The document is a project seminar submitted by Mr. Rahul Raju Kundiya on the topic of experimental analysis and modelling in micro drilling of CFRP-Ti6Al4V stacked composite materials. It discusses micro drilling, the objectives of the study, experimental setup, design of experimentation, results and discussion. The study aims to design experiments to analyze the effect of drilling parameters on hole quality and develop a mechanistic force model. It presents results on hole taper, radial overcut, delamination factor and burr formation when drilling the composite material stack at different speeds and feed rates.
Machinability Study Of 3D printed Ti-6Al-4VSajjadAhmad214
The objective of the research is to study the machinability of 3D printed materials and provide fundamental insight into the material removal mechanism. Specifically, this study aims to investigate how the porosity in 3D printed materials can affect its machinability in terms of cutting force, surface quality, and tool wear. It is believed that machining response during the subtractive cycle of the process could be used to provide feedback on printing quality for the upcoming addictive cycle to improve the quality of the parts. This could be achieved by the machinability studies of 3D printed parts with varying degrees of defects such as porosity to obtain a one-to-one correlation between the machining response, e.g., cutting forces and vibrations, and the defect concentration e,g, porosity.
The present study is limited to the most extensively used Titanium alloy-6Al-4V which is 3D printed by the Selective Laser Sintering process. Micro-end milling is used as the machining process to conduct the machining experiments.
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
Simulation of Stir Casting Process Using Computational Fluid DynamicsIJERA Editor
Stir casting process is one of the methods to produce Metal Matrix Composites (MMCs). But the Particle
Distribution of Non-Homogenous material is the greatest problem facing now days to produce MMCs. The
present simulations were conducted how the speed of the stirrer effects the Particle Distribution of Non-
Homogenous material. The Simulations were performed using Computational Fluid Dynamics. In this
experiment Copper is used as Semi Solid Metal (SSM) and Silicon-Carbide is used as solid metal. The
simulations were carried out by varying the stirrer speed 200 rpm and 400 rpm while keeping other parameters
constant such as Viscosity 4.4 mPa-s and Blade Angle 60 degrees. The results show that better distribution
obtained for the speed 400 rpm.
Optimization of Cutting Parameters Using Genetic Algorithm and Particle Swar...IJMER
In machining operations, achieving desired surface quality features of the machined product,
is really a challenging job. Because, these quality features are highly correlated and are expected to be
influenced directly or indirectly by the direct effect of process parameters or their interactive effects
(i.e. on process environment). However, the extents of significant influence of the process parameters
are different for different responses. Therefore, optimization of surface roughness is a multi-factor,
multi-objective optimization problem. Therefore, to solve such a multi-objective optimization problem, it
is felt necessary to identify the optimal parametric combination, following which all objectives could be
optimized simultaneously. In this context, it is essential to convert all the objective functions into an
equivalent single objective function or overall representative function to meet desired multi-quality
features of the machined surface. The required multi-quality features may or may not be conflicting in
nature. The representative single objective function, thus calculated, would be optimized finally. In the
present work, Design of Experiment (DOE) with Design of Expect software, Mini Tab & optimized
using genetic algorithm by MAT Lab and Particle Swarm Optimization (PSO) by “C” program in
straight turning operation. Collected data related to surface roughness have been utilized for
optimization. Due to complexity of this machining optimization problem, a genetic algorithm (GA) and
Particle Swarm Optimization (PSO) are applied to resolve the problem and the results obtained from
GA and PSO are compared
Machinability Study Of 3D printed Ti-6Al-4VSajjadAhmad214
The objective of the research is to study the machinability of 3D printed materials and provide fundamental insight into the material removal mechanism. Specifically, this study aims to investigate how the porosity in 3D printed materials can affect its machinability in terms of cutting force, surface quality, and tool wear. It is believed that machining response during the subtractive cycle of the process could be used to provide feedback on printing quality for the upcoming addictive cycle to improve the quality of the parts. This could be achieved by the machinability studies of 3D printed parts with varying degrees of defects such as porosity to obtain a one-to-one correlation between the machining response, e.g., cutting forces and vibrations, and the defect concentration e,g, porosity.
The present study is limited to the most extensively used Titanium alloy-6Al-4V which is 3D printed by the Selective Laser Sintering process. Micro-end milling is used as the machining process to conduct the machining experiments.
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
Simulation of Stir Casting Process Using Computational Fluid DynamicsIJERA Editor
Stir casting process is one of the methods to produce Metal Matrix Composites (MMCs). But the Particle
Distribution of Non-Homogenous material is the greatest problem facing now days to produce MMCs. The
present simulations were conducted how the speed of the stirrer effects the Particle Distribution of Non-
Homogenous material. The Simulations were performed using Computational Fluid Dynamics. In this
experiment Copper is used as Semi Solid Metal (SSM) and Silicon-Carbide is used as solid metal. The
simulations were carried out by varying the stirrer speed 200 rpm and 400 rpm while keeping other parameters
constant such as Viscosity 4.4 mPa-s and Blade Angle 60 degrees. The results show that better distribution
obtained for the speed 400 rpm.
Optimization of Cutting Parameters Using Genetic Algorithm and Particle Swar...IJMER
In machining operations, achieving desired surface quality features of the machined product,
is really a challenging job. Because, these quality features are highly correlated and are expected to be
influenced directly or indirectly by the direct effect of process parameters or their interactive effects
(i.e. on process environment). However, the extents of significant influence of the process parameters
are different for different responses. Therefore, optimization of surface roughness is a multi-factor,
multi-objective optimization problem. Therefore, to solve such a multi-objective optimization problem, it
is felt necessary to identify the optimal parametric combination, following which all objectives could be
optimized simultaneously. In this context, it is essential to convert all the objective functions into an
equivalent single objective function or overall representative function to meet desired multi-quality
features of the machined surface. The required multi-quality features may or may not be conflicting in
nature. The representative single objective function, thus calculated, would be optimized finally. In the
present work, Design of Experiment (DOE) with Design of Expect software, Mini Tab & optimized
using genetic algorithm by MAT Lab and Particle Swarm Optimization (PSO) by “C” program in
straight turning operation. Collected data related to surface roughness have been utilized for
optimization. Due to complexity of this machining optimization problem, a genetic algorithm (GA) and
Particle Swarm Optimization (PSO) are applied to resolve the problem and the results obtained from
GA and PSO are compared
Implementation of Response Surface Methodology for Analysis of Plain Turning ...IJERD Editor
This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface roughness of mild steel material with turning process. The response surface methodology (RSM) was employed in the experiment. The investigated turning parameters were cutting speed (CS) (1150, 850m/min), feed rate (FR) (1 and 0.5 mm/rev) and depth of cut (DOC) (1.0 and 0.5 mm) and no. of cuts(NOC) (2 and 1). The results showed that the interaction between the feed rate and depth of cut, was the primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The optimum condition required for minimum surface roughness(SR) include cutting speed of 1150 m/min, feed rate of 1 mm/rev, axial depth of cut of 0.5 mm and no. of cut 1. With this optimum condition, a surface roughness of 0.280μm was obtained. The methodology for above experimentation is presented in this paper along with results and interpretation.
IMPROVEMENT IN SURFACE QUALITY WITH HIGH PRODUCTION RATE USING TAGUCHI METHOD...IAEME Publication
Metal matrix composites possess significantly improved properties including high specific strength, damping capacity, specific modulus and wear resistance compared to unreinforced alloys.There has been an increasing interest in composites containing low density and low cost reinforcements with good properties. Among these reinforcements SiC is found to be chemically compatible with aluminum forming a sufficiently strong bond with the matrix. There are several
methods of manufacture of MMCs. Of these, the stir casting method is very popular due to its unique mixing property.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
Abstract: In this investigation, experimental work and computational work are combined to obtain improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time (Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are fed to the Minitab software and optimum input parameters for the desired output parameters are identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is performed in order to remove the recast layer and again the surface roughness is measured by using stylus type roughness tester. Finally from the obtained results it was found that there was significant improvement in the Surface roughness of the nickel alloy material. In addition using regression analysis this work is stimulated by computational method and the results are obtained
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.
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.
Experimental Investigation and Parametric Analysis of Surface Roughness in C...IJMER
The manufacturing industries are very much concerned about the quality of their products.
They are focused on producing high quality products in time at minimum cost. Surface finish is one of the
crucial performance parameters that have to be controlled within suitable limits for a particular process.
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. These include cutting tool variables, work
piece material variables, cutting conditions etc. Therefore, prediction or monitoring of the surface
roughness of machined components has been challenging and unexplored area of research
The present work is therefore in a direction to integrate effect of various parameters which effect the
surface roughness. Experiments were carried out with the help of factorial method of design of
experiment (DOE) approach to study the impact of turning parameters on the roughness of turned
surfaces. A mathematical model was formulated to predict the effect of machining parameters on surface
roughness of a machined work piece. Model was validated with the experimental data and the reported
data of other researchers. Further parametric investigations were carried out to predict the effect of
various parameters on the surface research
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
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
Experimental Study and Optimisation of Mrr In CNC Plasma ARC CuttingIJERA Editor
The research and development in the precise and accurate machining technology of hard metals (Ferrous, non-ferrous and glass etc) is gaining much importance in the industry since last many years. Due to the tremendous competition and cost factor, the non-conventional machining technology is becoming the first choice of the engineers and technicians. In this era of advanced technological processes the CNC plasma arc machining is gaining tremendous ground in the industry. It is much more capable of producing best finished, high accurate machining of very complicated non-symmetrical profile in no time. The main objective and targets of this practical experiment is based to achieve the best possible setting and parameters of operation on a CNC plasma arc machine to achieving speedy work i.e. Maximum material removal rate.
Optimization of cutting strategies for forging die manufacturing on cnc milli...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
Finite Element simulation of Rotary Sheet Bending.pdfmeet kalola
introduction, literature review, material selection and dimensions, steps to perform simulation in ls-dyna ,implementation issues, results, conclusion and further implementation.
Experimental Investigation on Cutting Force in Milling of Aluminium Hybrid Me...Adithya Krishnakant
As the title of the project suggests, it is a research on the effect of cutting force in milling of aluminium hybrid metal matrix composites. The combination of composites are Aluminium 6061-Alumina-Graphite.Face milling is performed on the fabricated workpiece. The composite is fabricated using stir casting technique.The experiments are designed according to the L27 model in taguchi method. The reults indicated that variation of alumina content in the workpiece or specimens was the predominant factor, feed rate was the second most predominant factor. Speed had less effect on measuring the cutting forces. This combination of composites is mainly used in the manufacturing of cylinder liners in automobiles. The reason is the presence of alumina which increases the hardness of the workpiece. Graphite is added due to its lubricating properties. Al6061 is chosen for its good machinable properties.
This topic has immense research possibilities that can change the face of manufacturing industry.
Optimization of Turning Parameters Using Taguchi MethodIJMER
Abstract: Today in manufacturing and metal industries customer satisfaction is very important to
make own place in competitive market and also to make mirror image with faith in the heart of
customer, because customer gives preference to buy good quality product. In the metal and
manufacturing industries for the product low surface roughness is very important. Lowest surface
roughness assures not only good quality but also reduces manufacturing cost. In this paper the main
objective is to study effect of cutting speed, feed rate and depth of cut on surface roughness of mild steel
in turning operation and as a result of that the combination of optimum level of factors was obtained to
get lowest surface roughness. Experiments have been conducted using Taguchi’s experimental design
technique. An orthogonal array, signal to noise ratio, and analysis of variance are employed to
investigate cutting characteristics of mild steel using high speed steel. Experimental results show that
among the cutting parameter cutting speed is the most significant machining parameter for surface
roughness followed by feed rate and depth of cut.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Implementation of Response Surface Methodology for Analysis of Plain Turning ...IJERD Editor
This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface roughness of mild steel material with turning process. The response surface methodology (RSM) was employed in the experiment. The investigated turning parameters were cutting speed (CS) (1150, 850m/min), feed rate (FR) (1 and 0.5 mm/rev) and depth of cut (DOC) (1.0 and 0.5 mm) and no. of cuts(NOC) (2 and 1). The results showed that the interaction between the feed rate and depth of cut, was the primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The optimum condition required for minimum surface roughness(SR) include cutting speed of 1150 m/min, feed rate of 1 mm/rev, axial depth of cut of 0.5 mm and no. of cut 1. With this optimum condition, a surface roughness of 0.280μm was obtained. The methodology for above experimentation is presented in this paper along with results and interpretation.
IMPROVEMENT IN SURFACE QUALITY WITH HIGH PRODUCTION RATE USING TAGUCHI METHOD...IAEME Publication
Metal matrix composites possess significantly improved properties including high specific strength, damping capacity, specific modulus and wear resistance compared to unreinforced alloys.There has been an increasing interest in composites containing low density and low cost reinforcements with good properties. Among these reinforcements SiC is found to be chemically compatible with aluminum forming a sufficiently strong bond with the matrix. There are several
methods of manufacture of MMCs. Of these, the stir casting method is very popular due to its unique mixing property.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
Abstract: In this investigation, experimental work and computational work are combined to obtain improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time (Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are fed to the Minitab software and optimum input parameters for the desired output parameters are identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is performed in order to remove the recast layer and again the surface roughness is measured by using stylus type roughness tester. Finally from the obtained results it was found that there was significant improvement in the Surface roughness of the nickel alloy material. In addition using regression analysis this work is stimulated by computational method and the results are obtained
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.
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.
Experimental Investigation and Parametric Analysis of Surface Roughness in C...IJMER
The manufacturing industries are very much concerned about the quality of their products.
They are focused on producing high quality products in time at minimum cost. Surface finish is one of the
crucial performance parameters that have to be controlled within suitable limits for a particular process.
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. These include cutting tool variables, work
piece material variables, cutting conditions etc. Therefore, prediction or monitoring of the surface
roughness of machined components has been challenging and unexplored area of research
The present work is therefore in a direction to integrate effect of various parameters which effect the
surface roughness. Experiments were carried out with the help of factorial method of design of
experiment (DOE) approach to study the impact of turning parameters on the roughness of turned
surfaces. A mathematical model was formulated to predict the effect of machining parameters on surface
roughness of a machined work piece. Model was validated with the experimental data and the reported
data of other researchers. Further parametric investigations were carried out to predict the effect of
various parameters on the surface research
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
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
Experimental Study and Optimisation of Mrr In CNC Plasma ARC CuttingIJERA Editor
The research and development in the precise and accurate machining technology of hard metals (Ferrous, non-ferrous and glass etc) is gaining much importance in the industry since last many years. Due to the tremendous competition and cost factor, the non-conventional machining technology is becoming the first choice of the engineers and technicians. In this era of advanced technological processes the CNC plasma arc machining is gaining tremendous ground in the industry. It is much more capable of producing best finished, high accurate machining of very complicated non-symmetrical profile in no time. The main objective and targets of this practical experiment is based to achieve the best possible setting and parameters of operation on a CNC plasma arc machine to achieving speedy work i.e. Maximum material removal rate.
Optimization of cutting strategies for forging die manufacturing on cnc milli...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
Finite Element simulation of Rotary Sheet Bending.pdfmeet kalola
introduction, literature review, material selection and dimensions, steps to perform simulation in ls-dyna ,implementation issues, results, conclusion and further implementation.
Experimental Investigation on Cutting Force in Milling of Aluminium Hybrid Me...Adithya Krishnakant
As the title of the project suggests, it is a research on the effect of cutting force in milling of aluminium hybrid metal matrix composites. The combination of composites are Aluminium 6061-Alumina-Graphite.Face milling is performed on the fabricated workpiece. The composite is fabricated using stir casting technique.The experiments are designed according to the L27 model in taguchi method. The reults indicated that variation of alumina content in the workpiece or specimens was the predominant factor, feed rate was the second most predominant factor. Speed had less effect on measuring the cutting forces. This combination of composites is mainly used in the manufacturing of cylinder liners in automobiles. The reason is the presence of alumina which increases the hardness of the workpiece. Graphite is added due to its lubricating properties. Al6061 is chosen for its good machinable properties.
This topic has immense research possibilities that can change the face of manufacturing industry.
Optimization of Turning Parameters Using Taguchi MethodIJMER
Abstract: Today in manufacturing and metal industries customer satisfaction is very important to
make own place in competitive market and also to make mirror image with faith in the heart of
customer, because customer gives preference to buy good quality product. In the metal and
manufacturing industries for the product low surface roughness is very important. Lowest surface
roughness assures not only good quality but also reduces manufacturing cost. In this paper the main
objective is to study effect of cutting speed, feed rate and depth of cut on surface roughness of mild steel
in turning operation and as a result of that the combination of optimum level of factors was obtained to
get lowest surface roughness. Experiments have been conducted using Taguchi’s experimental design
technique. An orthogonal array, signal to noise ratio, and analysis of variance are employed to
investigate cutting characteristics of mild steel using high speed steel. Experimental results show that
among the cutting parameter cutting speed is the most significant machining parameter for surface
roughness followed by feed rate and depth of cut.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
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Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
AKS UNIVERSITY Satna Final Year Project By OM Hardaha.pdf
MTP.pptx
1. A
Project seminar
On
Experimental Analysis and Modelling in Micro drilling of
CFRP-Ti6Al4V Stacked Composite
Submitted By
Mr. Rahul Raju Kundiya (2030332608001)
Under the Guidance of
Dr. R. S. Pawade
1
DEPARTMENT OF MECHANICAL ENGINEERING
Dr. Babasaheb Ambedkar Technological University, Lonere
1
2. Contents
Introduction
Literature Survey
Objectives
Micro Drilling
Tooling and Work material
Theme of Experimentation
Experimental Setup
Design of Experimentation
Mechanistic Force model
Result and Discussion
Conclusion
Future Scope
2
3. Introduction
Cowling is a covering on vehicle's engine, mostly found on highspeed sports
automobiles and aircraft vehicles. Cowling is used to reduce active
aerodynamic drag and cool engine by directing airflow as an air intake for jet
engines, also cover is used for decorative purposes of outboard motor.
Ti6Al4V/CFRP stack used in airspace industry for engine cowlings, wings
connection, wing panels, nacelles.
CFRP/Ti alloy stack of about 0.8 mm thick sheet is used for cowling of high
performance engine of 757 Dreamliner, Falcon 900 business jet, Airbus A320,
F-16XL aircraft.
3
4. Micro Drilling
Micro drilling is one of the most fundamental micro machining techniques and
is generally defined as the drilling of diameters between 1 micron and 1 mm.
Different researchers and manufacturers define micro drilling differently.
Sphinx, the Swiss micro drill manufacturer, defined micro drilling as having a
starting diameter of 0.05 mm and ranging to 2.5 mm.
Micro drills are typically made of either cobalt steel or micro grain tungsten
carbide. The drill point angle is based on the material to be drilled. The normal
point angle is 118 degrees and 140 degrees is used for hard materials. The
larger included point angle provides more strength at the drill point.
4
6. Continue
Delamination- Delamination factor decreased with decreasing feed. It
resulted due to the influence of micro-drilling size effect where specific
cutting forces increased non-linearly on downscaling of feed in CFRP
composite material.
Tool Wear- Smaller drill bit always face a problem of dissipating heat slower
than larger drill bits. At substantial speeds, there was a possibility of very high
temperature development. It produced micro-fractures and increased tool
wear.
6
7. Continue
Hole Quality- Higher feed rate increased induce higher dynamic vibrations in
the machining zone. Due to length of the uncut chip thickness increased in
turn increased the ploughing component of the cutting force. This increased
ploughing component increases the circularity error.
Burr formation- material deformed due to the effect of the point angle. The
distance between deformation starts and exit surface was affected by the thrust
force. Depending on the increased in thrust force which caused burrs to
increased at the exit point. Burr height increased at exit surface parallel to the
increased in feed rate. increased in spindle speed caused to chip height to
decreased at both entry and exit points
7
8. Continue
8
Thrust force- rise in feed rate caused an increased in chip section lifted in unit
time. This caused an increased in load affecting the cutting tool.
Torque- friction and chips sticking to the tool caused the chip to jam inside the hole
which affect higher torque value.
In addition to the size requirements, the micro holes require no taper or minimum
taper. When the diameter of the entrance hole is greater than exit hole. thus, taper
were positive.
9. Objectives
To design the experimentation using RSM CCD customize design for
mechanical micro drilling of Ti6Al4V/CFRP Stack Composite.
To study the effect of drilling parameters on hole quality in term of
delamination factor, hole taper, radial overcut and burr characteristics.
To develop mechanistic force model to determine the lateral, thrust and
cutting forces.
8
10. Tooling and Work material
Ti6Al4V (X ray- Spectroscopy Titanium Gr.5) 0.5mm thick
Chemical Composition- Ti-89.46%, Al-6.01%, V-4.06%, Fe- 0.24%
CFRP 16 fibric plies of ‘sigratex CE 8204-65-42’ prepregs. Woven with
twill 2/2 wave and epoxy resin.
Composition - Fiber volume 53.5- 54.7% and rest is epoxy resin.
Tool Material T5401 grade – TiN coated Tungsten carbide (Coating
thickness 0.2-0.5 micron)
Twist Drill- Dia-400µ, Helix angle 30 degrees, Clearance angle- 10
degrees, Web thickness 26µ, chisel edge angle 140 degrees, Tool edge
radius 2-2.5µ
9
11. Theme of Experimentation
10
The drilling parameters are spindle Speed, feed Rate (variable),diameter and
drill steps (fixed). The quality of holes was determined in terms of hole taper,
radial overcut and delamination factor. In addition the burrs formed while micro
drilling was measured.
12. Design of Experimentation
Design of Experiments is used to determine the appropriate number of tests
and the experimental conditions necessary to obtain the desired goal of
analyzing which factors of the process influence the response variable.
Table 1. Experimental design factor
11
13. Design of Experimentation
RSM CCD Method
A simple function, such as linear or quadratic polynomial, fitted to the data
obtained from the experiments is called response surface, and the approach is
called the response surface method.
It is a collection of statistical and mathematical techniques useful for
developing, improving, and optimizing processes. It is a method for
constructing global approximations to system behavior based on results
calculated at various points in the design space.
A CCD is an experimental design, useful in response surface methodology, for
building a second order model for the resposnse variable without needing to
use a complete three level factorial experiment.
12
14. Continue
Customized Multilevel multifactorial screening design is used to identify
main effects under consideration of average levels of other factors.
Mixed multilevel screening design suggested 20 runs for 3 factors and mixed
2,3,4 levels. Screening orthogonal arrays analysts simplifies the analysis and
interpretation of results.
They obtain a lot of information about the main effects in a relatively few
number of runs. It can test whether non-linear terms are needed in the model,
at least as far as the three-level factors are concerned.
13
15. Experimental Setup
The experimental setup was used for performing the experiments is CNC
Micromachining station made by Interface design associates pvt. limited.
Aerostatic spindle provided 6001 rpm to 60000 rpm capacity. Preliminary
micro hole making operations are performed by varying various spindle speed
and result limited to higher rpm of varying from 25000, 35000 and 45000 rpm
due to insufficient longitudinal strength and breakability of tools.
Experimentation is planned in these section of Ti6AlV4 & CFRP and
CFRP/Ti6AlV4 stack due to its anisotropic property in application.
14
17. Continue
Optical 3D surface measurement device and a form measurement device.
Form and roughness measurement.
Measurement of materials with varying reflection properties.
Measurement of areas and volumes in a vertical resolution of up to 10nm.
16
18. Result and Discussion
In this work, micro drilling of CFRP-Ti stacked composite was carried out. In
particular the quality of holes drilled have been examined in terms of hole
taper, radial overcut and delamination factor by using statistical design of
experiments. In addition burr formed were characterized for their nature and
type. In the last part, mechanistic force model is discussed that determine the
cutting, thrust and friction force generated during micro drilling.
17
19. Continue
Analysis of micro holes
Table 2. Drilling holes at different drilling condition
18
21. Analysis of hole taper
Hole taper is one of the inherent manufacturing problems associated with micro drilling.
A taper is defined as the uniform change of the diameter of a workpiece on its axis. The
quality of micro holes is determined by the taper of holes.
Table 4. ANOVA of hole taper
The model F-value of 3.13 implies that the model is significant relative to the noise.
There is a 2.56 percentage chance that an F-value this large could occur due to noise. P-
values less than 0.0500 indicate the model terms are significant.
20
22. Continue
Normal probability plot of residuals for hole taper
The point on this normal probability plot
form a nearly indicates that the normal
distribution is a good model for data set.
The normal probability plot of the residuals
is approximately linear supporting the
condition that the error terms are normally
distributed.
21
23. Response surface plots for taper
Hole taper is one of the inherent
manufacturing problems associated with
micro drilling. In order to achieve the
greater accuracy in micro drilling process
taper should be minimum. Therefore,
parameters affecting the taper are
essential to recognize.
Figure shows the influence of spindle
speed and feed rate on hole taper.
Minimum taper occurs for a middle level
of spindle speed and minimum level of
feed rate. It can be noticed that middle
level of spindle speed is the best for lower
taper.
22
24. Continue
The estimated surface response for
taper in relation to spindle speed and
MQL flow rate is shown in figure.
It can be seen that minimum taper
occurs for a minimum level of MQL
flow rate and near to the middle level
of spindle speed. It can be noticed
that higher level of spindle speed
produced maximum hole taper.
23
25. Continue
Figure shows the effect of feed rate
and MQL flow rate on taper.
It is clear that the minimum taper
occurs for near to the middle level of
feed rate and middle level of MQL
flow rate and also note that the
middle level of both factors are good
condition for lower taper but less
value of feed rate is good for the
minimum the size of hole taper.
24
26. Continue
The one factor effect plot for hole taper has
been depicted in figure 4.6. The one factor
plot helps in predicting the behavior of
each output by changing the respective
input parameter.
It can be noticed that increases the spindle
speed from 26591 rpm to 43409 rpm
results in decreased hole taper. The
increasing feed rate also resulted in
increased hole taper and also increasing
MQL flow rate results in decreased hole
taper.
25
27. Effects of drilling parameters on
hole taper
According to trend of graph, Spindle speed has tremendous effect on the machining
quality. The higher the feed and spindle the rougher the surface of the hole. Spindle
speed improved stiffness of drill due to self-piloting nature and higher stability of drill
bit at higher speeds which get resulted in better circular holes that is minimize the taper
hole.
In higher MQL flow rate condition the average taper values were positive, the diameter
at the entrance of the holes were bigger than at the outlet. These is due to the fact that
radial vibrations of the drill bit are present to the greater extent at the entry rather than
the exit.
The effect of MQL was remove debris from machining zone and thus avoids any built-
up edge formation. It dissipates the heat efficiently, avoiding thermal softening effect.
Circularity is minimum at lower feed rate and increases gradually as increase in feed
rate. This could be attributed due to increase in force required to fracture of fiber at
higher feed rate in CFRP.
26
28. Analysis of Radial Overcut
Radial overcut is the increases in the radius of the drilled hole compared to the tool
diameter. The qualiy of micro holes determined by radial overcut. During the high
spindle speed and maximum feed rate machining condition forming numerous
micro craters, recast layer which assists in increasing the surface area of radial
overcut.
Table 5. ANOVA of ROC
The model F-value of 3.698 implies that the model is significant relative to the
noise. There is a 3.98 percentage chance that an F-value this large could occur due
to noise.
27
29. Continue
Normal probability plot of
residuals for hole taper
Then test of the normality assumptions of the
data is conducted and it can be seen in Figure
that all the points on the normal plot come
close to forming a straight line. This indicates
that the data are fairly normal and there is no
deviation from the normality.
28
30. Response surface plot for ROC
Radial overcut is the inherent parameter to
the micro drilling process which is
unavoidable though suitable compensations
are provided at the tool design. In order to
achieve the greater accuracy in mechanical
micro drilling process overcut should be
minimum. Therefore, parameters affecting
the overcut are essential to recognize.
Figure shows the influence of spindle speed
and feed rate on radial overcut. Minimum
radial overcut occurs for middle level of
spindle speed and a minimum level of feed
rate. It can be noticed that minimum level
of feed rate is best for lower radial overcut.
29
31. Continue
The estimated surface response for
radial overcut in relation to spindle
speed and MQL flow rate shown in
figure
It can be seen that minimum radial
overcut occurs for amaximum level
of MQL flow rate and near to the
middle level of spindle speed. It can
be noticed that higher level of spindle
speed gives maximum the radial
overcut.
30
32. Continue
Figure shows the effect of feed rate
and MQL flow rate on radial overcut.
It is clear that the minimum radial
overcut occurs for near to the
minimum level of feed rate and
higher level of flow rate and also note
that the middle level of spindle speed
are the suitable condition for lower
radial overcut. It is cleared that radial
overcut depends more on feed rate
than on flow rate and spindle speed.
31
33. Continue
The one factor effect plot for radial
overcut has been depicted in figure.
The one factor plot shows the linear
effect of changing the level of a
single factor. It can be noticed that
increases the spindle speed from
26591 rpm to 43409 rpm results in
increased radial overcut. The slightly
increasing feed rate also resulted in
decreased radial overcut and also
decreasing MQL flow rate results in
increased radial overcut.
32
34. Effects of drilling parameters on
ROC
According to trend in graph, Spindle speed is directly proportional to the centrifugal
force acting on the lubrication fluid present in the gap between tool and workpiece,
which contains debris particles. Therefore, when the spindle speed increases, result
minimize radial overcut. When increment in feed rate with increase in spindle speed
attributed to the higher friction between tool and workpiece. Therefore, produce high
heat generation and wear leads to the occurrence of larger radial overcut.
33
35. Analysis of delamination factor
Drilling is the most frequently used operation for assembly of structures or components
but the composite damage called delamination is also associated with drilling composite
laminates. Delamination is one of the major problems encountered in drilling of
composite laminates as compared to that of metals.
Table 6. ANOVA of delamination factor
The model F-value of 3.452 implies that the model is significant relative to the noise.
There is a 3.06 percentage chance that an F-value this large could occur due to noise.
34
36. Continue
Then test of the normality
assumptions of the data is conducted
and it can be seen in Figure that all
the points on the normal plot come
close to forming a straight line. This
indicates that the data are fairly
normal and there is no deviation from
the normality.
35
37. Response surface plot for
delamination factor
Delamination is one of the inherent
manufacturing problems associated with
micro drilling of composites material. In
order to achieve the greater accuracy in
micro drilling process delamination should
be minimum. Therefore, parameters
affecting the delamination factor are
essential to recognize.
Figure shows the influence of spindle
speed and feed rate on delamination factor.
Minimum delamination factor occurs for
middle level of spindle speed and a middle
level of feed rate. It can be noticed that
middle level of feed rate is the best for
minimum delamination factor.
36
38. Continue
The estimated surface response for
delamination factor in relation to spindle
speed and MQL flow rate is shown in
figure.
It can be seen that maximum delamination
factor occurs for a maximum level of
spindle speed and near to the middle level
of MQL flow rate. It can be noticed that
lower level of feed rate maximize the
delamination factor.
37
39. Continue
Figure shows that effect of feed rate and
MQL flow rate on delamination factor.
It is clear that the minimum radial overcut
occurs for the minimum level of feed rate
and near to the higher level of MQL flow
rate and also note that the middle level of
spindle speed are better condition for
lower delamination factor. It is clear that
the delamination factor depends more on
spindle speed and feed rate than on flow
rate.
38
40. Continue
The one factor effect plot for delamination
factor has been depicted in figure.
The one factor plot constructed by
predicting the responses for the low and
high levels of a factor. It can be noticed
that increases the spindle speed from
26591 rpm to 43409 rpm results in
decreased delamination factor. The
increasing feed rate also resulted in
decreased delamination factor and also
increasing MQL flow rate results in
decreased delamination factor.
39
41. Effects of drilling parameter on
delamination
According to trend of graph, Increased in spindle speed and drill diameter minimizes
delamination factor and circularity error, whereas increase in feed rate increases
delamination.
Feed rate and drill diameter make the largest contribution to delamination damage and
becomes more prominent with the increase of tool wear. The rise in spindle speed
minimizing delamination tendency, therefore it reduces circularity error mainly
affected due to reduction in vibration effect of drill bit and machine.
Delamination was occurs due to the the separation of adjacent composite plies and
characterized by the formation of inter laminar cracks in CFRP. This damage occurs
during drilling, on the hole entrance (peel-up delamination).
At high feed, the tool enters the work faster, thus increasing the thrust force. The
quicker passage of the tool damages the inward surface decreases the surface
roughness
40
42. Regression equation
Taper = 4.48633 − (0.000022 × A) + (0.578648 × B) + (0.000784 × C)
ROC = 26.26529 − (0.000031 × A) − (3.69122 × B) − (0.029813 × C)
Fd = 1.46381 − (0.000022796 × A) − (0.012173 × B) + (0.000011 × C)
Where, A = Spindle speed, B = Feed rate and C = MQL flow rate
41
43. Burr formation
Formation of burrs at entrance is caused by lateral extrusion action and at the exit by
rubbing the margins of the drill. In drilling, the burr that forms at the entrance of the
hole can be a result of tearing, a bending action followed by clean shearing, or lateral
extrusion.
The burrs can have different shapes, however, there are three basic types of burr shapes
as 3 different types of burr shapes that usually form during micro drilling .
These are the ideal case with a very little burr formation, uniform, transient and crown
burrs. The uniform burr has relatively small and uniform burr height and thickness
around the hole periphery.
The crown burr has a larger and irregular height distribution around the hole.
The transient burr is a type of burr formed in the transient stage between the uniform
and the crown burrs.
42
45. Mechanistic Force Model
Point angle: 140 degrees , Half point angle (ϕ): 70 degrees =
1.22173 rad
Helix angle (α): 30 degrees = 0.52359 rad
Half web thickness (w): 0.0075 mm and Full web thickness =
0.015 mm
Drill diameter: 0.1 mm or 400 microns
44
47. Continue
Assumption
For the calibration of the model, cutting forces of rotational reference frame are
transformed to the inertial frame of reference where force measurements are performed.
Although geometrically drill bits are similar in both conventional and micro-drilling,
the chip thickness is comparable to the cutting tool edge radius in case of micro-drilling.
Round cutting edge is considered in micro-drilling (Fig. (c)) instead of sharp cutting
edge assumption of conventional drilling (Fig. (b)) for the development of mechanistic
cutting force model.
46
48. Model calibration
The coefficients (a0 −a4 and b0 −b4) are calibrated by designed experiments.
Considering the normal rake angle, speed along cutting lip are changing with respect to
radius, the coefficients for the specific normal and friction forces are calibrated with the
cutting lip by dividing it into a series of elemental segments with variable normal rake
angle and cutting speed. The cutting action of cutting lip is separated from that of chisel
edge by a pilot hole which is equal to or a bit larger than the chisel edge length.
After performing regression analysis on the results of the calibrated drilling
experiments, the coefficients obtained for the specific normal and friction force are
shown in table 8.
Table 8. Coefficient of cutting forces
47
50. Conclusion
Work on Micro Drilling of Ti6Al4V/CFRP Stack Composite is inadequate. In above experiment the results
we get that entry diameter is greater than exit diameter thustaper were positive.
When tool reached end of the holes the diameter decreased, due to the alignment of the tool caused by the
wall. Another important factor determining machining quality is feed rate. At medium spindle speed, feed
rates must be low for good machining quality. However very high spindle speed, high feed rate can be
adopt it has no significant effect on overall machining quality.
It is observed that higher point angle produces minimum hole delamination than small point angle. The
material used for the stacking i.e Aeroldite is suitable for microdrilling of Titanium CFRP composite with
proper lubrication.
49
51. Continue
In this study, an attempt was made to apply response surface methodology for prediction of
taper, radial overcut and delamination factor in mechanical micro drilling of CFRP/Ti6Al4V
stack composite. Twenty experiments were conducted successfully for three input parameters
at three levels as per central composite design (CCD) method.
ANOVA results show that spindle speed and feed rate are highly significant parameters, while
MQL flow rate are non-significant parameters by considering taper and radial overcut
responses. For delamination factor, ANOVA results show that MQL flow rate and feed rate are
highly significant parameters, while spindle speed are non-significant parameters.
50
52. Continue
From the response surface plots, it is cleared that lower level of feed rate an
medium level of spindle speed minimizes the taper considerably. It is observed that
higher level of MQL flow rate and medium level of spindle speed minimizes the
taper considerably and also it is cleared that medium level of feed rate and medium
level of spindle speed minimizes the delamination factor considerably.
51
53. Continue
From the mechanistic mathematical model, It was found that minimum cutting, lateral
and thrust forces gotten in seventh experimental run condition (spindle speed = 26591
rpm, feed rate = 1.03). and also maximum cutting, lateral and thrust forces gotten in 8 th
experimental run condition (spindle speed = 26591 rpm, feed rate = 1.03). It was
determined minimum and maximum cutting force 13.5168 Kgf and 24.8847 Kgf. Also
min. and max. lateral force 0.3246 Kgf and 0.5451 Kgf. It was determined minimum and
maximum thrust force 2.8894 Kgf and 4.6673 Kgf.
Cutting force is always greater than thrust force. The cutting forces increases as the feed
increases and rake angle decreases. Deeper cuts remove more materials, thus requiring
higher cutting force.
52
54. Future Scope
Mechanical micro drilling on cowling sheet of CFRP/Ti6Al4V stack material
will created interest in Aerospace industries due to micro hole design and its
pattern performance during air suction from cowling sheet to reduce skin drag
friction.
Structural aircraft researcher will be interested to modify airfoil shape of
cowling and micro hole pattern on cowling sheet.
Optical researcher can make interest to find effect of light heat source on micro
holes of Metal fiber laminate of CFRP/Ti6Al4V composite.
Metallurgy research scholars can be interested to implement on metal laminated
fiber material and developing new composition grades by testing mechanical
properties.
53
55. References
[1] National Jet Co., I. Micro Hole Drilling. 2013; Available from: http://www.najet.com/microhole- drilling
[2] Ohnishi, O., et al., Improvement in Drilling Performance of Micro Compound Tool. Advanced Precision Engineering, 2010. 447-448: p. 96-100.
[3] Egashira, K., et al., Fabrication and cutting performance of cemented tungsten carbide micro-cutting tools. Precision Engineering, 2011. 35(4): p. 547-553.
[4] Rajan K, P.N., Nagaranjan N, A Review of Current Micro Drilling Procsses. International journal of innovative science, engineering and technology, 2016. 3(1): p. 60-64.
[5] Hasan, M., Zhao, J. and Jiang, Z. (2017). A review of modern advancements in micro drilling techniques. Journal of Manufacturing Processes, 29 343-375.
[6] Wong, F., S. Sharif, and K. Kamdani, The effect of drill point geometry and drilling technique on tool life when drilling titanium alloy, Ti-6Al-4V. 2008.
[7] Szalay, T., K. Patra, and B.Z. Farkas, Experimental Investigation of Tool Breakage in Micro Drilling of EN AW-5083 Aluminium. Key Engineering Materials, 2013. 581: p. 119-124.
[8] Heinemann, R., et al., The performance of small diameter twist drills in deep-hole drilling. Journal of manufacturing science and engineering, 2006. 128(4): p. 884-892.
[9] Kudla, L. Strength properties of miniature drills. in euspen: european society for precision engineering and nanotechnology. International conference. 2001.
[10] Kudla, L. Limitations of Mechanical Micro-Drilling in Difficult-to-Machine Materials. in Proceedings of the 12th euspen International Conference. 2012. Stockholm.
[11] Aramcharoen, A. and P.T. Mativenga, Size effect and tool geometry in micromilling of tool steel. Precision Engineering, 2009. 33(4): p. 402-407.
[12] Kim, D.W., et al., Tool life improvement by peck drilling and thrust force monitoring during deep-micro-hole drilling of steel. International Journal of Machine Tools and Manufacture,
2009. 49(3-4): p. 246-255.
[13] Zheng, L., et al., Characteristics of chip formation in the micro-drilling of multimaterial sheets. International Journal of Machine Tools and Manufacture, 2012. 52(1): p. 40-49.
[14] Huang, Zhipeng and Gao, Lihong and Wang, Yangwei and Wang, Fuchi. (2016). Determination of the Johnson-Cook Constitutive Model Parameters of Materials by Cluster Global
Optimization Algorithm. Journal of Materials Engineering and Performance. 25. 10.1007/s11665-016-2178-1.
[15] Mohd-Lair, Noor-Ajian and Mohd-Shahdun, M and Mohd-Tahir, A and Paulus, James. (2019). THE EFFECTS OF SPINDLE SPEED AND FEED RATE ON HOLE QUALITY IN
DRILLING OPERATION: THE TAGUCHI BASED DESIGN OF EXPERIMENT. Journal of Mechanical Engineering Research and Developments. 42. 187-189.
10.26480/jmerd.05.2019.187.189.
[16] Waqar, Saad and Asad, Saad and Ahmad, Shamraiz and Abbas, Ch and Elahi, Hassan (2016). Effect of Drilling Parameters on Hole Quality of Ti-6Al-4V Titanium Alloy in Dry
Drilling. Materials Science Forum. 880. 33-36. 10.4028/www.scientific.net/MSF.880.33.
54