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.
An experiental investigation of effect of cutting parameters and tool materia...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
An experiental investigation of effect of cutting parameters and tool materia...eSAT Journals
Abstract The major needs of machining are high material removal rate, good work surface finish and low tool wear. Industries are hiring to increase economical benefits by reducing the cost of production. These objectives can be achieved by using proper cutting tool material and cutting parameters. This report presents comparisons of two different coated carbide inserts under different cutting parameters used during machining of cylinder liners made up of grey cast iron. The comparison has been realized through the tool life tests and productivity. The measurement has been carried out from rough boring operation at three cutting speed (Vc) and feed rate (f). Depth of cut (doc) is kept constant at 1.5mm. Cutting tool used in this work is titanium nitride (TiN) coated carbide and comparing with Multilayer coated tool is titanium nitride (TiN) + titanium carbo nitride (TiCN) + Aluminium oxide (Al2O3) coated carbide inserts. The type of the insert is SNMG 120408. Cutting conditions used is speed (Vc) 100m/min, 125m/min, 150m/min. Feed rate (f) 0.25mm/rev,0.3mm/rev,0.35mm/rev. Finally results of the present work determine the appropriate parameter for increasing the tool life, and productivity. Key words: Tool life, Coated tool material, Process parameters, Productivity.
IRJET- Selection for Better and Increased Tool Life by the Use of HSS Cutting...IRJET Journal
This document summarizes a research study that evaluated the optimal cutting parameters for maximum tool life when machining mild steel and aluminum with HSS cutting tools under dry conditions. Experiments were conducted using different spindle speeds, cutting speeds, and feed rates to determine their effects on depth of cut and tool life. Results showed that higher spindle speeds and feeds decreased tool life for both materials. Mild steel provided longer tool life than aluminum. The study aimed to identify cutting conditions for improved tool life by selecting appropriate workpiece and cutting tool materials along with suitable feed rates and lower cutting speeds.
2nd progress presentation on Minimum Quantity Lubrication(MQL) with vegitable...Nadaraja Sarmilan
This is a research based project of improving machining process as well as the environmental conditions using novel coconut oil based cutting fluid under Minimum Quantity Lubrication(MQL). In order to achieve the testing situations, the conceptual design of the experimental setup was finalized by following best solutions given through the morphological analysis of existing MQL systems. Solid models of nozzles, nozzle holding component, MWF tank, MWF tank support and finalized experimental setup were designed by solid modeling software. To corroboration the importance of novel vegetable oil based lubricant, the machining performances such as surface roughness and chip formation were evaluated.
Vegetable Oil Based Minimum Quantity Lubrication (MQL) During MachiningNadaraja Sarmilan
This document summarizes an experimental study that compared vegetable oil-based and mineral oil-based minimum quantity lubrication (MQL) during machining. Mild steel and stainless steel were machined under different conditions and their surface roughness, chip formation, tool wear, and chip-tool interface temperature were evaluated. Key results included the vegetable oil MQL providing better surface finish for mild steel, better chip formation for both materials, and lower tool wear and interface temperatures for stainless steel, compared to the mineral oil MQL. The study determined optimal cutting parameters for stainless steel of 45 rpm spindle speed, 5.231 m/min cutting speed, and 0.186 ml/s vegetable oil flow rate, which produced the lowest interface temperature
This document presents a comparative analysis of surface roughness and material removal rate during milling of AISI 410 steel and aluminum 6061. Experiments were conducted using a CNC milling machine varying spindle speed, feed rate, and depth of cut. Response surface methodology was used to optimize surface roughness. The results showed that for AISI 410 steel, spindle speed had the greatest effect on material removal rate and surface roughness, while for aluminum 6061, no parameters significantly affected the responses. Overall, different milling parameters impacted the materials differently in terms of surface finish and productivity.
IRJET - Mechanical and Wear Properties of Friction Stir Welding of Alumin...IRJET Journal
The document summarizes research on friction stir welding of aluminum alloys. It discusses how friction stir welding was used to join aluminum alloy plates using varying process parameters like rotational speed and transverse speed. Mechanical properties of the welded joints like tensile strength, hardness, and impact strength were evaluated. Microstructure of the joints was analyzed with microscopes. Wear properties were also assessed. The optimal welding parameters were determined to be a tapered cylindrical tool at 560 rpm, which produced joints with the highest tensile strength and lowest defects.
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.
An experiental investigation of effect of cutting parameters and tool materia...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
An experiental investigation of effect of cutting parameters and tool materia...eSAT Journals
Abstract The major needs of machining are high material removal rate, good work surface finish and low tool wear. Industries are hiring to increase economical benefits by reducing the cost of production. These objectives can be achieved by using proper cutting tool material and cutting parameters. This report presents comparisons of two different coated carbide inserts under different cutting parameters used during machining of cylinder liners made up of grey cast iron. The comparison has been realized through the tool life tests and productivity. The measurement has been carried out from rough boring operation at three cutting speed (Vc) and feed rate (f). Depth of cut (doc) is kept constant at 1.5mm. Cutting tool used in this work is titanium nitride (TiN) coated carbide and comparing with Multilayer coated tool is titanium nitride (TiN) + titanium carbo nitride (TiCN) + Aluminium oxide (Al2O3) coated carbide inserts. The type of the insert is SNMG 120408. Cutting conditions used is speed (Vc) 100m/min, 125m/min, 150m/min. Feed rate (f) 0.25mm/rev,0.3mm/rev,0.35mm/rev. Finally results of the present work determine the appropriate parameter for increasing the tool life, and productivity. Key words: Tool life, Coated tool material, Process parameters, Productivity.
IRJET- Selection for Better and Increased Tool Life by the Use of HSS Cutting...IRJET Journal
This document summarizes a research study that evaluated the optimal cutting parameters for maximum tool life when machining mild steel and aluminum with HSS cutting tools under dry conditions. Experiments were conducted using different spindle speeds, cutting speeds, and feed rates to determine their effects on depth of cut and tool life. Results showed that higher spindle speeds and feeds decreased tool life for both materials. Mild steel provided longer tool life than aluminum. The study aimed to identify cutting conditions for improved tool life by selecting appropriate workpiece and cutting tool materials along with suitable feed rates and lower cutting speeds.
2nd progress presentation on Minimum Quantity Lubrication(MQL) with vegitable...Nadaraja Sarmilan
This is a research based project of improving machining process as well as the environmental conditions using novel coconut oil based cutting fluid under Minimum Quantity Lubrication(MQL). In order to achieve the testing situations, the conceptual design of the experimental setup was finalized by following best solutions given through the morphological analysis of existing MQL systems. Solid models of nozzles, nozzle holding component, MWF tank, MWF tank support and finalized experimental setup were designed by solid modeling software. To corroboration the importance of novel vegetable oil based lubricant, the machining performances such as surface roughness and chip formation were evaluated.
Vegetable Oil Based Minimum Quantity Lubrication (MQL) During MachiningNadaraja Sarmilan
This document summarizes an experimental study that compared vegetable oil-based and mineral oil-based minimum quantity lubrication (MQL) during machining. Mild steel and stainless steel were machined under different conditions and their surface roughness, chip formation, tool wear, and chip-tool interface temperature were evaluated. Key results included the vegetable oil MQL providing better surface finish for mild steel, better chip formation for both materials, and lower tool wear and interface temperatures for stainless steel, compared to the mineral oil MQL. The study determined optimal cutting parameters for stainless steel of 45 rpm spindle speed, 5.231 m/min cutting speed, and 0.186 ml/s vegetable oil flow rate, which produced the lowest interface temperature
This document presents a comparative analysis of surface roughness and material removal rate during milling of AISI 410 steel and aluminum 6061. Experiments were conducted using a CNC milling machine varying spindle speed, feed rate, and depth of cut. Response surface methodology was used to optimize surface roughness. The results showed that for AISI 410 steel, spindle speed had the greatest effect on material removal rate and surface roughness, while for aluminum 6061, no parameters significantly affected the responses. Overall, different milling parameters impacted the materials differently in terms of surface finish and productivity.
IRJET - Mechanical and Wear Properties of Friction Stir Welding of Alumin...IRJET Journal
The document summarizes research on friction stir welding of aluminum alloys. It discusses how friction stir welding was used to join aluminum alloy plates using varying process parameters like rotational speed and transverse speed. Mechanical properties of the welded joints like tensile strength, hardness, and impact strength were evaluated. Microstructure of the joints was analyzed with microscopes. Wear properties were also assessed. The optimal welding parameters were determined to be a tapered cylindrical tool at 560 rpm, which produced joints with the highest tensile strength and lowest defects.
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.
Nitriding improves the wear and corrosion properties of tool steels. Three tool steels - IS-T110W6Cr4, JIS-SK3, and AISI-M35 - were analyzed. Nitriding increased the surface hardness and case depth while reducing the wear rate and weight loss compared to the raw and heat treated conditions. Corrosion resistance also improved with nitriding. Overall, nitriding provides enhanced properties for applications requiring good wear and corrosion performance.
COMPARISON OF MAIN EFFECT OF VEGETABLE OIL AND AL2O3 NANOFLUIDS USED WITH MQL...IAEME Publication
The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Application of cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions. But the conventional cutting fluids are not that effective in such high production machining, particularly in continuous cutting of materials likes steels. So Nanofluids have novel properties that make them potentially useful in heat transfer medium in cutting zone and Minimum quantity lubrication (MQL) presents itself as a viable alternative for turning with respect to tool wear, heat dissipation, and machined surface quality.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
IRJET- Optimization Machining Parameters in a Turning Operation of Steels to ...IRJET Journal
The document presents an experimental study to optimize machining parameters during turning operations of different steel grades to minimize surface roughness and temperature. The study uses Taguchi methodology to determine the effects of cutting speed, feed rate, and depth of cut on temperature, hardness, and surface roughness. Experiments were conducted turning EN8 steel, mild steel, and OHNS steel using tungsten and cemented carbide inserts. Results from Taguchi analysis and ANOVA showed that cutting speed has the most significant impact on surface roughness and hardness, while depth of cut alone significantly impacts temperature. The optimum parameters were identified to minimize surface roughness and temperature for the different materials.
IRJET - Characteristics of Butt Joint Produced by Friction Stir Welding ProcessIRJET Journal
The document discusses characteristics of butt joints produced using friction stir welding (FSW) of aluminum alloys. It investigates the effects of various FSW process parameters on the mechanical properties and microstructure of the welded joints. Specifically, it examines rotational speed, transverse speed, and tool geometry. Joints of aluminum alloy AA5083 were welded and tested in tension, hardness, impact, and corrosion to analyze properties. The results showed that process parameters significantly affected the weld strength and microstructure. Defect-free joints with optimal mechanical properties could be produced using appropriate FSW conditions.
Studies on Tool Life and Cutting Forces for Drilling Operation using Uncoated...IRJET Journal
This document summarizes a study that compares the tool life and cutting forces of uncoated and coated high-speed steel (HSS) drill bits during dry drilling of EN8 steel. Specifically, it examines uncoated HSS drill bits, as well as HSS drill bits coated with titanium nitride (TiN) and titanium aluminium nitride (TiAlN). Experimental results showed that the TiAlN coated HSS drill bit had the greatest tool life. When measuring cutting forces, the TiAlN coated drill bit produced the highest thrust force, while torque was similar across all drill bits. In conclusion, coatings like TiN and TiAlN can improve the performance of HSS drill bits during machining operations
Performance evaluation of ti n coated carbide insert for optimum surface roug...eSAT Journals
Abstract In manufacturing industry, beside the dimensional and geometric tolerance of a component, surface quality is most commonly specified requirements. Surface roughness plays an important role in the performance of the component. This paper presents a study of the influence of the cutting parameters on the surface roughness during the turning of AISI1045 steel with TiN coated carbide tool. The design of experiments based on the Taguchi technique. The objective was to optimization of the machining parameters as cutting speed, feed rate and depth of cut for surface roughness. Main effect plots are generated and analyzed to find out the relationship between them. Afterwords a confirmation test were performed to make a comparison between the predicted results and the theoretical results. Keywords: TiN carbide insert, AISI 1045 alloy steel, Taguchi method, Surface roughness, ANOVA
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
An Experimental Investigation on Mechanical Properties of Friction Stir Weldi...IRJET Journal
The document presents an experimental investigation on the mechanical properties of friction stir welding of aluminum alloy 6061-T6 and brass IS319 using EN19 tools with circular and taper profiles. Friction stir welding is a solid-state joining process that generates heat through friction between the rotating tool and workpieces.
The experiment was conducted on a milling machine using EN19 tools with circular and taper profiles to weld aluminum and brass plates. The welded joints were tested for tensile strength, yield strength, and hardness. The taper profile tool achieved a tensile strength of 108.5 N/mm2, yield strength of 76.05 N/mm2, and Vickers hardness of 51.73 HV. The circular
Review on investigation and optimization of turning process parameter in wet ...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
IRJET- Review Paper Optimizationof MachiningParametersbyusing of Taguchi'...IRJET Journal
This document summarizes an experimental study that used the Taguchi method to optimize machining parameters for turning AA6063 alloy steel. The study aimed to maximize the material removal rate (MRR) by investigating the effects of cutting speed, depth of cut, and feed rate. A number of turning experiments were conducted using an L9 orthogonal array with different combinations of the machining parameters. Analysis of the experimental results found that feed rate had the greatest influence on MRR, followed by depth of cut. The Taguchi method was effective for determining the optimal machining parameters for maximizing the material removal rate during turning of AA6063 alloy steel.
Design and modification of bale cutting machine to improve its productivityeSAT Journals
Abstract The aim of this paper is to present the results of the successful implementation of the redesigned bale cutting machine in Falcon tyre manufacturing company. Modification of hydraulic bale cutting machine is carried out to increase the productivity of the machine, to reduce the time and stress on the workers. The system is consisting of modified shear blade, suitable blade holder, hydraulic system according to new tonnage capacity and conveyor system. Unigraphics is used to model the blade and blade holder, meshing and analysis is carried out by using hypermesh and nastran. The parts are manufactured accordingly to new design parameters, and the following are installed and the performance characteristics to be determined are time, cost and productivity for this new modified design relative to the old system. It is established from the test results taken for a period of three months, that there is reduction in the time and cost of 70-80%, and 50-60% which in directly increased the productivity of machine and making the process economical. Keywords: shear blade, blade holder, hydraulic system, conveyor system
IRJET-Enhancement of Mechanical Property of Aluminum Alloy 2024 : A ProposedIRJET Journal
This document summarizes a study on enhancing the mechanical properties of aluminum alloy 2024 through grain refinement. The researchers used room temperature rolling to reduce the aluminum alloy's grain size from 49 micrometers to 860 nanometers. Testing showed that room temperature rolling increased the alloy's Vickers hardness from an average of 935.3 MPa to 1404 MPa. Optical microscopy images confirmed the production of ultra-fine grains after room temperature rolling. In conclusion, reducing the aluminum alloy's grain size through room temperature rolling significantly improved its mechanical properties including increased hardness.
A Literature Review on Optimization of Input Cutting Parameters for Improved ...IRJET Journal
This document reviews literature on optimizing input cutting parameters to improve surface finish in turning processes. It aims to present various methodologies for predicting surface roughness. The literature compiles works on optimizing process parameters like cutting speed, feed rate, depth of cut, insert radius, and cutting fluid. It is concluded that these parameters most significantly impact surface roughness. Optimization techniques commonly used include Taguchi methodology, response surface methodology, full factorial analysis, and neural networks. The document provides a table summarizing 18 research papers on this topic, including details on materials machined, cutting parameters analyzed, outputs measured, and optimization methods employed.
The document experimentally investigates the material removal rate (MRR) and tool wear in turning hardened AISI 52100 steel using the Taguchi technique. Experiments were conducted using different cutting speeds, feed rates, and depths of cut based on an L9 orthogonal array. The results were analyzed using signal-to-noise ratios and ANOVA to determine the optimal process parameters for maximizing MRR and minimizing tool wear. The analysis found that cutting speed had the greatest influence on MRR, followed by depth of cut and feed rate. The optimal parameters for MRR were a cutting speed of 1120 rpm, feed rate of 0.12 mm/rev, and depth of cut of 0.4 mm.
Experimental Investigation for Mechanical Properties of Aluminium Alloy Al 60...IRJET Journal
This document presents an experimental investigation of the mechanical properties of friction stir welded aluminum alloy Al 6061 joints considering different friction stir welding parameters. Specifically, it examines the effects of tool shape (taper or threaded), welding speed, and feed rate on the tensile strength, impact toughness, and microhardness of the welded joints. Experiments were conducted according to a Taguchi L8 orthogonal array design of experiments. Results indicated that welding speed had the greatest influence on tensile strength, feed rate most influenced impact toughness and microhardness, and the optimal parameters were a taper tool, 600 RPM welding speed, and 40 mm/min feed rate. These parameters produced joints with maximum mechanical property strengths.
Studies on jet penetration and kerf width at various operating pressure in ma...eSAT Journals
Abstract Abrasive Water Jet (AWJ) machining is one of the non-traditional machining method popular method for machining of hard, heat sensitive and brittle materials. The present work attempts to investigate the effect of operating pressure on depth of penetration and kerf characteristics generated while machining of D2 heat treated steel. It is found that increase in operating pressure increases the depth of penetration and decreases the surface taper on the work-piece. Keywords: Kerf width, Depth of cut, Operating pressure, AWJ Machining
Machining of Aircraft Bearing Rings using High Quality Bearing SteelIJERA Editor
Bearing rings for Aircraft application are machined using high quality M50 High Speed Steel conforming to
AMS 6491B. The raw material for the rings of Ball bearing is prepared from a single bar stock using trepanning.
Special collet type soft jaw and Mandrels were devised and used on CNC Lathes to reduce manufacturing
problems like ovality. Raceway forms are turned using single point copy turning insert. The problems faced
during rings manufacture were discussed in this study.
Investigation on Properties of Structural Steel Joints using Arc and MIG Weld...IRJET Journal
This document investigates the properties of structural steel joints welded using arc and MIG welding processes. Mild steel plates of varying thicknesses were welded using both processes. Samples from the welded joints underwent tensile testing, impact testing, hardness testing, and microscopic analysis to evaluate and compare the mechanical properties. The investigation found that MIG welding joints produced higher mechanical properties than arc welding joints when joining mild steel plates. V-shaped joints also performed better than square butt joints.
Prediction of Tool Life of Different Coated Cutting Tools During Machining of...IRJET Journal
This document summarizes research on predicting the tool life of different coated cutting tools during machining of Inconel 718. Two coatings, TiAlSiN and TiAlN, were deposited on tungsten carbide end mills. Experiments were conducted to analyze tool wear and surface roughness at various cutting speeds, feeds, and depths of cut. The results showed that coated tools performed better than uncoated tools with longer tool life. TiAlSiN coated tools performed the best with the longest tool life. As flank wear increased with cutting time, the surface roughness of the machined parts also increased. Cutting forces generally increased with progression of tool wear and other factors like work hardening. Higher cutting speeds and feeds led
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.
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.
Nitriding improves the wear and corrosion properties of tool steels. Three tool steels - IS-T110W6Cr4, JIS-SK3, and AISI-M35 - were analyzed. Nitriding increased the surface hardness and case depth while reducing the wear rate and weight loss compared to the raw and heat treated conditions. Corrosion resistance also improved with nitriding. Overall, nitriding provides enhanced properties for applications requiring good wear and corrosion performance.
COMPARISON OF MAIN EFFECT OF VEGETABLE OIL AND AL2O3 NANOFLUIDS USED WITH MQL...IAEME Publication
The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Application of cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions. But the conventional cutting fluids are not that effective in such high production machining, particularly in continuous cutting of materials likes steels. So Nanofluids have novel properties that make them potentially useful in heat transfer medium in cutting zone and Minimum quantity lubrication (MQL) presents itself as a viable alternative for turning with respect to tool wear, heat dissipation, and machined surface quality.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
IRJET- Optimization Machining Parameters in a Turning Operation of Steels to ...IRJET Journal
The document presents an experimental study to optimize machining parameters during turning operations of different steel grades to minimize surface roughness and temperature. The study uses Taguchi methodology to determine the effects of cutting speed, feed rate, and depth of cut on temperature, hardness, and surface roughness. Experiments were conducted turning EN8 steel, mild steel, and OHNS steel using tungsten and cemented carbide inserts. Results from Taguchi analysis and ANOVA showed that cutting speed has the most significant impact on surface roughness and hardness, while depth of cut alone significantly impacts temperature. The optimum parameters were identified to minimize surface roughness and temperature for the different materials.
IRJET - Characteristics of Butt Joint Produced by Friction Stir Welding ProcessIRJET Journal
The document discusses characteristics of butt joints produced using friction stir welding (FSW) of aluminum alloys. It investigates the effects of various FSW process parameters on the mechanical properties and microstructure of the welded joints. Specifically, it examines rotational speed, transverse speed, and tool geometry. Joints of aluminum alloy AA5083 were welded and tested in tension, hardness, impact, and corrosion to analyze properties. The results showed that process parameters significantly affected the weld strength and microstructure. Defect-free joints with optimal mechanical properties could be produced using appropriate FSW conditions.
Studies on Tool Life and Cutting Forces for Drilling Operation using Uncoated...IRJET Journal
This document summarizes a study that compares the tool life and cutting forces of uncoated and coated high-speed steel (HSS) drill bits during dry drilling of EN8 steel. Specifically, it examines uncoated HSS drill bits, as well as HSS drill bits coated with titanium nitride (TiN) and titanium aluminium nitride (TiAlN). Experimental results showed that the TiAlN coated HSS drill bit had the greatest tool life. When measuring cutting forces, the TiAlN coated drill bit produced the highest thrust force, while torque was similar across all drill bits. In conclusion, coatings like TiN and TiAlN can improve the performance of HSS drill bits during machining operations
Performance evaluation of ti n coated carbide insert for optimum surface roug...eSAT Journals
Abstract In manufacturing industry, beside the dimensional and geometric tolerance of a component, surface quality is most commonly specified requirements. Surface roughness plays an important role in the performance of the component. This paper presents a study of the influence of the cutting parameters on the surface roughness during the turning of AISI1045 steel with TiN coated carbide tool. The design of experiments based on the Taguchi technique. The objective was to optimization of the machining parameters as cutting speed, feed rate and depth of cut for surface roughness. Main effect plots are generated and analyzed to find out the relationship between them. Afterwords a confirmation test were performed to make a comparison between the predicted results and the theoretical results. Keywords: TiN carbide insert, AISI 1045 alloy steel, Taguchi method, Surface roughness, ANOVA
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
An Experimental Investigation on Mechanical Properties of Friction Stir Weldi...IRJET Journal
The document presents an experimental investigation on the mechanical properties of friction stir welding of aluminum alloy 6061-T6 and brass IS319 using EN19 tools with circular and taper profiles. Friction stir welding is a solid-state joining process that generates heat through friction between the rotating tool and workpieces.
The experiment was conducted on a milling machine using EN19 tools with circular and taper profiles to weld aluminum and brass plates. The welded joints were tested for tensile strength, yield strength, and hardness. The taper profile tool achieved a tensile strength of 108.5 N/mm2, yield strength of 76.05 N/mm2, and Vickers hardness of 51.73 HV. The circular
Review on investigation and optimization of turning process parameter in wet ...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
IRJET- Review Paper Optimizationof MachiningParametersbyusing of Taguchi'...IRJET Journal
This document summarizes an experimental study that used the Taguchi method to optimize machining parameters for turning AA6063 alloy steel. The study aimed to maximize the material removal rate (MRR) by investigating the effects of cutting speed, depth of cut, and feed rate. A number of turning experiments were conducted using an L9 orthogonal array with different combinations of the machining parameters. Analysis of the experimental results found that feed rate had the greatest influence on MRR, followed by depth of cut. The Taguchi method was effective for determining the optimal machining parameters for maximizing the material removal rate during turning of AA6063 alloy steel.
Design and modification of bale cutting machine to improve its productivityeSAT Journals
Abstract The aim of this paper is to present the results of the successful implementation of the redesigned bale cutting machine in Falcon tyre manufacturing company. Modification of hydraulic bale cutting machine is carried out to increase the productivity of the machine, to reduce the time and stress on the workers. The system is consisting of modified shear blade, suitable blade holder, hydraulic system according to new tonnage capacity and conveyor system. Unigraphics is used to model the blade and blade holder, meshing and analysis is carried out by using hypermesh and nastran. The parts are manufactured accordingly to new design parameters, and the following are installed and the performance characteristics to be determined are time, cost and productivity for this new modified design relative to the old system. It is established from the test results taken for a period of three months, that there is reduction in the time and cost of 70-80%, and 50-60% which in directly increased the productivity of machine and making the process economical. Keywords: shear blade, blade holder, hydraulic system, conveyor system
IRJET-Enhancement of Mechanical Property of Aluminum Alloy 2024 : A ProposedIRJET Journal
This document summarizes a study on enhancing the mechanical properties of aluminum alloy 2024 through grain refinement. The researchers used room temperature rolling to reduce the aluminum alloy's grain size from 49 micrometers to 860 nanometers. Testing showed that room temperature rolling increased the alloy's Vickers hardness from an average of 935.3 MPa to 1404 MPa. Optical microscopy images confirmed the production of ultra-fine grains after room temperature rolling. In conclusion, reducing the aluminum alloy's grain size through room temperature rolling significantly improved its mechanical properties including increased hardness.
A Literature Review on Optimization of Input Cutting Parameters for Improved ...IRJET Journal
This document reviews literature on optimizing input cutting parameters to improve surface finish in turning processes. It aims to present various methodologies for predicting surface roughness. The literature compiles works on optimizing process parameters like cutting speed, feed rate, depth of cut, insert radius, and cutting fluid. It is concluded that these parameters most significantly impact surface roughness. Optimization techniques commonly used include Taguchi methodology, response surface methodology, full factorial analysis, and neural networks. The document provides a table summarizing 18 research papers on this topic, including details on materials machined, cutting parameters analyzed, outputs measured, and optimization methods employed.
The document experimentally investigates the material removal rate (MRR) and tool wear in turning hardened AISI 52100 steel using the Taguchi technique. Experiments were conducted using different cutting speeds, feed rates, and depths of cut based on an L9 orthogonal array. The results were analyzed using signal-to-noise ratios and ANOVA to determine the optimal process parameters for maximizing MRR and minimizing tool wear. The analysis found that cutting speed had the greatest influence on MRR, followed by depth of cut and feed rate. The optimal parameters for MRR were a cutting speed of 1120 rpm, feed rate of 0.12 mm/rev, and depth of cut of 0.4 mm.
Experimental Investigation for Mechanical Properties of Aluminium Alloy Al 60...IRJET Journal
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Studies on jet penetration and kerf width at various operating pressure in ma...eSAT Journals
Abstract Abrasive Water Jet (AWJ) machining is one of the non-traditional machining method popular method for machining of hard, heat sensitive and brittle materials. The present work attempts to investigate the effect of operating pressure on depth of penetration and kerf characteristics generated while machining of D2 heat treated steel. It is found that increase in operating pressure increases the depth of penetration and decreases the surface taper on the work-piece. Keywords: Kerf width, Depth of cut, Operating pressure, AWJ Machining
Machining of Aircraft Bearing Rings using High Quality Bearing SteelIJERA Editor
Bearing rings for Aircraft application are machined using high quality M50 High Speed Steel conforming to
AMS 6491B. The raw material for the rings of Ball bearing is prepared from a single bar stock using trepanning.
Special collet type soft jaw and Mandrels were devised and used on CNC Lathes to reduce manufacturing
problems like ovality. Raceway forms are turned using single point copy turning insert. The problems faced
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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.
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.
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
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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.
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3. Analysis of variance found feed rate to be the most influential parameter on material removal rate, followed by depth of cut and then spindle speed. The optimal combination for maximum material removal rate was found to be a spindle speed of 2100 rpm, feed rate of 0.3 mm/rev, and depth of cut of 0.6 mm.
manufacturers are facing the challenges of
higher Quality and productivity are two
important . Productivity can be interpreted
in terms of material removal rate in the
machining operation and quality represents
satisfactory yield in terms of product
characteristics as desired by the customers.
but conflicting criteria in any machining
operations. In order to ensure high
productivity, extent of quality is to be
compromised.
The document summarizes various cooling and lubrication techniques used in machining difficult-to-cut materials like titanium alloys and nickel alloys. It discusses dry machining, conventional cooling, high-pressure cooling and nano-minimum quantity lubrication (MQL) techniques. Experimental results show that dry machining leads to high tool wear due to heat accumulation. Conventional cooling provides some benefits but its effectiveness reduces at high speeds. High-pressure cooling helps reduce tool wear compared to other techniques but requires high energy. Nano-MQL mixing nanoparticles into cutting oil enhances thermal conductivity and lubrication, lowering tool wear.
Multiresponse optimization of surface grinding operation of en19 alloy steel ...IAEME Publication
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Multiresponse optimization of surface grinding operation of EN19 alloy steel ...IAEME Publication
Conventional grinding fluid is widely used in grinding process, which results in high consumption and impacting the environment. Minimum Quantity Lubrication (MQL) is alternative source for the Conventional grinding process. In this study, Water based nanofluid applied to grinding process with MQL approach for its excellent convection heat transfer and thermal conductivity properties.
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.
Assembly of the components (Crank shaft, Connecting rod, Gudgeon pin and Piston) by
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manufacturing of different products through various processes.
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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
Effect of Process Parameters on Micro Hardness of Mild Steel Processed by Sur...IOSR Journals
The document discusses an experimental investigation into the effect of surface grinding process parameters on the microhardness of mild steel specimens. An experiment was conducted using a surface grinding machine to grind mild steel workpieces under different combinations of inlet coolant pressure, grinding wheel speed, workpiece speed, and nozzle angle. Microhardness measurements were then taken on the specimens. The results showed that all process parameters affected microhardness, with values ranging from 292.63 to 370.73 HV. Minimum microhardness was obtained at an inlet pressure of 25 kg/cm2, wheel speed of 2800 RPM, workpiece speed of 1.5 m/min, and nozzle angle of 6 degrees.
This document summarizes a study that used the Taguchi method to optimize the material removal rate (MRR) when turning mild steel 1018 on a CNC lathe. The document describes the experimental setup including the workpiece material, CNC machine, tool material, and selection of cutting parameters (speed, feed, depth of cut). An L16 orthogonal array was used to conduct the experiments. Analysis of variance was performed on the signal-to-noise ratios to determine the optimal cutting conditions for maximizing MRR. The analysis found cutting speed to be the most influential parameter, followed by feed and then depth of cut. Validation experiments confirmed the optimal settings achieved the predicted maximum MRR.
Optimization of Cylindrical Grinding Process Parameters on C40E Steel Using T...IJERA Editor
Surface finish and dimensional accuracy play a vital role in the today’s engineering industry. There are several methods used to achieve good surface finish like burnishing, honing and lapping, and grinding. Grinding is one of these ways that improves the surface finish and dimensional accuracy simultaneously. C40E steel has good industrial application in manufacturing of shafts, axles, spindles, studs, etc. In the present work the cylindrical grinding of C40E steel is done for the optimization of grinding process parameters. During this experimental work input process parameters i.e. speed, feed, depth of cut is optimized using Taguchi L9 orthogonal array. Analysis of variance (ANOVA) concluded that surface roughness is minimum at the 210 rpm, 0.11mm/rev feed, and 0.04mm depth of penetration.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
Conversational agents, or chatbots, are increasingly used to access all sorts of services using natural language. While open-domain chatbots - like ChatGPT - can converse on any topic, task-oriented chatbots - the focus of this paper - are designed for specific tasks, like booking a flight, obtaining customer support, or setting an appointment. Like any other software, task-oriented chatbots need to be properly tested, usually by defining and executing test scenarios (i.e., sequences of user-chatbot interactions). However, there is currently a lack of methods to quantify the completeness and strength of such test scenarios, which can lead to low-quality tests, and hence to buggy chatbots.
To fill this gap, we propose adapting mutation testing (MuT) for task-oriented chatbots. To this end, we introduce a set of mutation operators that emulate faults in chatbot designs, an architecture that enables MuT on chatbots built using heterogeneous technologies, and a practical realisation as an Eclipse plugin. Moreover, we evaluate the applicability, effectiveness and efficiency of our approach on open-source chatbots, with promising results.
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https://bit.ly/Automation_Student_Kickstart
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In response to the urgency and scale required to effectively address climate change, open source solutions offer significant potential for driving innovation and progress. Currently, there is a growing demand for standardization and interoperability in energy data and modeling. Open source standards and specifications within the energy sector can also alleviate challenges associated with data fragmentation, transparency, and accessibility. At the same time, it is crucial to consider privacy and security concerns throughout the development of open source platforms.
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LF Energy Webinar: Carbon Data Specifications: Mechanisms to Improve Data Acc...
Ds34728732
1. Chintan. H. Patel, Chirag. P. Patel / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 4, Jul-Aug 2013, pp.728-732
728 | P a g e
Parametric Optimization of End Milling Of AISI 1018 Mild Steel
by Various Lubricants with Solid Carbide End Mills.
Chintan. H. Patel1
, Chirag. P. Patel2
1
Student, M.Tech, (Department of MechanicalEngineering, Ganpat University, Kherva-384012,
2
Associate Prof., (Department of Mechanical Engineering, Ganpat University, Kherva-384012,
Abstract
This study investigated the optimization
of End milling of AISI 1018mild steel by various
lubricants using the Grey relational analysis
method. Quaker 7101, Blasocut strong 4000 and
Velvex have been selected as lubricant. All the
experiment are carried out at different cutting
parameter (Number of Tool Flutes, Depth of cut,
Spindle speed and Feed rate) in various lubricant
assisted environment.Twenty Seven experiments
runs based on an orthogonal array of Taguchi
method were performed. Each nine experiments
were carried out in Quaker 7101, Blasocut strong
4000 and Velvex lubricant. Surface roughness,
cutting force andpower consumption selected as
aresponse variable.An optimal parameter
combination of the milling operation was
obtained via Grey relational analysis. By
analyzing the Grey relational grade matrix, the
degree of influence for each controllable process
factor onto individual quality targets can be
found. The optimal parameter combination is
then tested for accuracy of conclusion with a test
run using the same parameters.
Keywords: Optimization, Grey relational analysis,
surface roughness, cutting force and power
consumption.
I. Introduction
Milling is the process of cutting away
material by feeding a work piece past a rotating
multiple tooth cutter. The cutting action of the many
teeth around the milling cutter provides a fast
method of machining. The machined surface may be
flat, angular, or curved. The surface may also be
milled to any combination of shapes. The machine
for holding the work piece, rotating the cutter, and
feeding it is known as the Milling machine.
Among different types of milling processes,
end milling is one of the most vital and common
metal cutting operations used for machining parts
because of its capability to remove materials at faster
rate with a reasonably goodsurfacequality. Also, it is
capable of producing a variety of configurations
using milling cutter. In recent times, computer
numerically controlled (CNC) machine tools have
been adopted to make the milling process fully
automated. It provides greater improvements in
productivity, increases the quality of the machined
parts and requires less operator input. For these
reasons, CNC end milling process has been recently
proved to be very versatile and useful machining
operation in most of the modern manufacturing
industries. Only the implementation of automation in
end milling process is not the last achievement. It is
also necessary to improve the machining process and
machining performances continuously for effective
machining and also for the fulfilment of
requirements of the industries.
Application of three lubricants in
machining process utilize water miscible cutting
lubricant, if it can be applied properlyThe main
objectives of this study investigate and evaluate the
effect of different cutting parameters (spindle speed,
feed rate and depth of cut, no of tool flute) on
surface roughness, cutting forces and tool life during
End milling of AISI 1018 material by coated carbide
end mill tools of different three type of lubricant
cutting environment. This three lubricant has been
selected to improve the quality of the material during
milling process.
One of the primary functions of cutting
fluids in machining is to cool the work piece by
efficiently removing heat away from the cutting
zone.Higher surface finish quality and better
dimensional accuracy are also obtained from cutting
fluids.Today’s cutting fluids are special blends of
chemical additives, lubricants and water formulated
to meet the performance demands of the
metalworking industry. During metal cutting heat
generated as a result of work done. Heat is carried
away from the tool and work by means of cutting
fluids, which at the same time reduced the friction
between the tool and chip and between tool and
work and facilitates the chip formation. Cutting
fluids usually in the form of a liquid are to the
formation zone to improve the cuttingcondition.
Cutting fluids is one of the important aids to
improve production efficiency.
Cutting fluids play a significant role in
machining operations and impact shop productivity,
tool life and quality of work. With time and use,
fluids degrade in quality and eventually require
disposal once their efficiency is lost. Waste
management and disposal have become increasingly
more complex and expensive. Environmental
liability is also a major concern with waste disposal.
Many companies are now paying for environmental
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cleanups or have been fined by regulatory agencies
as the result of poor waste disposal practices.
II. Experimental details
2.1 Work piece material
AISI 1018 has been selected as work piece
Material. It widely used for Axles, bolts, connecting
rods, motor Shafts, hydraulic shafts, pump shafts,
pins, and machinery parts. The diameter and Length
of work piece was 200 mm and 400 mm
respectively. Chemical composition of this material
is Carbon 0.14 to 0.20%, Manganese 0.6 to0.9,
phosphorus 0.04% max, Silicon 0.27%, Sulphur
0.50max, iron 98.81 to 99.26%.
2.2 Cutting end mills
All the experiments were performed by
using solid carbide end mills of series (Art No
3021, 3680 and 3023) of different geometry. It
is hard pvd coated super micro-grain carbide
end mills having superior toughness and heat
resistance. It is used for Finishing and light
interrupted cutting of stainless steel. Different
types of three tool flutes are used.
2.3 Cutting fluid
In order to perform the experiment in
Quaker 7101, Blasocut strong 4000 and Velvex
which is water miscible cutting Lubricant. All three
lubricants forms are milky white emulsion. Suitable
for all metals for machining operations where
emulsifiable oil are normallyused. Emulsion strength
of quaker 7101 is (10-20%), blasocut strong 4000
(3-10%) and velvex (5-10%) have been used as a
cutting fluids Sometimes used successfully for even
milling process.
2.4Experimental apparatus
The milling of work piece is conducted on
TAKANG vmc-850 having followingSpecifications:
Table size:510×1000 mm, Working size: X Axis:
850mm, Y Axis: 560mm, Z Axis: 560mm, Spindle:
800 to 12000 RPM, No of tool: 24, CNC system:
Fanucoimb model, Cutting capacity: 220Cc/min,
Tool Holder Pull Stud Type: MAS P40T-1-45,
Power Supply: 415 v, 3ph, 50Hz, Width: 2230 mm,
Depth: 2350mm, Weight: 4500kg.
2.5 Measurement of surface roughness and
cutting forces
The surface roughness of the turned
samples was measured with Mitutoyo make Surface
roughness tester (SJ-110) and the cutting forces
measured with the help of equation.
2.6Design of experiment
In this study, four controllable variables,
namely, tool flutes, feed rate, depth of cut and
spindle speed has been selected. In the machining
parameter design, three levels of the cutting
parameters were selected, shown in Table 1.
Table1.Factors with levels value
Factors
Level
1
Level 2 Level 3
No of tool flute 2 3 4
Depth of cut (mm) 0.5 0.75 1
Feed rate(mm/rev) 0.122 0.184 0.239
Spindle speed (rpm) 800 1000 1200
As per table 1, L9 orthogonal array of
“Taguchi method” has been selected for the
experiments in MINITAB 16. Each 9 experiments
will carry out in quaker 7101, blasocut strong 4000
and velvex cutting fluid. Surface roughness, cutting
force and power consumption has been selected as
response variable.All these data are used for the
analysis and evaluation of the optimal parameters
combination.Experiment result as shown in Table2.
Table2. Experimental results.
Sr.
no
TF
DOC
(mm)
SS
(rpm)
FR
(mm)
SR
(µm)
Fc
(Kg)
PC
(KW
)
Quaker 7101
1 2 0.5 800 0.122 3.756 297 2.138
2 2 0.75 1000 0.184 4.355 334 1.658
3 2 1 1200 0.239 4.372 315 2.439
4 3 0.5 1000 0.239 4.172 387 2.215
5 3 0.75 1200 0.122 2.340 366 2.414
6 3 1 800 0.184 4.741 276 1.788
7 4 0.5 1200 0.184 1.611 394 2.218
8 4 0.75 800 0.239 3.836 369 1.731
9 4 1 1000 0.122 3.257 270 1.781
Blasocut strong 4000
10 2 0.5 800 0.122 3.247 263 1.591
11 2 0.75 1000 0.184 3.717 291 1.898
12 2 1 1200 0.239 3.696 272 1.904
13 3 0.5 1000 0.239 3.450 338 1.630
14 3 0.75 1200 0.122 2.009 324 2.241
15 3 1 800 0.184 4.077 245 2.078
16 4 0.5 1200 0.184 1.493 343 1.701
17 4 0.75 800 0.239 3.298 321 1.731
18 4 1 1000 0.122 2.681 241 1.534
Velvex
19 2 0.5 800 0.122 4.352 327 1.491
20 2 0.75 1000 0.184 5.453 432 2.261
21 2 1 1200 0.239 5.046 338 1.902
22 3 0.5 1000 0.239 4.574 356 2.131
23 3 0.75 1200 0.122 2.743 352 1.854
24 3 1 800 0.184 5.569 231 2.501
25 4 0.5 1200 0.184 2.183 392 1.676
26 4 0.75 800 0.239 4.492 352 1.735
27 4 1 1000 0.122 3.803 236 2.405
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III. Methodology
3.1 Grey relational analysis method
In the grey relational analysis, experimental
results were first normalized and then the grey
relational coefficient was calculated from the
normalized experimental data to express the
relationship between the desired and actual
experimental data. Then, the grey relational grade
was computed by averaging the grey relational
coefficient corresponding to each process response
(3 responses). The overall evaluation of the multiple
process responses is based on the grey relational
grade. [5]
3.2 Data preprocessing
In grey relational generation, the
normalized data corresponding to Lower-the-Better
(LB) criterion can be expressed as:
(1)
For Higher-the-Better (HB) criterion, the normalized
data can be expressed as:
(2)
Where xi (k) is the value after the grey relational
generation, min yi (k) is the smallest value ofyi (k)
for the kth response, and max yi (k) is the largest
value of yi (k) for the kth response.
An ideal sequence is x0(k) (k=1, 2) for two
responses. The definition of the grey relational grade
in the grey relational
analysis is to show the relational degree between the
twenty-seven sequences (x0(k) and xi(k), i=1, 2, . . .
, 27; k=1, 2). The grey relational coefficient ξi (k)
can be calculated as:
(3)
Where Δi = | X0 (k) – Xi (k) | = difference of the
absolute value x0 (k) and xi (k); θ is the
distinguishing coefficient 0 ≤ θ ≤ 1; minΔ = ∀j min
ϵ i∀kmin= | X0 (k) – Xi (k) | = the smallest value
of Δ0i; and maxΔ = ∀jmax ϵ i∀kmax = largest
value of Δ0i. After averaging the grey relational
coefficients, the grey relational grade γi can be
computed as
(4)
Where n = number of process responses. The higher
value of grey relational grade corresponds to intense
relational degree between the reference sequence x0
(k) and the given sequence xi (k). The reference
sequence x0 (k) represents the best process
sequence. Therefore, higher grey relational grade
means that the corresponding parameter combination
is closer to the optimal. [4]
IV. Results and discussions
A level standard analysis was adopted to
interpret the results. This analysis is based on
combining the data associated with each level for
each factor. The deviation in the average results for
the highest and lowest average response is the
measure of the effect of that factor. The higher value
of this difference is related to the largest effects of
that particular factor. Data preprocessing of each
performancecharacteristic and the experimental
results for the grey relational according to formulas
(1),(2),(3) and (4) are given in Table 3 and 4.
Table 3 Normalize value of SR, Fc and Ff for dry,
wet and solid lubricant environment.
Ex
NO.
Normalize
value of SR
Normalize
value of CF
Normalize value
of PC
Quaker 7101
1 0.3146 0.7822 0.3854
2 0.1233 0.4838 1
3 0.1178 0.6370 0
4 0.1817 0.0564 0.2868
5 0.7670 0.2258 0.3201
6 0 0.9516 0.8335
7 1 0 0.2829
8 0.2891 0.2016 0.9065
9 0.4741 1 0.8425
Blasocut strong 4000
10 0.3212 0.7443 0.9193
11 0.1393 0.5098 0.4851
12 0.1474 0.6960 0.4766
13 0.2426 0.4901 0.8642
14 0.8003 0.1862 0
15 0 0.9607 0.2305
16 1 0 0.7637
17 0.3014 0.2156 0.7213
18 0.5402 1 1
Velvex
19 0.3594 0.5223 1
20 0.0342 0 0.2376
21 0.1544 0.4676 0.5930
22 0.2937 0.3781 0.3663
23 0.8246 0.3980 0.6405
24 0 1 0
25 1 0.1990 0.8168
26 0.3180 0.3880 0.7584
27 0.5215 0.9751 1
Table 4 Calculation of GRC and GRD
Experime
nt No.
GRC
of
SR
GRC
of
CF
GRC
of
PC
GRG Grad
e No.
Quaker 7101
1 0.421
8
0.696
6
0.448
5
0.522
3
6
2 0.363
2
0.492
1
1 0.618
4
3
3 0.361
8
0.579
4
0.333
3
0.424
8
8
4 0.379 0.346 0.412 0.379 9
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3 4 1 2
5 0.682
2
0.392
4
0.423
7
0.499
4
7
6 0.333
3
0.911
8
0.750
1
0.665
0
2
7
1
0.333
3
0.410
8
0.581
3
4
8 0.412
9
0.385
1
0.842
4
0.546
8
5
9 0.487
4 1
0.760
4
0.749
2
1
Blasocut strong 4000
10 0.424
2
0.698
6
0.861
0
0.661
2
3
11 0.367
5
0.505
0
0.492
6
0.455
0
9
12 0.369
7
0.622
0
0.488
5
0.493
4
6
13 0.397
7
0.344
6
0.786
4
0.509
5
5
14 0.714
6
0.380
6
0.333
3
0.476
1
8
15 0.333
3
0.927
3
0.393
8
0.551
4
4
16
1
0.333
3
0.679
0
0.670
7
2
17 0.417
2
0.389
3
0.642
0
0.482
8
7
18 0.521
0
1 1 0.840
3
1
Velvex
19 0.438
4
0.511
5
1 0.649
9
3
20 0.341
1
0.333
3
0.396
0
0.356
8
9
21 0.371
6
0.484
3
0.551
2
0.469
0
7
22 0.414
5
0.445
7
0.441
0
0.433
7
8
23 0.751
4
0.453
7
0.581
7
0.595
6
4
24 0.333
3 1
0.333
3
0.555
5
5
25
1
0.384
3
0.731
8
0.705
3
2
26 0.423
0
0.453
7
0.674
2
0.516
9
6
27 0.511
0
0.952
6
1 0.821
2
1
In grey relational analysis higher the grey
relational grade of experiment says that the
corresponding experimental combination is optimum
condition for multi objective optimization and gives
better product quality. Also form the basis of the
grey relational grade, the factor effect can be
estimated and the optimal level for each controllable
factor can also be determined. From Table 4. It is
found that experiment 18 has the best multiple
performance characteristic among 27 experiments,
because it has the highest grey relational grade of
0.8403.
The main effects plot of grey relational
grade vs. process parameter can generated by
Minitab 16 statistical software to find out optimum
parameter combination, is shown in graph 1.
432
0.65
0.60
0.55
0.50
0.45
1.000.750.50
12001000800
0.65
0.60
0.55
0.50
0.45
0.2390.1840.122
No of tool flute
MeanofMeans
Depth of cut
Spindle speed Feed Rate
Main Effects Plot for Means (Quaker 7101)
Data Means
432
0.65
0.60
0.55
0.50
0.45
1.000.750.50
12001000800
0.65
0.60
0.55
0.50
0.45
0.2390.1840.122
No of tool flute
MeanofMeans
Depth of cut
Spindle speed Feed Rate
Main Effects Plot for Means (Blasocut Strong 4000)
Data Means
432
0.70
0.65
0.60
0.55
0.50
1.000.750.50
12001000800
0.70
0.65
0.60
0.55
0.50
0.2390.1840.122
No of tool flute
MeanofMeans
Depth of cut
Spindle speed Feed Rate
Main Effects Plot for Means (Velvex)
Data Means
Graph 1. Mean effect plot of grey relational grad
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Vol. 3, Issue 4, Jul-Aug 2013, pp.728-732
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Vs. no of tool flutes, depth of cut, spindle speed
and feed rate.
From the graph 1. It is conclude that the
optimum condition for better surface finish is
meeting at no of tool flutes, depth of cut, spindle
speed and feed rate.The graph shows that different
types of mean effect value for all machining
parameters. In this graph the optimum value is
calculated based on higher value of parameter which
is consider as the larger is better ratio.
V. Conclusion
It is concluded that the application of
quaker 7101 cutting lubricant utilize in end milling
process has proved to be a feasible cutting fluid with
combination of water and chemical (Emulsions), if it
can be applied properly. Whose results show that
there is a considerable improvement in surface
roughness and quality of product created.
VI. Acknowledgment
It is a privilege for me to have been
associated with Mr. C. P. Patel, Asso. Prof. of
Mechanical Engg. Dept. at U.V Patel College of
engineering, Kherva. During this paper work. I have
been greatly benefited by his valuable suggestions
and ideas. It is with great pleasure that I express my
deep sense of gratitude to him for his valuable
guidance and constant encouragement throughout
this work.
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