel-Based Superalloy Inconel 738 and Comparison With End Milling

2014 ◽  
Author(s):  
Abram Pleta ◽  
Durul Ulutan ◽  
Laine Mears
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Extreme Environments ◽  
High Strength ◽  
Machining Time ◽  
Trochoidal Milling ◽  
Nickel Based Superalloy

Nickel-based superalloys are designed for use in extreme environments and are getting progressively better for these environments, therefore much harder to machine. They play a crucial role in elevated temperature applications where high strength, high resistance to corrosion and creep resistance are required. Machinability suffers as a result of these properties and harsh machining conditions occur, resulting in high cutting forces and tool wear. To combat the difficulties in the machining of nickel-based superalloys, such as poor thermal diffusivity and high levels of abrasive wear, trochoidal milling was introduced as an alternative method of milling. This method of milling combines linear motion with uniform circular motion, reducing chip load in exchange for increased machining time. Industry is averse to its widespread adoption due to increasing cycle times when compared to conventional milling methods, however it has been shown that overall productivity can be improved due to less tool wear with a more predictable behavior. This work characterizes the effects of trochoidal milling and provides a comparison of trochoidal milling with a traditional milling technique, end milling, for the machining of Inconel 738. In order to compare the trochoidal and conventional machining approaches directly, metrics of productivity normalized to tool wear are introduced. The normalized metrics introduced in this study aim to provide a more representative comparison of productivity and efficiency characteristics: volumetric material removal per unit tool wear (MR/VB) and the material removal rate per unit tool wear (MRR/VB). It was found that significantly higher volumetric material removal is possible using trochoidal milling, and fewer tools are needed; material removal rates that competitive with end milling can be achieved. When the amount of time spent on tool change for the same volume of material removal is considered, material removal rate of trochoidal milling can even be higher than end milling, indicating that better productivity and efficiency of the process is possible at reduced tooling costs.

scholarly journals Multi-Response Optimization of process Parameter in Vertical Milling Machine of EN 31 Using Taguchi Method

2021 ◽  
Vol 23 (11) ◽  
pp. 228-235
Author(s):  
Sunil Kumar ◽  
◽  
P.N . Rao ◽  
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Tool Wear Rate ◽  
Vertical Milling Machine ◽  
En 31

The purpose of this experimental research is to compare the effectiveness of using Taguchi approaches for multi-response optimization of process parameters in Vertical Milling Machine of EN 31 Material intending to minimize surface roughness and tool wear rate while maximizing material removal rate to improve the productivity of the process with coated carbide insert. Taguchi L9 and Annova have been applied for experimental design and analysis. This experiment shows that feed and depth of cut are factors that are important for tool wear, Depth of cut is a notable factor for Material Removal Rate and feed is the most notable factor for surface roughness. Spindle speed has little effect on tool wear rate, surface roughness, and material removal rate. Mathematical models for three response parameters i.e. tool wear rate, surface roughness, and material removal rate were obtained by regression analysis

scholarly journals Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3749 ◽  
Author(s):  
Adel T. Abbas ◽  
Neeraj Sharma ◽  
Saqib Anwar ◽  
Faraz H. Hashmi ◽  
Muhammad Jamil ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

Optimal flank wear in turning of Inconel 625 super-alloy using ceramic tool

2016 ◽  
Vol 232 (2) ◽  
pp. 208-216 ◽  
Author(s):  
M Jahanbakhsh ◽  
A Akhavan Farid ◽  
Mohammad Lotfi
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Flank Wear ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Optical Microscope ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Cutting Condition

Rapid tool wear is one of the major machinability aspects of nickel-based super alloys. In this article, the effect of cutting parameters on material removal rate and tool wear of a whisker ceramic insert in turning of Inconel 625 was examined. Optical microscope and scanning electron microscope were applied to measure and study tool wear mechanism. Response surface method was used to develop a mathematical model which confirmed by experimental tests. The statistical analysis done by analysis of variance showed that depth of cut is the most effective factor on the tool wear. Experiments showed that increment of feed rate had an insignificant effect on the progress of flank wear, and it is an important controlling factor when material removal rate is considered as a desired output. Finally, optimized cutting condition is presented in this work.

scholarly journals The Application of WSM, WPM and WASPAS Multicriteria Methods for Optimum Operating Conditions Selection in Machining Operations

2021 ◽  
Vol 10 (1) ◽  
pp. 1-14
Author(s):  
Onoyeyan Onajite ◽  
Sunday Ayoola Oke
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Operating Conditions ◽  
Depth Of Cut ◽  
Multicriteria Methods ◽  
Machining Operations

Optimal condition selection in machining operations is an imperative decision for the process engineer as it influences improved tool life and surface roughness values. As the aluminium market is extremely competitive, process engineers strive to understand what to do to gain preference from prospective customers. From this viewpoint, the criteria responsible for operating decisions should be examined. In this paper the WSM, WPM and WASPAS multicriteria methods are proposed for optimal machining conditions for turned aluminium bars. A stepwise methodology of the WSM, WPM and WASPAS methods is detailed. The proposed technique was tested on published data regarding the turning of an aluminium bar, machined on a lathe machine. The case study consists of three input parameters (spindle speed, feed rate and depth of cut) and four responses (cutting temperature, cutting force, surface roughness and material removal rate). After analysing the experimental data using the models, the entropy method chose material removal rate was chosen as the best. Using the three other models, the best selection was run 17 which correspond to an input parameter of 605 rpm spindle speed, 0.12 mm/rev feed rate and 1.8 mm depth of cut. This article offers a completely new approach to operating condition selection in the turning of the aluminium bar. In the current aluminium market, it is extremely important to understand the operating conditions of the machine for enlarged customer patronage and sustainability. The unique feature of this approach is the elevated level of reliability it exhibits.

Investigation of Surface Roughness and Material Removal Rate on Machining of TIB2 Reinforced Aluminum 6063 Composites: A Taguchi’s Approach

2020 ◽  
Vol 22 (4) ◽  
pp. 1319-1328
Author(s):  
L. Emmanual ◽  
T. Karthikeyan
Keyword(s):  
Surface Roughness ◽  
Analysis Of Variance ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Tib2 Particles

AbstractThe utilization of TiB2 particles reinforced aluminum (Al6063) metal matrix composite materials in many different engineering fields has undergone a tremendous increase. Accordingly, the need of accurate machining of composites has increased enormously; an attempt has been made to assess the factors influencing surface roughness and material removal rate on machining the composite. The orthogonal array, the signal-to-noise ratio, and analysis of variance were employed to study the performance characteristics in turning operations of 5 and 10 wt. % TiB2 particles reinforced aluminum (Al6063) metal matrix composites. Taguchi method was used to find the optimal cutting factors for surface roughness (Ra) and material removal rate (MRR). Three cutting factors namely speed; feed and depth of cut were optimized with considerations of Ra and MRR. The experimental plan and analysis was based on the Taguchi L27 orthogonal array with three cutting factors using carbide tool (K20). The optimal parametric combination for K20 carbide insert was found to be feed, speed and depth of cut. The analysis of variance (ANOVA) result shows that feed the most significant process parameter on surface roughness followed by speed. For MRR result show that the speed and the feed are the significant parameters followed by the composition of composite material.

An Investigation on Machining Behaviour of Metal Matrix Composites by Using PCD Inserts

2005 ◽  
Author(s):  
N. Muthu Krishnan ◽  
D. Vikram ◽  
S. Kaushik ◽  
K. Prahalada Rao
Keyword(s):  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Wear Behavior ◽  
Removal Rate ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Worn Surface ◽  
Poly Crystalline Diamond

The present work has been undertaken to study the tool wear behavior of poly crystalline diamond (PCD) inserts during the machining of Al-SiC – MMC; Al-Si alloy containing 15%wt of SiC was used for machining and PCD inserts of three different grades were used as cutting tools. The main aim of this paper is to explore the feasibility of machining conditions by setting the spindle speed, depth of cut and thereby determining the cutting force, surface roughness, power consumed, material removal rate and tool wear. The worn surface of the insert was examined by Scanning electron microscope (SEM). The influence of cut was examined for the PCD inserts.

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