scholarly journals Sustainable Manufacturing and Parametric Analysis of Mild Steel Grade 60 by Deploying CNC Milling Machine and Taguchi Method

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1303
Author(s):  
Shakir Azim ◽  
Sahar Noor ◽  
Qazi Salman Khalid ◽  
Aqib Mashood Khan ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Feed Rate ◽  
Sustainable Manufacturing ◽  
Steel Grade ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine

Design and manufacturing are the key steps in the sustainable manufacturing of any product to be produced. Within the perspective of injection molds production, increased competitiveness and repeated changes in the design require a complete optimized manufacturing process. Local and minor improvements in the milling process do not generally lead to an optimized manufacturing process. The goal of the new geometry and parametric analysis of the mould is to reduce the quality issues in mild steel grade 60. In this explicit research, the surface roughness (smoothness) of indigenously produced injection moulds in the local market in Pakistan is investigated. The CNC milling machine (five-axis) is used for the manufacturing of an injection mould, and the Taguchi method of the design of the experiment is applied for parameters optimization. Hence, the overall process is assisted in balancing the milling machine parameters to trim down the surface roughness issue in mild steel moulds and increase their sustainability. The spindle speed (rpm), the depth of cut (mm), and the feed rate (mm/rev) are considered as input variables for process optimization, and the experiments are performed on mild steel grade 60. It is deduced that the combination of a spindle speed of 800 rpm, feed rate of 10 mm/rev and depth of cut of 0.5 mm is the best case in case of minimum surface roughness, which leads to sustainable products. It is also deduced from ANOVA, that the spindle speed is a factor that affects the surface roughness of mild steel products, while the feed rate turns out to be insignificant.

scholarly journals Effect of feed rate and depth of cut on face milling process on surface roughness of Al-Mg alloy using CNC milling machine 3 axis

2021 ◽  
Vol 3 (11) ◽  
pp. 11-18
Author(s):  
Rachmawati Achadiah ◽  
Putu Hadi Setyarini ◽  
Mas Ayu Pambayoen ◽  
Irfan H. Djunaidi ◽  
Dan Sti Azizah
Keyword(s):  
Surface Roughness ◽  
Control System ◽  
Feed Rate ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
Rate Variation ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine

The purpose of this study was to determine the effect of feed rate and depth of cut on the surface roughness of Al-Mg aluminum using a DIY CNC Milling Machine and Krisbow Universal Milling Machine as a comparison. The open-loop control system is a control system used in the design of DIY CNC Milling machines. A PC with Mach3 software is used as a PC Based Direct Digital Controller to control the system. In this study, the feed rate variation 24 mm/minute and 42 mm/minute and depth of cut 0.25 mm, 0.5 mm, and 0.75 mm were used. After the face milling process, the surface roughness test was carried out using the Mitoyo Surface Roughness Tester to determine the level of surface roughness of the machining results the DIY Milling Machine and Krisbow Universal Milling Machine as a comparison. The results showed that as the feed rate and depth of cut increased, the surface roughness values of both tools increased.

Optimizing the Machining Parameters in Glass Grinding Operation on the CNC Milling Machine for Best Surface Roughness

2010 ◽  
Vol 154-155 ◽  
pp. 721-726 ◽  
Author(s):  
Mohd Sayuti ◽  
Ahmed Aly Diaa Mohammed Sarhan ◽  
Mohd Hamdi Bin Abd Shukor
Keyword(s):  
Surface Roughness ◽  
Machining Process ◽  
Depth Of Cut ◽  
Response Analysis ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Cnc Milling Machine ◽  
Tool Diameter

Glass is one of the most difficult materials to be machined due to its brittle nature and unique structure such that the fracture is often occurred during machining and the surface finish produced is often poor. CNC milling machine is possible to be used with several parameters making the machining process on the glass special compared to other machining process. However, the application of grinding process on the CNC milling machine would be an ideal solution in generating special products with good surface roughness. This paper studies how to optimize the different machining parameters in glass grinding operation on CNC machine seeking for best surface roughness. These parameters include the spindle speed, feed rate, depth of cut, lubrication mode, tool type, tool diameter and tool wear. To optimize these machining parameters in which the most significant parameters affecting the surface roughness can be identified, Taguchi optimization method is used with the orthogonal array of L8(26). However, to obtain the most optimum parameters for best surface roughness, the signal to noise (S/N) response analysis and Pareto analysis of variance (ANOVA) methods are implemented. Finally, the confirmation test is carried out to investigate the improvement of the optimization. The results showed an improvement of 8.91 % in the measured surface roughness.

scholarly journals Incremental Sheet Forming (ISF) of AISI 316 Stainless Steel Sheet Using CNC Milling Machine

2014 ◽  
Vol 939 ◽  
pp. 322-327 ◽  
Author(s):  
M. Moayedfar ◽  
Zulkiflle Leman ◽  
B.T. Hang Tuah bin Baharudin
Keyword(s):  
Stainless Steel ◽  
Sheet Metal ◽  
Feed Rate ◽  
Steel Sheet ◽  
Incremental Sheet Forming ◽  
Spindle Speed ◽  
Milling Machine ◽  
Cnc Milling ◽  
Stainless Steel Sheet ◽  
Cnc Milling Machine

Incremental sheet forming (ISF) is a method to form a sheet metal into desired shape and surface features in a batch production series. This method includes forming a clamped sheet metal in controlled conditions by a CNC milling machine, lathe machine or a robot. In this study, the effects of forming parameters on the amount of stretch in stainless steel sheet using a CNC milling machine have been investigated. A ball-point shaped tool made of a bronze alloy was fabricated and used throughout the experiments. The tool acted as the indenter that formed the stainless steel sheet into a small pyramid-like shape. The results showed that as the spindle speed and feed rate increased, the amount of sheet stretch also increased, up to a point where the sheet could not stretch anymore and the process changed from forming to shear thinning and chipping. In addition, the surface quality of the part was badly affected at higher spindle speed and feed rate settings. The temperature of the lubrication oil was also measured during the process and the maximum temperature recorded was 45°C which remained constant until the end of the process. In conclusion, to obtain a good quality part while increasing the productivity of ISF, the optimized values of the feed rate and spindle speed in this work were found to be at 500 mm/min and 1000 rpm respectively.

Rapid and Versatile Micromold Fabrication Using Micromilling and Nanopolishing for Microfluidic Devices

2019 ◽  
Author(s):  
Thanh-Qua Nguyen ◽  
Jeongmin Mah ◽  
Woo-Tae Park ◽  
Sangyoup Lee
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Surface ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Milling ◽  
Tool Marks ◽  
Mold Fabrication

Abstract In an effort to make microfluidic research more attractive and cost-effective, micromilled polymethyl methacrylate (PMMA) has gained interests as an alternative method to the conventional cleanroom-based micromolds fabrication technologies. The most enabling aspects of micromilling are flexibility on the design changes and the ability to fabricate three-dimensional structures. However, the major drawback of micromilling based micromold fabrication is the presence of burrs and tool marks on the surface after machining. High surface roughness on replicated polymer results in poor bonding strength and optical clarity. The roughness of micromilled surface strongly depends on the machining parameters such as tool size, spindle speed, feed rate, width of cut, and depth of cut. Thus, it is crucial to optimize the machining parameters to obtain a good surface finish. Although the optimal fabrication parameters are used to machine the micromold, the surface roughness of micromilled mold is still relative high compared to the surface of unprocessed PMMA. In this paper, we first optimize the micromilling parameters of Computer Numerical Control (CNC) milling machine to achieve the best possible of surface roughness. We have optimized the machining parameters for a flat endmill with 100 μm, 200 μm, and 400 μm in diameter of spindle speed, feed rate, width of cut, and the depth of cut respectively at 18000 rpm, 20 mm/min, 30 μm, and 20 μm. Then, a method to polish the structured surface of the micromilled mold was developed using the rotary magnetic field. By modifying the CNC program language G-code, we were able to control the polishing path, polishing force and time precisely. Consequently, the burrs and tool marks are completely removed, such that the roughness of the surface is decreased from 350 nm Ra to 30 nm Ra, and 1200 nm Rz to 300 nm Rz while the profile of microstructures is not deteriorated. Finally, we demonstrate our mold fabrication scheme by building a microfluidic immunoassay device with four Quake’s valves and showed the sequential assay process successfully.

scholarly journals Study The Effect of Process Parameters of CNC Milling Surface Generation Using Al-alloy 7024

2019 ◽  
Vol 12 (3) ◽  
pp. 103-112
Author(s):  
Nareen Hafidh Obaeed
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Surface Finish ◽  
Feed Rate ◽  
Spindle Speed ◽  
Surface Generation ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Cnc Milling ◽  
Tool Diameter

A wonderful unique research developments in modeling surface roughness and optimization of the predominant parameters to get a surface finish of desired level since only suitable selection of cutting parameters can get a better surface finish, so the objective of this work is to study the milling process parameters which include tool diameter, feed rate, spindle speed, and depth of cut resulting in optimal values of the surface roughness during machining AL-alloy 7024. The machining operation implemented on XK7124 3-axis CNC milling machine. The effects of the selected parameters on the chosen characteristics have been accomplished using Taguchi’s parameter design approach. The parameters considered are – depth of cut with two levels (0.2, 0.5 mm), tool diameter with two levels (6, 8 mm), spindle speed with two levels (1000, 2500 rpm), and finally feed rate with two levels (200, 500 mm/min). Analysis of the results showed that the optimal settings for low values of surface roughness are large tool diameter (8 mm), high spindle speed (2500 r.p.m), low feed rate (200 mm/min) and high depth of cut (0.5 mm). Response Table for mean of surface roughness showed that tool diameter has the most effected factors (rank one) followed by feed rate (rank two) then depth of cut which is the third effected factors and finally spindle speed with the less effected factors of surface roughness (rank four).

scholarly journals OPTIMIZATION OF VARIABEL HELIX ANGLE PARAMETERS IN CNC MILLING OF CHATTER AND SURFACE ROUGHNES USING TAGUCHI METHOD

2021 ◽  
Vol 9 (1) ◽  
pp. 35-44
Author(s):  
Festo Andre Hardinsi ◽  
◽  
Oyong Novareza ◽  
Achmad As'ad Sonief
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Feed Rate ◽  
Helix Angle ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Excited Vibration ◽  
Optimal Value ◽  
Variable Helix

In the manufacturing industries, the main problem in process of operating CNC milling machine was chatter effect (self-excited vibration) which increases the quality of the surface roughness. In this study is to determine optimal value of parameters for chatter and surface roughness. The chatter measured using accelerometer MPU-6050 with Arduino by software LabVIEW-2019 based on peaks-FFT value and the surface roughness measured by SJ-301 tester. The research parameters like variable helix angle, spindle speed, feed rate, and depth of cut using stainless steel 304 by Taguchi method. The optimum parameters value obtained are variable helix 35/38 degrees, spindle speed 3000 RPM, feed rate 150 mm/min and depth of cut 0.4 mm. Based on ANOVA value, the variable helix angle and depth of cut are found to be significant for chatter and surface roughness. The depth of cut was high contribution by ANOVA chatter by 93.84% and surface roughness by 91.93%.

Prediction of Surface Roughness and Optimization of Cutting Parameters in CNC Turning of Rotational Features

2020 ◽  
Vol 38 (8A) ◽  
pp. 1143-1153
Author(s):  
Yousif K. Shounia ◽  
Tahseen F. Abbas ◽  
Raed R. Shwaish
Keyword(s):  
Surface Roughness ◽  
Linear Regression ◽  
Regression Model ◽  
Linear Regression Model ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Non Linear ◽  
Optimization Of Cutting Parameters

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

Application of Taguchi and Response Surface Methodologies for Surface Roughness in Rotary Tool Polishing Hardness Mould Steels

2011 ◽  
Vol 87 ◽  
pp. 82-89
Author(s):  
Potejanasak Potejana ◽  
Chakthong Thongchattu
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Laser Scanning ◽  
Cutting Speed ◽  
Optimal Level ◽  
Confocal Laser ◽  
Milling Machine ◽  
Cnc Milling ◽  
Polishing Process ◽  
Cnc Milling Machine

This research proposes a new application of 3-axis CNC milling machine for polishing the 60 HRC hardness steels. The rotary polishing tools are designed by refer to the end-mill ball nose’s design. The diamond powder are coated in rotary polishing tools by resinoid bonding method and concentrated in 4.4 karat/cm2. The Zig-milling tool paths are used to polish the hardness steel. After polishing, the confocal laser scanning microscope is used to analyze the arithmetic mean surface roughness of the hardness steels. The L12 orthogonal array of the Taguchi’s method is selected to conduct the matrix experiment to determine the optimal polishing process parameters. The diamond grit size and cutting speed of the rotary polishing tools, feed rate and step over of the tool path, the depth of polishing process penetration, and polishing time are used to study. The combination of the optimal level for each factor of the hardness steel polishing process are used to study again in the confirmation experiment. The predicted signal to noise ratio of smaller - the better under optimal condition are calculated by using the data from the experiment. The combination of the optimal level for each factor are used to study again in the confirmation experiment and the result show that polishing time was a dominant parameter for the surface roughness and the next was depth of penetration. The response surface design is then used to build the relationship between the input parameters and output responses. The experimental results show that the integrated approach does indeed find the optimal parameters that result in very good output responses in the rotary polishing tools polished hardness mould steel using CNC milling machine. The mean surface roughness of hardness steel polishing process is improved by the diamond rotary tools with the 3-axis CNC milling machine.

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

scholarly journals Penerapan Metode Taguchi untuk Optimasi Setting Parameter CNC Milling Terhadap Kekasaran Permukaan Material

2020 ◽  
Vol 2 (2) ◽  
pp. 49-60
Author(s):  
Farizi Rachman Farizi Rachman ◽  
Bayu Wiro K ◽  
Tri Andi Setiawan ◽  
Pradita Nurkholies
Keyword(s):  
Feed Rate ◽  
Base Plate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
End Mill

Industri manufaktur di Indonesia semakin meningkat seiring dengan tingkat kebutuhan manusia yang beraneka ragam dan memicu berkembangnya teknologi, salah satunya industri proses permesinan atau machining. Kualitas produk yang baik dapat dilihat dari tingkat kekasaran permukaannya karena kekasaran permukaan dapat mempengaruhi performa yang berkaitan dengan aspek fungsional dari produk. Pada penelitian ini telah dilakukan optimasi setting parameter CNC milling terhadap kekasaran permukaan pada material S50C dengan end mill HSS diameter 8 mm. Material S50C banyak digunakan dalam manufaktur mesin seperti mekanis base plate, roda gigi, standart punch head dan komponen mesin lainnya. Penelitian ini menggunakan metode Taguchi. Parameter yang digunakan yaitu spindle speed, Feed rate dan depth of cut dengan cairan pendingin sebagai variabel konstan. Parameter optimum untuk mendapatkan nillai kekasaran yang rendah yaitu spindle speed 1100 rpm, feed rate 46 mm/min dan depth of cut 0.5 mm. Dengan taraf signifikansi 0.1 menunjukkan bahwa spindle speed berpengaruh secara signifikan dengan kontribusi 38.42% diikuti feed rate dengan kontribusi 34.16%.

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