Metal cutting is one of the most significant manufa cturing processes in the area of material removal. It is Block it is defined metal cutting as the removal of metal chips from a work piece in order to obtain a finished product with de sired attributes of size,shape,and surface roughness.The imperative objective of the science o f metal cutting is the solution of practical problems associated with the efficient and precise removal of metal from work piece. It has been recognized that the reliable quantitative pred ictions of the various technological performance measures,preferably in the form of equ ations,are essential to develop optimization strategies for selecting cutting condi tions in process planning. In this thesis experiments has to be conducted to improve the surf ace finish quality of a work piece by using carbide tips. The type is bull nose tip. A se ries of experiments have to be done by varying the milling parameters spindle speed,feed rate and depth of cut and modeling is done by ANN. and Analysis is done by ANSYS.
Prediction of output Responses in Milling of Casted Aluminum by using ANNijiert bestjournal
The important goal in the modern industries is to m anufacture the products with lower cost and with hi gh quality in short span of time. There are two main p ractical problems that engineers face in a manufacturing process. The first is to determine th e values of process parameters that will yield the desired product quality (meet technical specificati ons) and the second is to maximize manufacturing system performance using the available resources. T he increase of customer needs for quality products (more precise tolerances and better product surface roughness) have driven the metal cutting process. The main objective of this project work is to study the effect of surface roughness and Material Removal R ate in a machining of cast aluminum on CNC milling mach ine with High Speed Steel cutting tool. The feasibility of implementation of design of experime nts (DOE),and Artificial Neural network in milling process is analyzed.
Impact of Mechanical System in Machining Of AISI 1018 Using Taguchi Design o...IJMER
The imperative objective of the science of metal cutting is the solution of practical problems
associated with the efficient and precise removal of metal from work piece. Optimization of process
parameters is done to have great control over quality, productivity and cost aspects of the process.
Taguchi method stresses the importance of studying the response variation using the signal–to–noise
(S/N) ratio, resulting in minimization of quality characteristic variation due to uncontrollable
parameter. Orthogonal array was adopted in order to planning the (L9) experimental runs in turning of
AISI 1018 by taking the help of software Minitab 16. The MRR and time
Experimental Analysis of Material Removal Rate in Drilling of 41Cr4 by a Tagu...IJERA Editor
In manufacturing industries the largest amount of money spent on drills. Therefore, from the viewpoint of cost and productivity, modeling and optimization of drilling processes parameter are extremely important for the manufacturing industry this paper presents a detailed model for drilling process parameter. The detailed structure includes in the model, are three parameters such as such as Spindle Speed, feed and depth of cut on material removal rate in drilling of 41 Cr 4 material using HSS spiral drill .We an effect of this three parameters on material removal rate .The detailed mathematical model is simulated by Minitab14 and simulation results fit experiment data very well In this investigation, an effective approach based on Taguchi method, analysis of variance (ANOVA), multivariable linear regression (MVLR), has been developed to determine the optimum conditions leading to higher MRR. Experiments were conducted by varying Spindle Speed, feed and depth of cut using L9 orthogonal array of Taguchi method. The present work aims at optimizing process parameters to achieve high MMR. Experimental results from the orthogonal array were used as the training data for the MVLR model to map the relationship between process parameters and MMR the experiment was conducted on drilling machine. From the investigation It concludes that speed is most influencing parameter followed by feed and depth of cut on MRR
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
“Optimization of Cutting Parameters for Turning AISI 316 Stainless Steel Base...IOSRJMCE
The objective of this work is the optimization of the cutting parameters for turning AISI 316 stainless steel to achieve the better surface finish using Taguchi’s methodology. Taguchi Parameter Design is a powerful and efficient method for optimizing quality and performance output of manufacturing processes, thus a powerful tool for meeting this challenge. This work discusses an investigation into the use of Taguchi Parameter Design for optimizing surface roughness generated by a Turning operation. In this method, four control factors viz. cutting speed, feed rate, depth of cut, three different cutting fluids (sherol B, sherol ENF, straight cutting oil) and one work piece material (AISI 316 stainless steel) were investigated at three different levels and the turning operations are done on Banka 1000 lathe machine. Cutting speed followed by cutting fluid has the significant role. The quality characteristic identified is surface roughness. Experiments carried out using L9 (34 ) Orthogonal Array with three different levels of control factors.The test results were analyzed using “smallerthe-better” criteria for Signal-to-Noise ratio in order to optimize the process. The experimental results were analyzed, conformed and successfully used to achieve good surface finish on work piece materials.
Vibration control of newly designed Tool and Tool-Holder for internal treadi...IJMER
Machining processes are manufacturing methods for ensuring processing quality, usually within
relatively short periods and at low cost. Several machining parameters, such as cutting speed, feed rate, work
piece material, and cutting tool geometry have significant effects on the process quality. Many researchers have
studied the impact of these factors. The cutting tool overhang affects the surface quality, especially during the
internal turning process, but this has not been reviewed much [9].
Full factorial method for optimization of process parameters for surface roug...Editor IJMTER
Quality and productivity play significant role in today’s manufacturing market.In
machining operations, achieving desired surface quality features of the machined product, is really a
challenging job on cnc machine. Because, these quality features are highly correlated and are
expected to be influenced directly or indirectly by the direct effect of process parameters. There are a
number of parameters like cutting speed, feed and depth of cut etc. which must be given
consideration during the machining of SS 316L. The prediction of optimal machining conditions for
good surface roughness and material removal rate plays a very important role in process planning.
Prediction of output Responses in Milling of Casted Aluminum by using ANNijiert bestjournal
The important goal in the modern industries is to m anufacture the products with lower cost and with hi gh quality in short span of time. There are two main p ractical problems that engineers face in a manufacturing process. The first is to determine th e values of process parameters that will yield the desired product quality (meet technical specificati ons) and the second is to maximize manufacturing system performance using the available resources. T he increase of customer needs for quality products (more precise tolerances and better product surface roughness) have driven the metal cutting process. The main objective of this project work is to study the effect of surface roughness and Material Removal R ate in a machining of cast aluminum on CNC milling mach ine with High Speed Steel cutting tool. The feasibility of implementation of design of experime nts (DOE),and Artificial Neural network in milling process is analyzed.
Impact of Mechanical System in Machining Of AISI 1018 Using Taguchi Design o...IJMER
The imperative objective of the science of metal cutting is the solution of practical problems
associated with the efficient and precise removal of metal from work piece. Optimization of process
parameters is done to have great control over quality, productivity and cost aspects of the process.
Taguchi method stresses the importance of studying the response variation using the signal–to–noise
(S/N) ratio, resulting in minimization of quality characteristic variation due to uncontrollable
parameter. Orthogonal array was adopted in order to planning the (L9) experimental runs in turning of
AISI 1018 by taking the help of software Minitab 16. The MRR and time
Experimental Analysis of Material Removal Rate in Drilling of 41Cr4 by a Tagu...IJERA Editor
In manufacturing industries the largest amount of money spent on drills. Therefore, from the viewpoint of cost and productivity, modeling and optimization of drilling processes parameter are extremely important for the manufacturing industry this paper presents a detailed model for drilling process parameter. The detailed structure includes in the model, are three parameters such as such as Spindle Speed, feed and depth of cut on material removal rate in drilling of 41 Cr 4 material using HSS spiral drill .We an effect of this three parameters on material removal rate .The detailed mathematical model is simulated by Minitab14 and simulation results fit experiment data very well In this investigation, an effective approach based on Taguchi method, analysis of variance (ANOVA), multivariable linear regression (MVLR), has been developed to determine the optimum conditions leading to higher MRR. Experiments were conducted by varying Spindle Speed, feed and depth of cut using L9 orthogonal array of Taguchi method. The present work aims at optimizing process parameters to achieve high MMR. Experimental results from the orthogonal array were used as the training data for the MVLR model to map the relationship between process parameters and MMR the experiment was conducted on drilling machine. From the investigation It concludes that speed is most influencing parameter followed by feed and depth of cut on MRR
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
“Optimization of Cutting Parameters for Turning AISI 316 Stainless Steel Base...IOSRJMCE
The objective of this work is the optimization of the cutting parameters for turning AISI 316 stainless steel to achieve the better surface finish using Taguchi’s methodology. Taguchi Parameter Design is a powerful and efficient method for optimizing quality and performance output of manufacturing processes, thus a powerful tool for meeting this challenge. This work discusses an investigation into the use of Taguchi Parameter Design for optimizing surface roughness generated by a Turning operation. In this method, four control factors viz. cutting speed, feed rate, depth of cut, three different cutting fluids (sherol B, sherol ENF, straight cutting oil) and one work piece material (AISI 316 stainless steel) were investigated at three different levels and the turning operations are done on Banka 1000 lathe machine. Cutting speed followed by cutting fluid has the significant role. The quality characteristic identified is surface roughness. Experiments carried out using L9 (34 ) Orthogonal Array with three different levels of control factors.The test results were analyzed using “smallerthe-better” criteria for Signal-to-Noise ratio in order to optimize the process. The experimental results were analyzed, conformed and successfully used to achieve good surface finish on work piece materials.
Vibration control of newly designed Tool and Tool-Holder for internal treadi...IJMER
Machining processes are manufacturing methods for ensuring processing quality, usually within
relatively short periods and at low cost. Several machining parameters, such as cutting speed, feed rate, work
piece material, and cutting tool geometry have significant effects on the process quality. Many researchers have
studied the impact of these factors. The cutting tool overhang affects the surface quality, especially during the
internal turning process, but this has not been reviewed much [9].
Full factorial method for optimization of process parameters for surface roug...Editor IJMTER
Quality and productivity play significant role in today’s manufacturing market.In
machining operations, achieving desired surface quality features of the machined product, is really a
challenging job on cnc machine. Because, these quality features are highly correlated and are
expected to be influenced directly or indirectly by the direct effect of process parameters. There are a
number of parameters like cutting speed, feed and depth of cut etc. which must be given
consideration during the machining of SS 316L. The prediction of optimal machining conditions for
good surface roughness and material removal rate plays a very important role in process planning.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation u...IJMER
Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchi’s L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis
optimization of process parameters for cnc turning using taguchi methods for ...INFOGAIN PUBLICATION
Coated and uncoated tool inserts offers certain degrees of control on the desired rate of tool wear and surface roughness to an extent. This work pursues the quest for realizing the optimal values for the significant process parameters that bears an influence on the response parameters. Experiments were conducted on the samples of EN 24 alloy steel material with the help of PVD coated TiAlN insert and uncoated carbide insert. The experimental runs carried out with proper variation in the levels. Levels are selected with the help of manufacturing catalogue and by pilot experimentation and results are recorded for further analysis. For this study, 9 runs designed using L9 orthogonal array of Taguchi Design of Experiment. Surface roughness was measured using a Mitutoyo surface tester at test lab and material removal rate is calculated by mathematical equation. The data was compiled into Minitab 17 software for analysis. The relationship between the machining parameters and the response variables were analyzed using the Taguchi Method. Optimization of process parameters is carried out by Grey Relational Analysis method (GRA). GRA method is a powerful and most versatile tool which can manipulate the input data as per requirement and comes with results that can be used to have best multi-objective in respective concerns
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Journals
Abstract Modern manufacturers, seeking to remain competitive in the market, rely on their Manufacturing engineers and production personnel to quickly and effectively set up manufacturing processes for new products. This paper presents the multi response optimization of turning parameters for Turning on AISI 4340 Alloy Steel. Experiments are designed and conducted based on Taguchi’s L27 Orthogonal array design. This paper discusses an investigation into the use of Taguchi parameter Design and Regression analysis to predict and optimize the Surface Roughness, Metal Removal Rate and Power Consumption in turning operations using CVD Cutting Tool. The Analysis of Variance (ANOVA) is employed to analyze the influence of Process Parameters during Turning. This paper also remarks the advantages of multi-objective optimization approach over the single-objective one. The useful results have been obtained by this research for other similar type of studies and can be helpful for further research works on the Tool life and Vibration of tools etc. Keywords: Turning, Ra, MRR, PC, Taguchi, Anova etc…
Taguchi Method for Optimization of Cutting Parameters in Turning OperationsIDES Editor
Surface roughness an indicator of surface quality is
one of the prime customer requirements for machined parts.
For efficient use of machine tools, optimum cutting
parameters are required. The turning process parameter
optimization is highly complex and time consuming. In this
paper taguchi parameter optimization methodology is applied
to optimize cutting parameters in turning. The turning
parameters evaluated are, cutting velocity, feed rate, depth of
cut, and nose radius of tool and hardness of the material each
at two levels. The results of analysis show that feed rate,
cutting velocity and nose radius have present significant
contribution on the surface roughness and depth of cut and
hardness of material have less significant contribution on the
surface roughness.
Experimental Investigation and Parametric Studies of Surface Roughness Analys...IJMER
The modern machining industries are focused on achieving high quality, in terms of
part/component accuracy, surface finish, high production rate and increase in product life. Surface
roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter.
The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other
parameters such as cutting force and power consumption in different conditions.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation u...IJMER
Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchi’s L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis
optimization of process parameters for cnc turning using taguchi methods for ...INFOGAIN PUBLICATION
Coated and uncoated tool inserts offers certain degrees of control on the desired rate of tool wear and surface roughness to an extent. This work pursues the quest for realizing the optimal values for the significant process parameters that bears an influence on the response parameters. Experiments were conducted on the samples of EN 24 alloy steel material with the help of PVD coated TiAlN insert and uncoated carbide insert. The experimental runs carried out with proper variation in the levels. Levels are selected with the help of manufacturing catalogue and by pilot experimentation and results are recorded for further analysis. For this study, 9 runs designed using L9 orthogonal array of Taguchi Design of Experiment. Surface roughness was measured using a Mitutoyo surface tester at test lab and material removal rate is calculated by mathematical equation. The data was compiled into Minitab 17 software for analysis. The relationship between the machining parameters and the response variables were analyzed using the Taguchi Method. Optimization of process parameters is carried out by Grey Relational Analysis method (GRA). GRA method is a powerful and most versatile tool which can manipulate the input data as per requirement and comes with results that can be used to have best multi-objective in respective concerns
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Journals
Abstract Modern manufacturers, seeking to remain competitive in the market, rely on their Manufacturing engineers and production personnel to quickly and effectively set up manufacturing processes for new products. This paper presents the multi response optimization of turning parameters for Turning on AISI 4340 Alloy Steel. Experiments are designed and conducted based on Taguchi’s L27 Orthogonal array design. This paper discusses an investigation into the use of Taguchi parameter Design and Regression analysis to predict and optimize the Surface Roughness, Metal Removal Rate and Power Consumption in turning operations using CVD Cutting Tool. The Analysis of Variance (ANOVA) is employed to analyze the influence of Process Parameters during Turning. This paper also remarks the advantages of multi-objective optimization approach over the single-objective one. The useful results have been obtained by this research for other similar type of studies and can be helpful for further research works on the Tool life and Vibration of tools etc. Keywords: Turning, Ra, MRR, PC, Taguchi, Anova etc…
Taguchi Method for Optimization of Cutting Parameters in Turning OperationsIDES Editor
Surface roughness an indicator of surface quality is
one of the prime customer requirements for machined parts.
For efficient use of machine tools, optimum cutting
parameters are required. The turning process parameter
optimization is highly complex and time consuming. In this
paper taguchi parameter optimization methodology is applied
to optimize cutting parameters in turning. The turning
parameters evaluated are, cutting velocity, feed rate, depth of
cut, and nose radius of tool and hardness of the material each
at two levels. The results of analysis show that feed rate,
cutting velocity and nose radius have present significant
contribution on the surface roughness and depth of cut and
hardness of material have less significant contribution on the
surface roughness.
Experimental Investigation and Parametric Studies of Surface Roughness Analys...IJMER
The modern machining industries are focused on achieving high quality, in terms of
part/component accuracy, surface finish, high production rate and increase in product life. Surface
roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter.
The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other
parameters such as cutting force and power consumption in different conditions.
The selection of optimal cutting parameters in turning operation is very important to
achieve high cutting performance. This paper deals with the optimization of performance
characteristics of turning EN-16 steel alloy using tungsten carbide inserts by Taguchi approach. The
experiments were performed on the basis of an L-18 orthogonal array given by Taguchi’s parameter
design approach. The performance characteristics such as thrust force and Material Removal Rate
(MRR) are optimized with the optimal combination of cutting parameters such as nose radius,
cutting speed, feed rate and depth of cut. Analysis of variance (ANOVA) is applied to identify the
most significant factor using MINITAB-16 software. The cutting parameters are varied to observe
the effects on performance characteristics and find the optimal results. Finally, confirmation tests are
performed to verify the experimental results. The results from the confirmation tests proved that the
performance characteristics such as thrust force and MRR are improved simultaneously through
optimal combination of process parameters obtained from Taguchi approach
Experimental Approach of CNC Drilling Operation for Mild Steel Using Taguchi...IJMER
Drilling is the most common (multi-point) cutting technique targeted for the production of
small-diameter holes. Hole making is among the most important operations in manufacturing, and
drilling is a major and common hole-making process in components. Productivity can be interpreted in
terms of material removal rate in any machining operation. It is, therefore, essential to optimize quality
and productivity simultaneously. Mild steel are soft, ductile, easily machined and is extensive used us a
main engineering material in various industry such as air craft and aerospace industry. The Taguchi
method is applied to formulate the experimental layout to ascertain the Element of impact each
optimum process parameters for CNC drilling machining with drilling operation of mild steel. A total of
27 experimental runs were conducted using an orthogonal array, and the ideal combination of
controllable factor levels was determined for the material removal rate, time of machining and
circularity has been measured. Design optimization for quality was carried out and single to noise ratio
and analysis of variance (ANOVA) were employed using experiment result to confirm effectiveness of
this approach.
tcStatistical and regression analysis of vibration of carbon steel cutting to...ijmech
Machining is a convoluted process in which many variables can deleterious the desired results. Among them, cutting tool vibration is the most decisive phenomenon which influences dimensional precision of the components machined, functional behavior of the machine tools and life of the cutting tool. In a machining operation, cutting speed, depth of cut and the tool feed rate principally influence cutting tool vibrations. In this paper, effects of cutting speed, feed rate and depth of cut on cutting tool vibration in both the directions, i.e. axial and tangential are investigated by the statistical methods of signal to noise ratio
(SNR), analysis of variance (ANOVA) and regression analysis. Experiments have been conducted using the L9 orthogonal array in the centre lathe machine. Carbon steel was selected as cutting tool materials to conduct the experiments. From experimental results, the amplitude of vibration of the cutting tool was ascertaining for each machining performance criteria. The significance and percentage contribution of each parameter were determined by Analysis of variance (ANOVA).It has been observed that cutting speed has a maximum contribution on cutting tool vibration in both the directions. Variation of the vibration of cutting tool with machining parameters was mathematically modeled by using the regression analysis
method. The predicted value from the developed model and experimental values are found to be very close
to each other justifying the significance of the model. Confirmation runs demonstrates that the optimized result and the values obtained through regression analysis are within the prescribed limit
The inspiration driving CNC machining undertakings is to make explicit shapes or surface
characteristics for a thing. In view of math and surface completion determinations, conditions for machining
assignments have for the most part been chosen. Assembling ventures endeavor to make high phenomenal things
at decay cost to stay serious inside the market. This exploration zeroed in on growing the advantage of benefit
on PC mathematical control (CNC) by enhancing machining boundaries by processing activities. In this
exploration, the profundity of cut, cutting velocity and feed rate on the aluminum amalgam work piece by the
utilization of carbide unit, embed shaper, HSS were utilized to enhance the advantage of CNC processing
measures by advancing machining boundaries picked to be assessed in this investigation by utilizing Taguchi's
System approach including symmetrical exhibit. The Taguchi strategy is utilized to notice the impact of cycle
boundaries and to look at a portion of the decrease speed, feed and profundity with acknowledgment of the
essential machinability part, surface end. The surface completion has been portrayed as quality attributes and is
accepted to be straightforwardly identified with efficiency.
Machining of duplex stainless steels: a comparative studyRasper Dellshad
This paper investigates the machining of super duplex EN 1.4410, standard duplex EN 1.4462 and austenitic EN 1.4404 stainless steels through a two-phase experimental study. In the first phase, a new methodology based on Mamdani fuzzy interference of classified chip shapes in chip breaking charts to predict the chip volume ratio is presented. Chip volume ratios, specific cutting pressures, cutting powers and resultant cutting forces are considered as performance characteristics and converted into single indices using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS), Grey Relational Analysis (GRA), VIKOR method and Utility Analysis (UA). An expert system based on fuzzy rule modelling approach is then adopted to combine the computed indices into a single Universal Characteristics Index (UCI). Results showed that converting the output of different Multiple Attribute Decision Making (MADM) methods into a single UCI index is a simple and efficient technique in determining an optimal combination of the cutting parameters. Constrained simulated annealing optimization procedure is then employed to evaluate the optimal process parameters thereby satisfying conflicting requirements of each of performance factors. First ranking UCI values are analyzed and compared with the output of multi-objective optimization techniques (MOO) using Weighted Sum Method. A remarkable improve in reduction of cutting power consumption, specific cutting pressure, resultant cutting forces are reported when first rank UCI value is directly reported as optimum point instead of performing conventional optimization. In the second phase, cutting force and machine current consumption signals are adopted as indirect cutting tool wear monitoring techniques to graph the tool wear progression. Results showed that the tool life strongly affected by cutting speed and workpiece material.
Similar to Artificial Neural Network Modeling and Analysis of EN24 &EN36 Using CNC Milling Machine (18)
Since so many years a problem occurs in KSB Pump Va mbori for casting process i.e. cracks occurs in the castings & it is repeated one. Therefore the compan y has given opportunity to me to solve this problem . In case of steel casting there are mainly cracks & also blo w holes induced due to the casting procedure. There are many factors for the casting defects .The factor is unev en material feeding in casting & also due to the mo uld material & also the core material. These cracks finally brea k directly the component of the casting i.e. in cas e of pump the casting component is like Impeller,Volute casing & casing cover. At the time of feeding of steel material in to the casting the material is in liquid us form i.e. it i s hot material & this material is feeding into casting at the time o f feeding it develop different region of heat. At o ne side the temp is high &at other side the temp is low this also pr oduce cracks. To simulate that casting we use the M AGMA SOFTWARE for simulation & validate it using NDT.
A COMPARATIVE STUDY OF DESIGN OF SIMPLE SPUR GEAR TRAIN AND HELICAL GEAR TRAI...ijiert bestjournal
In recent times,the gear design has become a highl y complicated and comprehensive subject. A designer of modern gear drive system must have to r emember that the main objective of gear drive is to transmit higher power with comparatively smaller overall dim ensions of the driving system which can be construc ted with minimum possible manufacturing cost,runs reas onably free of noise and vibration and which requir es little maintenance. In this paper single stage spur gear t rain and helical gear train with a idler gear are d esigned by American Gear Manufacturing Association (AGMA) stan dard. A idler gear is placed between two gearwheel to obtained the same direction of rotation. AGMA stres s equation is used to determined the tooth bending strength and surface contact strength. As a result,dimensio ns of gears are find out and comparative study is c arried out to select the optimum design of gear train for a give n input parameter
COMPARATIVE ANALYSIS OF CONVENTIONAL LEAF SPRING AND COMPOSITE LEAFijiert bestjournal
A leaf spring is a simple form of spring,commonly used for the suspension in wheeled vehicles. It is also one of the oldest forms of spring. Sometimes referred to as a semielliptical l eaf spring (SELS) it takes the form of a slender ar c-shaped length of spring steel of rectangular cross section. The centre of the arc p rovides location for the axle,while tie holes are provided at either end for attaching to the vehicle body. In the present work,a seven-leaf steel spring use d in passenger cars is replaced with a composite mu lti leaf spring made of glass/epoxy composites. The dimensions sand the num ber of leaves for both steel leaf spring and compos ite leaf springs are considered to be the same. The primary objective is to compare their load carrying capacity,stiffness and weight savings of composite leaf spring. Finally,fatigue life of steel and com posite leaf spring is also predicted using life dat a
Brimmed diffuser is collection�acceleration device which shrouds a wind turbine.For a given turbine di ameter,the power augmentation can be achieved by brimmed diffuser,p opularly known as wind lens. The present numerical investigation deals with the effect of low pressure region created by wind l ens and hence to analyze the strong vortices formed by a brim attached to the shroud diffuser at exit. Also in this analysis,a c omparative numerical prediction of mass flow rates through the wind turbine has been carried out with various types of wind lens wh ich in turn helps to optimize the torque augmentati on. It has been numerically proved that there is significant increase in the wa ke formation & vortex strength when brimming effect is added to a diffuser
FINITE ELEMENT ANALYSIS OF CONNECTING ROD OF MG-ALLOY ijiert bestjournal
The automobile engine connecting rod is a high volume production,critical component. It co nnects reciprocating piston to rotating crankshaft,transmitting the thrust of the piston to the crankshaft. Every vehicle that uses an internal combustion engine requires at least one connecting rod depending upon the number of cylinders in the engine. As the purp ose of the connecting rod is to transfer the reciprocating motion of the piston into rotary motion of the crankshaft. Connecting ro ds for automotive applications are typically manufactured by forging from either w rought steel or powdered metal. the material used f or this process is Mg-Alloy and also finite element analysis of connecting rod
REVIEW ON CRITICAL SPEED IMPROVEMENT IN SINGLE CYLINDER ENGINE VALVE TRAINijiert bestjournal
The purpose of valve train is to operate the inlet and outlet valves of the engine. The valve train m ainly consists of rocker arm,push rod,cam,poppet valve and spring for kee p the valves closed position. The Greaves G400WG en gine valve train is operated at the maximum speed of 3600 rpm. The main objective of this project is to improve the valve train speed up to safe speed limit that is up to 5000 rpm. The valve spring parameters are optimized based on space availability,stress limit,stiffness,buckl ing of pushrod and natural frequency of the system. The optimized valv e spring configuration is used in the push rod type valve train and the valve train dynamics for different engine speed is studie d using commercially available multi-body dynamic A DMAS software. A comparative valve train dynamics analysis is also c arried out with the existing and optimized valve sp ring combinations. It is observed that valve jump engine speed with respect to optimized valve spring is enhanced to considerab le amount when compared to the existing valve spring configuration. Design improvements include detail study on following topi cs:1. Valve Spring Stiffness. 2. Push rod buckling. 3. Valve closing Velocity. 4. Contact stress between cam and follower
ENERGY CONVERSION PHENOMENON IN IMPLEMENTATION OF WATER LIFTING BY USING PEND...ijiert bestjournal
This paper consist of working of reciprocating pump which is driven by a compound pendulum. It provide s the energy required to lift the water from a tank placed approximately several meter below the ground level. Basic application of the mechanism will be for watering the garden which will be operated by means of operation opening and closing of entrance gate. Paper consists of basic concept,design of pump and compound pendulum mecha nism and fabricationed model. The concept can also be implemented in the rural areas,having the problem of electric supply. We aim at making a prototype for providing some me an for pumping of water by the pump which requires less human efforts,conside ring cost effectiveness,easy to operate and portab le mechanism.
The IC engine has seen numerous revolutionary and e volutionary modifications in technology and design over the past few decades. The sole motto behind the modifications wa s to increase the overall efficiency of the IC Engi ne including volumetric and thermal efficiency. Recently few benchmarking techn ologies like the CRDI,MPFI,HCCI,etc. in the Otto cycle and Diesel cycle engines have created an enormous revolution in the automobile industry. In spite of these technologica l and design advances,the efficiencies are not being more than a particular l imit. However,the concept of split cycle engines has dra stically increased the overall performance in all respect. The split cycle concept basically separates the fou r strokes of the conventional cycle. The Scuderi engine one of the best-in-class engine desi gns based on the split cycle concept. The Scuderi engine works on the split cycle and gives higher efficiency than the previous split cycle engines resulting overall high perform ance. It also eliminates the problems faced by previous engines based on the spl it cycle in terms of breathing (volumetric efficien cy) and thermal efficiency. This paper throws light on the greater volumetric,thermal and overall efficiency key points related t o the Scuderi Engines.
EXPERIMENTAL EVALUATION OF TEMPERATURE DISTRIBUTION IN JOURNAL BEARING OPERAT...ijiert bestjournal
The excessive rise of temperature in the journal be aring operating at boundary/mixed lubrication regim es. Journal bearing test set- up is used to measure the temperature along the cir cumference of the bearing specimen for different lo ading conditions. Here in this journal bearing of l/d ratio 1,diameter of jo urnal is 60mm and the bearing length is 60mm,clear ance is .06mm has been designed and tested to access the temperature rise of the bearing. The result shows that as the load o n the bearing is increasing temperature also increasing. Temperature analysis o f journal bearing is also done by the Ansys workben ch software
STUDY OF SOLAR THERMAL CAVITY RECEIVER FOR PARABOLIC CONCENTRATING COLLECTOR ijiert bestjournal
Energy is one of the building blocks of the country . The growth of the country has been fueled by chea p,abundant energy resources. Solar energy is a form of renewable ener gy which is available abundantly and collected unre servedly. The parabolic concentrator reflects the direct incident solar rad iation onto a receiver mounted above the dish at it s focal point. The conversion of concentrated solar radiation to heat takes place in receiver. The heat transfer characteristics of the receiver changes during the rotation of the receiver which affects thermal performance. The working temperature may also influence the ther mal performance and overall efficiency of the system. Thermal as well as optica l losses affect the performance of a solar paraboli c dish-cavity receiver system. The thermal losses of a solar cavity receiver include c onvective and radiative losses to the air in the ca vity and conductive heat loss through the insulation used behind the helical tube surface. Convective and radiative heat losses form the major constituents of the thermal losses. The convection heat loss from cavit y receiver in parabolic dish solar thermal power sy stem can significantly reduce the efficiency and consequently the cost effectiveness of the system. It is important to assess this heat loss and subsequently improve the thermal performance of the receiver.
DESIGN, OPTIMIZATION AND FINITE ELEMENT ANALYSIS OF CRANKSHAFTijiert bestjournal
Crankshaft is a crucial component in an engine asse mbly. Crankshaft is consisting of two web sections and one crankpin,which converts the reciprocating displacement of the pist on to a rotary motion with a four link mechanism. G enerally crankshafts are manufactured using cast iron and forged steel mater ial. In this work to design and finite element anal ysis of crankshaft of 4 cylinder petrol engine of Maruti swift Vxi. of 1200 cubic capacity. The finite element analysis in ABA QUS software by using six materials based on their composition viz. Cast iron,EN30B,SAE4340,Structural steel,C70 Alloy steel and Aluminium based composite material reinforced with silicon carbide & fly ash. The parameter like von misses stress,deformation;maximum and minimum principal stress & strain were obtained from analysis software. The results of Finite element show that t he Aluminium based composite material is best mater ial among all. Compare the result like weight and Stiffness parameter. It is resulted of 65.539 % of weight,with reduction i n deformation.
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICRO...ijiert bestjournal
Nowadays,necessity of small components is a common trend. These requirements encourage the researcher s to develop very minutest size components to fulfill the demand. The manufact uring of these type of components is a difficult ob ligation and for that various machining methods are develop to manufacture such c omponents. In this article the Electro Chemical mac hining and Electrical Discharge Machining is reviewed. We tried to summar ize the work of various researchers. The study show s that this type of machining processes gives good alternative.
HEAT TRANSFER ENHANCEMENT BY USING NANOFLUID JET IMPINGEMENTijiert bestjournal
An experimental investigation was carried out for s tudying the heat transfer performance of the water-Al2O3 (28nm average particle size) nanofluid inside a liquid evacuated impinging jet system dest ined to the cooling of circular target surface. Results have shown that th e surface heat transfer coefficient increases consi derably when the mass flow rate is increased,but is relatively insensitive to the nozzle-to heated-surface distance. It was foun d that the use of a nanofluid can provide a heat transfer enhancement when compared t o water. Thus most practical applications of jet im pingement occur in industries where the heat transfer requirements hav e exceeded capacity of ordinary heating and cooling techniques. This work presents and discusses the results of an experiment al investigation of heat transfer between the horiz ontal smooth plate of impinged jets.
MODIFICATION AND OPTIMIZATION IN STEEL SANDWICH PANELS USING ANSYS WORKBENCH ijiert bestjournal
The demand for bigger,faster and lighter moving ve hicles,such as ships,trains,trucks and buses has increased the importance of efficient str uctural arrangements. In principle two approaches exist to develop efficient structures:e ither application of new materials or the use of new structural design. A proven and well-establi shed solution is the use of composite materials and sandwich structures. In this way high strength to weight ratio and minimum weight can be obtained. The sandwich structures have potential to offer a w ide range of attractive design solutions. In addition to the obtained weight reduction,these so lutions can often bring space savings,fire resistance,noise control and improved heating and cooling performance. Laser-welded metallic sandwich panels offer a number of outstand ing properties allowing the designer to develop light and efficient structural configuratio ns for a large variety of applications. These panels have been under active investigations during the last 15 years in the world.
IMPACT ANALYSIS OF ALUMINUM HONEYCOMB SANDWICH PANEL BUMPER BEAM: A REVIEW ijiert bestjournal
Bumper is a energy absorbing protective element whi ch absorb the energy in front collision and protect valuable parts like radiator etc. Bumper is act like protect ive shield generally made of steel material. As eco nomic point of view and to reduce consumption of fuel manufacturin g of light weight vehicle is requirement of current situation. Application of composite material in automobile sec tor is now day common thing. Aluminum honeycomb san dwich panel is basically material from aerospace industri es and known for its high strength to weight ratio. Sandwich structure basically having its properties due to ge ometry. To determine various properties of sandwich structure conducting experiments is expensive,so generally F EA is used .However complex geometry is hurdle so t here are various theories are available for simplification o f model. These theories convert 3D model in to homo genous model .As far as concerning India manufacturing rate of s andwich structure is very less,so generally cost i s more. Greatest giant manufacturer is china we can observe their bu llet train and metro transport facility constructio n. Recently in march 2014 largest selling Indian cars are failed in NCap test in 100% frontal crash test. So requirement of more energy absorbing material with economy cons ideration is important.
Robotic welding requires specialized fixtures to ac curately hold the work piece during the welding operation. Despite the large variety of welding fix tures available today the focus has shifted in maki ng the welding arms more versatile,not the fixture. T he new fixture design reduces cycle time and operat or labor while increasing functionality;and allows co mplex welding operations to be completed on simple two axis welding arms
ADVANCED TRANSIENT THERMAL AND STRUCTURAL ANALYSIS OF DISC BRAKE BY USING ANS...ijiert bestjournal
In these paper structural fields of the solid disc brake during short and emergency braking with four different materials is studied. The distribution of the tempe rature depends on the various factors such as frict ion,surface roughness and speed. The effect of the angular velo city and the contact pressure induces the temperatu re rise of disc brake. The finite element simulation for three -dimensional model was preferred due to the heat fl ux ratio constantly distributed in circumferential direction . Here value of temperature,friction contact power,nodal displacement and deformation for different pressure condition using analysis software with four materi als namely cast iron,cast steel,aluminium and carbon fibre reinforced plastic are taken. Presently the D isc brakes are made up of cast iron and cast steel. With the v alue of simulation result best suitable material fo r the brake drum with higher life span is determined.
REVIEW ON MECHANICAL PROPERTIES OF NON-ASBESTOS COMPOSITE MATERIAL USED IN BR...ijiert bestjournal
Metallic matrix composites are combinations of two or more different metals inter metallic compounds or second phases in which dispersed phases are embe dded within the metallic matrix. They are produced by controlling the morphologies of the constituents to achieve optimum combination of properties. Properties of the composites depend on the properti es of the constituent phases,their relative amount,and dispersed phase geometry including particle siz e,shape and orientation in the matrix. In this pap er,The mechanical properties,behaviour and micro stru ctural evolution of aluminium metal matrix metallic composites fabricated under various process conditi ons were investigated to understand their process- structure�property relations by optimization proces s. Addition of silicon carbide to aluminum has show n an increase in its mechanical properties.
PERFORMANCE EVALUATION OF TRIBOLOGICAL PROPERTIES OF COTTON SEED OIL FOR MULT...ijiert bestjournal
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Magnetic abrasive finishing is a machining process where the tooling allowance is remove by media wi th both magnetic and abrasive properties,with a magnetic f ield acting as a binder of a grain. Such machining falls into the category of erosion by abrasive suspension and lend itself to the finishing of any type of surface . The possibility of finishing complex surfaces is a spec ial benefit of this machining. Magnetic abrasive fi nishing process is most suitable for obtaining quality fini sh on metallic and non-metallic surfaces. Magnetic abrasive finishing used for complicated product finishing & Roughness and tolerance band achieved that is diffi cult using conventional machine process. The product dimension al requirement easily possible with taking trial wi th MAF parameters.
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A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
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Immunizing Image Classifiers Against Localized Adversary Attacks
Artificial Neural Network Modeling and Analysis of EN24 &EN36 Using CNC Milling Machine
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Artificial Neural Network Modeling and Analysis of EN24
&EN36 Using CNC Milling Machine
A Bhargav,
Assistant professor
CNV Sridhar
Professor& Head
S Girivardhan Naidu
PG student
Abstract
Metal cutting is one of the most significant manufacturing processes in the area of material
removal. It is Block it is defined metal cutting as the removal of metal chips from a work
piece in order to obtain a finished product with desired attributes of size, shape, and surface
roughness.The imperative objective of the science of metal cutting is the solution of practical
problems associated with the efficient and precise removal of metal from work piece. It has
been recognized that the reliable quantitative predictions of the various technological
performance measures, preferably in the form of equations, are essential to develop
optimization strategies for selecting cutting conditions in process planning. In this thesis
experiments has to be conducted to improve the surface finish quality of a work piece by
using carbide tips. The type is bull nose tip. A series of experiments have to be done by
varying the milling parameters spindle speed, feed rate and depth of cut and modeling is done
by ANN. and Analysis is done by ANSYS.
Introduction
The important goal in the modern industries is to manufacture the products with lower cost
and with high quality in short span of time. There are two main practical problems that
engineers face in a manufacturing process. The first is to determine the values of process
parameters that will yield the desired product quality (meet technical specifications) and the
second is to maximize manufacturing system performance using the available resources.
Machining is the process of removing the unwanted material from the work piece in the form
of chips. If the work piece is a metal, the process is often called as metal cutting process chip
forming processes. Metal cutting is a machining process by which a work piece is given as
follows
• A desired shape
• A desired size
• A desired surface finish
To achieve one or all of these, the excess (undesired) material is removed (from the work
piece) in the form of chips with the help of some properly shaped and sized tools. Metal
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cutting processes are performed on metal cutting machines, more commonly termed as
Machine Tools by means of various types of cutting tools.
The increase of customer needs for quality products (more precise tolerances and better
product surface roughness) have driven the metal cutting process. In the global antagonism,
manufacturing organizations are working in the direction of improving the product quality
and performance of the product with lower cost in short span of time, but practices aimed at
lowering the costs don’t usually improve quality.
There is hierarchical relationship between cost and quality. The intense international
competition has focused the attention of the manufacturers on automation as means to
increase productivity and improve quality. To realize full automation in machining, computer
numerically controlled (CNC) machine tools have been implemented during the past decades.
CNC machine tools require less operator input, provide greater improvements in productivity
and increase the quality of the machined part.
Among several CNC industrial machining processes, milling is a fundamental machining
operation. End milling is the most common metal removal operation encountered. It is widely
used in a variety of manufacturing industries including the aerospace and automotive sectors,
where quality is an important factor in the production of slots, pockets, precision molds and
dies etc.,.
The surface roughness plays an imperative role in the manufacturing industry. The quality of
surface affects functional requirements and plays a very important role in the performance of
the milling as a good quality of milled surface significantly improves fatigue strength,
corrosion resistance or creep life. Surface roughness also affects the several functional
attributes of parts such as contact causing surface friction, wearing, light reflection, heat
transmission and ability of distributing and holding lubricant coating or resisting fatigue.
Therefore the desired finish surface is usually specified and the appropriate processes are
selected to reach the required quality.
Several factors will influence the final surface roughness in a CNC milling operation. The
final surface roughness might be considered as the sum of two independent effects.
1. The ideal surface roughness is a result of the geometry of the tool & feed and
2. The natural surface roughness is a result of the irregularities in the cutting operation.
(Boothoryd and Knight, 1989).
In this work, the design of experiments techniques such as orthogonal arrays in
Taguchi design, ANOVA and Artificial Neural Network has been implemented to develop
model and analysis for a better product quality.
II DESIGN OF EXPERIMENTS (DOE):
A Design of Experiment (DOE) is a structured, organized method for determining the
relationship between factors affecting a process and the output of that process. Conducting
and analyzing controlled tests to evaluate the factors that control the value of a parameter or
group of parameters. “Design of Experiments" (DOE) refers to experimental methods used to
quantify indeterminate measurements of factors and interactions between factors statistically
through observance of forced changes made methodically as directed by mathematically
systematic tables.
2.1Design of Experiment Techniques
1. Factorial Design.
2. Response Surface methodology.
3. Mixture Design.
4. Taguchi Design.
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Among those we had selected Taguchi Design for optimizing surface finish and cutting
forces in face milling Operation.
2.2Orthogonal array
In order to reduce the total number of experiments “Sir Ronald Fisher” developed solution:”
orthogonal arrays”. The orthogonal array can be thought of as a distillation mechanism
through which the engineers experiment passes (Ealey, 1998). The array allows the engineer
to vary multiple variables at one time and obtain the effects which that set of variables has an
average and the dispersion. Taguchi method can be calculated based on the degrees of
freedom approach.
Nୋେୌ୍ = 1 + ∑ ሺܮ − 1ሻே
ୀଵ ---------- (3.1)
Taguchi employs design experiments using specially constructed table, known as
"Orthogonal Arrays (OA)" to treat the design process, such that the quality is build into the
product during the product design stage. Orthogonal Arrays (OA) are a special set of Latin
squares, constructed by Taguchi to lay out the product design experiments. An orthogonal
array is a type of experiment where the columns for the independent variables are
“orthogonal” to one another. Orthogonal arrays are employed to study the effect of several
control factors. Orthogonal arrays are used to investigate quality. Orthogonal arrays are not
unique to Taguchi, they were discovered considerably earlier (Bendell, 1998). However
Taguchi has simplified their use by providing tabulated sets of standard orthogonal arrays and
corresponding linear graphs to fit specific projects (ASI, 1989; Taguchi and Kenishi, 1987).
Table3.1 A typical L9 orthogonal array: (34
)
A B C D
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 2 1 2 3
5 2 2 3 1
6 2 3 1 2
7 3 1 3 2
8 3 2 1 3
9 3 3 2 1
In this array the columns are mutually orthogonal. That is for any pair of columns all
combination of factors occurs; and they occur an equal number of times. Here there are 4
parameters, A, B, C and D each at three levels. This is called an ‘L9’ design; with the 9
indication the nine rows, configurations or prototypes to be tested. Specific test
characteristics for each experimental evaluation are identified in the associated row of the
table. Thus L9 (34
) means that nine experiments are to be carried out to study four variables
with three levels. There are greater savings in testing for larger arrays.
III EXPERIMENTATION
Experiments have been performed in order to investigate the effects of one or more factors of
the process parameters (spindle speed, feed rate and depth of cut) on the surface finish of the
machined surface.
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The main aim of the project is to determine the influence of radius carbide tips in metal
working. The investigation is based on surface roughness during milling of EN24 and EN36
steel with carbide tool. The cutting parameters considered are feed rate, spindle speed and
depth of cut.
3.1Experimental Procedure
This experiment employed a CNC vertical milling machine. Carbide cutting tool is used. The
experiment has been done under conditions of feed rate 700mm/min, 980mm/min, 1400
mm/min, 1900 mm/min and 2600 mm/min. For EN24 Spindle speeds are2000rpm, 1800rpm,
2100rpm, and depth of cut 0.25mm, And for EN36, spindle speeds are 2100rpm, 2200rpm,
2300rpm, 2400rpm and 2500rpm.
Five square pieces of EN 24 material and EN36 material are taken for machining.
fig3.1 spindle rotation
3.2Cemented carbide Tool
Advantage of cemented carbide in around 1905 made a break through at that time in the
history of cutting tool materials though got later superseded by many other novel tool
materials like cemented carbides and ceramics which could machine much faster than the
HSS tools. The basic composition of HSS is 94% WC, 6.0% CO, 1% and rest Fe. Such
carbide tool could machine (turn) mild steel jobs at speed only up to 20 ~ 30 m/min
Carbide is used as cutting tool material where;
• The tool geometry and mechanics of chip formation are complex, such as helical twist
drills, reamers, gear shaping cutters, hobs, form tools, broaches etc.
• Brittle tools like carbides, ceramics etc. are not suitable under shock loading
• The small scale industries cannot afford costlier tools
• The old or low powered small machine tools cannot accept high speed and feed.
Table 3.1 CNC milling machine and its specifications
DESCRIPTION SPECIFICATION
Model CKEN 40
Table clamping area 2M/1800
Travel X-axis
Y-axis
Z-axis
1800 mm
850 mm
750mm
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Table size
2000 X 800mm
Spindle Motor Capacity 0.5 HP
Spindle speeds 150 - 4500RPM
Power Source 230V, Single Phase, 50 Hz
Feed rates BT 50
Rapid traverse x, y, z-axis 0-1 m/min
CNC control system PNEUMATIC
Machine Dimensions 1000x575x650mm
Fig.3.2. CNC milling machine CKEN 40
Table 3.2 Material Input Parameters of EN-24
SECTION-A
S.NO. FEED
(mm/min )
SPEED
(rpm)
DEPTH OF CUT
(mm)
1. 700 2000 0.25
2. 980 1800 0.25
3. 1400 2100 0.25
4. 1900 2000 0.25
5. 2600 2000 0.25
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Table 3.3 Machining input Parameters of EN 24
SECTION-B
S.NO. FEED
(mm/min)
SPEED
(rpm)
DEPTH OF CUT
(mm)
1. 700 2100 0.25
2. 980 2200 0.25
3. 1400 2300 0.25
4. 1900 2400 0.25
5. 2600 2500 0.25
Table 3.4 Material Input Parameters of EN-36
SECTION-A
S.NO. FEED
(mm/min)
SPEED
(rpm)
DEPTH OF CUT
(mm)
1. 700 2000 0.25
2. 980 1800 0.25
3. 1400 2100 0.25
4. 1900 2000 0.25
5. 2600 2000 0.25
Table 3.5 Machining input Parameters of EN 36
SECTION-B
S.NO. FEED
(mm/min)
SPEED
(rpm)
DEPTH OF CUT
(mm)
1. 700 2100 0.25
2. 980 2200 0.25
3. 1400 2300 0.25
4. 1900 2400 0.25
5. 2600 2500 0.25
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3.3 Surface finish measurement
Talysurf meter instrument is widely used to measure the shape or form of components. A
profile measurement device is usually based on a tactile measurement principle. The surface
is measured by moving a stylus across the surface. As the stylus moves up and down along
the surface, a transducer converts these movements into a signal which is then transformed
into a roughness number and usually a visually displayed profile. Multiple profiles can often
be combined to form a surface representation. Talysurf meter is shown in fig 4.4.
Fig.3.3. Talysurf roughnessmeter
3.4 Experimental procedure
i) The parameters which influence the milling process and their levels are listed based on
previous works (table 4.4 and 4.5).
ii) Milling operation is performed on EN24 and EN36 by using the CNC Milling machine.
iii) The surface finish values of work are measured using Talysurf meter (table 4.6).
The experimental results are presented in Table.-3.6
Table 3.6Material Surface Finish Result for EN-24
SECTION-A
S.NO. FEED
(mm/min)
SPEED
(rpm)
DEPTH OF CUT
(mm)
Surface finish (Ra)
1. 700 2000 0.25 4.36+2.78/2=3.57
2. 980 1800 0.25 4.1+2.85/2=3.475
3. 1400 2100 0.25 1.16+3.76/2=2.46
4. 1900 2000 0.25 1.34+1.30/2=1.32
5. 2600 2000 0.25 1.2+1.24/2=1.22
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Table 3.7Material Surface Finish Result for EN-24
SECTION-B
S.NO. FEED
(mm/min)
SPEED
(rpm)
DEPTH OF CUT
(mm)
Surface finish (Ra)
1. 700 2100 0.25 4.23+2.90/2=3.63
2. 980 2200 0.25 4.6+2.97/2=3.785
3. 1400 2300 0.25 1.45+3.92/2=2.685
4. 1900 2400 0.25 2.13+1.72/2=2.785
5. 2600 2500 0.25 1.61+1.4/2=2.31
Table 3.8 Experimental results Raof EN24
SECTION-A
S.NO. FEED
(mm/min)
SPEED
(rpm)
DEPTH OF CUT
(mm)
Surface finish (Ra)
1. 700 2000 0.25 4.76+3.1/2=3.93
2. 980 1800 0.25 4.41+3.1/2=3.755
3. 1400 2100 0.25 1.32+3.86/2=3.25
4. 1900 2000 0.25 1.53+1.71/2=1.62
5. 2600 2000 0.25 1.3+1.56/2=1.96
Table 3.9 Experimental results Ra of EN36
SECTION-B
S.NO. FEED
(mm/min)
SPEED
(rpm)
DEPTH OF CUT
(mm)
Surface finish (Ra)
1. 700 2100 0.25 4.86+3.31/2=4.085
2. 980 2200 0.25 4.92+3.42/2=4.17
3. 1400 2300 0.25 1.61+3.92/2=2.765
4. 1900 2400 0.25 2.42+2.1/2=2.26
5. 2600 2500 0.25 1.71+1.52/2=1.615
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RESULTS AND DISCUSSIONS
Thrust Force and Torque Calculations of Materials - En-24 and En-36b
Cutter dia = 25R5
Width of Workpiece = 75mm
No of Teeth on cutter = 4 = nc
Depth of Cut = d = 0.2
Width of Cut = b = 5mm
Width of chip = bc = 5mm
V = Cutting Velocity
rt = Chip Thickness Ratio
rt = t/tc = vc/v = lc/l
LC = Length of Chip = 7mm
L = Uncut Chip Length = 75mm
∝ = Rake Angle = 20°
β = Friction Angle = 40
∅ = Shear Angle
Speeds (RPM) Feed (mm/min)
3000 200
2500 300
2000 400
Chip Thickness Ratio
rt = t/tc = vc/v = L_C/L
rt = L_c/L = 7/75 = 0.093
Shear Angle ( ∅ )
Tan ∅ = (r_tcos∝)/(1-r_t sin∝)
Tan ∅ = (0.093 cos20)/(1-0.093 sin20)
∅ = 5.781
To Calculate Thrust Force
Ft = µ [ (HA_c)/3 ((Cot∅)/√3+1)]+A_F (0.62H√(43H/E))
AC = Cross – Section of Chip
Af = Area of Tool Flank Face
∅ = Shear Angle in w/p
µ = Friction Coefficient on Rake Face
H = Hardness of w/p
E = Young’s Modulus of w/p
EN-24 Material with speed of 2000rpm, feed 700mm/min.
Cutting speed (V)=πDN/1000m/min
Where D=cutter dia =25mm
N= spindle speed = 2000rpm
V=cutting speed
V=(π×25×2000)/1000=157.07 m/min
Feed per tooth of cutter :
ft=F/((n_(c )×N) ) mm/rev/tooth
n_(c ) = no.of cutting edges or teeth on cutter = 4
F = 700mm/min= table feed
ft=700/((4×2000) )=0.087 mm/rev/tooth
Ac = plan area of cut =cross section of chip
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Ac= w×d
w =width of work piece being cut =75mm
d = depth of cut
Ac= 15sq.mm
A=feed length for cutter to reach full depth = Af =area of tool flank face
A = √((D-d)×d)=√((25-0.25)×0.25)=2.487mm
Cutting Forces in Orthogonal Cutting
Fh=horizontal force component parallel to cutting velocity
Fv=vertical force component normal to Fh
Fs=force component parallel to shear plane
Fp= force component normal to Fs
Ft= force component parallel to tool rake face
Fn= force component normal to Ft
F_S=R cos (∅+β-α)
F_h=R cos (β-α)
F_n=R cos (β)
F_V=R sin (β-α)
F_S=R sin (∅+β-α)
F_t=R sin β
WHERE
R=(t.b.K)/sin 〖∅cos (∅+β-α) 〗
Where k= yield stress of material in shear =325Mpa
Thrust Force Calculation
F_t=µ[(HA_c)/3 (cot ∅/√3+1)]+A_f (0.62H√(43H/E))
A_c=w×d=15sq.mm
w = 75mm=width of work piece being cut
d=depth of cut=0.25
A= A_f=area of tool flank face = 2.487
A=√((D-d)d)
Where D = cutter dia
d=depth of cut
A=√((25-0.25)0.2) 5
A = A_f=2.487
µ=friction angle=tan 〖β=0.8〗
Where β=90
H=hardness of the work piece = 292
Density = 0.000007850 J/goC
E=young’s modulus of work piece =213000 Mpa
F_t=0.8[(292×15)/3 (cot 5.781/√3+1)]+2.487(0.62×292√((43×292)/213000))
F_t=55350.39N
EN-36 Material with speed of 2000rpm, feed 700mm/min.
Cutting speed (V)=πDN/1000m/min
Where D=cutter dia =25mm
N= spindle speed = 2000rpm
V=cutting speed
V=(π×25×2000)/1000=157.07 m/min
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Feed per tooth of cutter :
ft=F/((n_(c )×N) ) mm/rev/tooth
n_(c ) = no.of cutting edges or teeth on cutter = 4
F = 700mm/min= table feed
ft=700/((4×2000) )=0.087 mm/rev/tooth
Ac = plan area of cut =cross section of chip
Ac= w×d
w =width of work piece being cut =75mm
d = depth of cut
Ac= 15sq.mm
A=feed length for cutter to reach full depth = Af =area of tool flank face
A = √((D-d)×d)=√((25-0.25)×0.25)=2.487mm
Cutting Forces in Orthogonal Cutting
Fh=horizontal force component parallel to cutting velocity
Fv=vertical force component normal to Fh
Fs=force component parallel to shear plane
Fp= force component normal to Fs
Ft= force component parallel to tool rake face
Fn= force component normal to Ft
F_S=R cos (∅+β-α)
F_h=R cos (β-α)
F_n=R cos (β)
F_V=R sin (β-α)
F_S=R sin (∅+β-α)
F_t=R sin β
WHERE
R=(t.b.K)/sin 〖∅cos (∅+β-α) 〗
Where k= yield stress of material in shear =325Mpa
Thrust Force Calculation
F_t=µ[(HA_c)/3 (cot ∅/√3+1)]+A_f (0.62H√(43H/E))
A_c=w×d=15sq.mm
w = 75mm=width of work piece being cut
d=depth of cut=0.25
A= A_f=area of tool flank face = 2.487
A=√((D-d)d)
Where D = cutter dia
d=depth of cut
A=√((25-0.25)0.2) 5
A = A_f=2.487
µ=friction angle=tan 〖β=0.8〗
Where β=90
H=hardness of the work piece = 341
Density = 0.000007850 J/goC
E=young’s modulus of work piece =207000 Mpa
F_t=0.8[(341×15)/3 (cot 5.781/√3+1)]+2.487(0.62×341√((43×341)/207000))
F_t=64650.93N
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CONCLUSION:
In this thesis, experiments are conducted to improve the surface finish quality of a work piece
by using carbide tips. The type of tip is bull nose tip. A series of experiments is done by
varying the milling parameters spindle speed, feed rate. The experiments are conducted on
vertical milling machine of make Chenho. The work piece materials are alloy steel EN24 and
EN36.
Two sets of each work piece material are machined by specifying following parameters:
Feed rates of 700mm/min, 980mm/min, 1400mm/min, 1900mm/min and 2600mm/min,
Spindle speeds of 2000rpm, 1800rpm, 2100rpm, and 2000rpm. By observing the
experimental results, for EN24 material machining at 2600mm/min feed rate and spindle
speed of 2000rpm yields better results as the surface finish is good.
For material EN36 machining at 1900mm/min and 2000rpm yields better results as
the surface finish is good.Theoretical calculations are done to calculate the thrust force and
torque. Structural analysis is also done to verify the strength and modeling is done in ANN