scholarly journals Multi-Aspects Optimization of Process Parameters in CNC Turning of LM 25 Alloy Using the Taguchi-Grey Approach

Metals ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 453 ◽  
Author(s):  
S. Dhanalakshmi ◽  
T. Rameshbabu
Keyword(s):  
Aluminum Alloy ◽  
Performance Measures ◽  
Material Removal ◽  
Interaction Analysis ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Process Variables ◽  
Grey Relational

LM 25 is an aluminum alloy that has numerous applications such as in the manufacturing of automobile components and food industries, and especially in marine and seawater applications, due to its exceptional properties. An exertion has been taken for attaining the best-suited group of machining variables to attain improved and better performance in machining such as increased rate of material removal, lessened roughness values at the machined surface and the total cost incurred during machining. Taguchi’s design methodology has been implemented for devising the experimental combinations and also for single aspects optimization of deemed performance measures. Grey’s theory concept has been adopted for attaining Grey Relational Coefficient values and the values have been further utilized for evolving Grey Relational Grade. Analysis of Variance (ANOVA) has been employed to determine the significance of input process variables on the desired performance measures and interaction analysis also has been performed to determine the interaction effect between the selected process variables. As a result of optimization, the optimal combination of cutting parameters in turning LM25 aluminum alloy is cutting speed (A) = 150.79 m/min, feed (B) = 0.15 mm/min, depth of cut (C) = 0.9 mm and cutting fluid flow rate (D) = 75 mL/h. Compared with the initial parameter settings, surface roughness (Ra) decreases by 67.97%, material removal rate (MRR) increases by 88.12% and total machining cost (TMC) decreases by 93.86%. The proposed approach helps the manufacturer to attain better machining performance at an affordable cost.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

scholarly journals Multiple Response Optimization of machining parameters on turning of AA 6063 T6 aluminum alloy which established on Taguchi L9 orthogonal array coupled with Grey relational analysis

2021 ◽  
pp. 974-982
Author(s):  
D. S. Sai Ravi Kiran ◽  
Sanapala Sri Ram ◽  
Tangeti Bhaskararao ◽  
Boddu Eswar Venkat Sai ◽  
Kari Suraj Kumar ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Orthogonal Array ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting ◽  
Grey Relational Grade ◽  
Grey Relational

With numerous responses established on Taguchi L9, orthogonal array coupled with current work proposes a novel methodology for optimizing machining parameters on turning of AA 6063 T6 aluminum alloy. Experimental assessments are accomplished on AA 6063 T6 aluminum alloy. Turning trails are carried out under dry cutting conditions using an uncoated carbide insert. Cutting parameters such as cutting speed, feed rate, and depth of cut are optimized in this effort while numerous responses such as surface roughness(Ra) and material removal rate are taken into consideration (MRR). From the grey analysis, a grey relational grade(GRG) is calculated. The optimal amounts of parameters have been identified based on the values of grey relational grade, and then ANOVA is used to determine the significant influence of parameters. To authenticate the test result, a confirmation test is executed. The result of the experiments shows that by using this method. the turning process responses can be significantly improved.

scholarly journals Use of Multi-Objective Optimization Technique (Taguchi-GRA Approach) in Dry Hard Turning of Inconel 625

2020 ◽  
Vol 12 (2) ◽  
pp. 133-142
Author(s):  
Chinmaya PADHY ◽  
Pariniti SINGH
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Removal Rate ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Grey Relational

Current developments in manufacturing industries consider developing a suitable optimization technique for achieving improved machining performance. This study investigates the optimum values of machining parameters required namely –cutting speed (v), feed rate (f) and depth-of-cut (d) during dry hard turning of Inconel 625 with the aim of enhancing the productivity by minimizing surface roughness (Ra), cutting force (Fc), whereas maximizing material removal rate(MRR). This kind of multi-response process variable (MRP) problems usually known as multi-objective optimizations (MOOs) are solved with the help of Taguchi- Grey Relational Approach (T-GRA). Thus, here is a study conducted to apply Taguchi and Grey relational analysis to optimize multiple performance characteristics during dry hard turning of Inconel -625. As a result, the attained process variables, viz., cutting speed (60 m/min), feed rate (0.3 mm/rev), depth- of- cut (0.25mm) lead to value of optimum response variables –mean cutting force (340 N), surface roughness (0.998 μm) and material removal rate (0.786 mm3/min). In this setup, PVD coated carbide tool inserts were used for dry hard machining (turning) operation.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

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.

Improvement in the performance with less stiff air layer formation around the rubber tube-pasted grinding wheel

2019 ◽  
Vol 233 (15) ◽  
pp. 5175-5189 ◽  
Author(s):  
Spandan Guha ◽  
Partha Protim Das ◽  
Shankar Chakraborty
Keyword(s):  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Rubber Tube ◽  
Layer Formation ◽  
Relational Analysis ◽  
Grinding Performance ◽  
Roughness Amplitude ◽  
Grey Relational

In the grinding operation, a stiff layer of air gets formed around the periphery of the grinding wheel that causes deterioration of its performance. In the present work, in order to restrict the generation of stiff air layer around the periphery of the grinding wheel, a rubber tube is pasted on its surface to improve the grinding performance. An experimental investigation is carried out with low alloy steel as the work material. Taguchi's L9 orthogonal array is considered for the design of experiments while taking cutting speed, depth of cut, and type of the cutting fluid as the input grinding parameters. A comparative analysis using rubber tube-pasted grinding wheel and normal grinding wheel reveals that the developed wheel significantly improves the grinding performance with respect to surface roughness, amplitude of vibration and grinding ratio, as compared to the normal wheel. Moreover, grey relational analysis aided with fuzzy logic is applied in the experimental results to derive the optimal combination of process parameters for further enhancement of the grinding performance. Finally, analysis of variance results identify cutting speed as the most significant parameter while grinding with normal wheel, whereas depth of cut appears to be the most important parameter while machining with rubber tube-pasted grinding wheel.

Dimensional Instability Studies in Machining of Inconel 718 Nickel Based Superalloy as Applied to Aerogas Turbine Components

1999 ◽  
Vol 122 (1) ◽  
pp. 55-61 ◽  
Author(s):  
B. K. Subhas ◽  
R. Bhat ◽  
K. Ramachandra ◽  
H. K. Balakrishna
Keyword(s):  
Inconel 718 ◽  
Structural Integrity ◽  
Removal Rate ◽  
Research Work ◽  
Cutting Speed ◽  
Simultaneous Optimization ◽  
Depth Of Cut ◽  
Systematic Research ◽  
Process Variables ◽  
Dimensional Instability

Inconel 718 alloy is used extensively in aerogas turbines and this alloy is most difficult to machine and highly prone to dimensional instability after machining. Such detrimental phenomenon poses an enormous problem in engine assembly and affects structural integrity. This paper highlights the systematic research work undertaken to study the plastic deformation characteristics of Inconel 718, and the effect of process variables on machined surface, subsurface, and dimensional instability. Also illustrated is the technique developed for simultaneous optimization of several process variables such as cutting speed, feed, depth of cut, rake angle, and tool nose radius to control the residual stresses and dimensional instability within the acceptable tolerance band of the component. Prediction equations were developed for residual stress, dimensional instability, tool life, surface finish, and material removal rate. Predicted data were validated experimentally. This paper also presents the qualitative and quantitative data on dimensional instability with specific case studies of jet engine components, and it clearly illustrates the approach followed to develop a technique to control such detrimental effect. [S0742-4795(00)00901-7]

Research on Microscopic Grain-Workpiece Interaction in Grinding through Micro-Cutting Simulation, Part 2: Factorial Study

2009 ◽  
Vol 76-78 ◽  
pp. 15-20 ◽  
Author(s):  
Lan Yan ◽  
Xue Kun Li ◽  
Feng Jiang ◽  
Zhi Xiong Zhou ◽  
Yi Ming Rong
Keyword(s):  
Cutting Force ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Shear Angle ◽  
Depth Of Cut ◽  
Specific Cutting Force ◽  
Single Grain

The grinding process can be considered as micro-cutting processes with irregular abrasive grains on the surface of grinding wheel. Single grain cutting simulation of AISI D2 steel with a wide range of cutting parameters is carried out with AdvantEdgeTM. The effect of cutting parameters on cutting force, chip formation, material removal rate, and derived parameters such as the specific cutting force, critical depth of cut and shear angle is analyzed. The formation of chip, side burr and side flow is observed in the cutting zone. Material removal rate increases with the increase of depth of cut and cutting speed. Specific cutting force decreases with the increase of depth of cut resulting in size effect. The shear angle increases as the depth of cut and cutting speed increase. This factorial analysis of single grain cutting is adopted to facilitate the calculation of force consumption for each single abrasive grain in the grinding zone.

scholarly journals EFFECT OF PROCESS PARAMETERS FOR OPTIMUM MATERIAL REMOVAL RATE OF CYLINDRICAL GRINDING OF AISI 1045 STEEL

2015 ◽  
Vol 44 (2) ◽  
pp. 100-104
Author(s):  
Taranveer Singh ◽  
Khushdeep Goyal ◽  
Parlad Kumar
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Wheel Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Input Parameters ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Number Of Passes

In this experimental work, the effect of various input parameters viz. work speed, wheel speed,abrasive material, depth of cut, concentration of cutting fluid and number of passes has been studied on thematerial removal rate of cylindrical grinded AISI. For experimentation, three levels of each variable have beenselected except wheel speed. Two levels of wheel speed have been taken. Heat treated AISI 1045 has beenconsidered as work piece material. The result reveals that number of passes followed by the type of abrasivematerial is the most significant to influence material removal rate. The optimum set of input parameters formaximizing the material removal rate has also been found.

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