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IJSRD - International Journal for Scientific Research & Development| Vol.

3, Issue 10, 2015 | ISSN (online): 2321-0613

Evaluation The Effect of Machining Parameters for MRR using Turning of


Aluminium 6063
Sudhir1 Karun2 Neeraj Kumar3
1
Lecturer 2,3Assistant Professor
1,2,3
Department of Mechanical Engineering
1
Peti, India 2,3Grimt, India
Abstract Turning is a basic operation for various
industries & it is very essential to optimize the various
parameters affecting turning for the optimum condition.
Turning operation is affected by both machining parameters
& Cutting fluids. The parameter influence most are cutting
speed, depth of cut , feed, geometry of cutting tool like
principle cutting edge angle ,rake angle, nose radius etc. In
order to control MRR it is very necessary to control these
parameters. In the project turning operation the different
values of cutting parameters, cutting speed (45, 90,140,330),
feed rate (.1, 22, 44, 68 mm/rev), depth of cut (.5, 1, 1.5,2
mm) are selected. MRR is largely influenced by Speed then
Feed then DOC. MRR shows an increasing trend with
increasing Speed. MRR shows an increasing trend with
increasing Feed. MRR shows an increasing trend with
increasing DOC.
Key words: Taguchi Design, Orthogonal Array, Turning,
cutting speed, feed.
I. INTRODUCTION
The first lathe machine that was developed was the twoperson lathe machine which was designed by the Egypt in
about 1300 BC. Primarily, there are two things that are
achieved in this lathe machine tool. The first is the turning
of the wood working piece manually by a rope; and the
second is the cutting of shapes in the wood by the use of a
sharp cutting tool., there have been constant modifications
and improvements over the two-person lathe machine, most
importantly on the production of the rotary motion. P.
Abinesh, Dr. K. Varatharajan, Dr. G. Satheesh Kumar (1)
concluded that MRR increases with increasing in the pulse
time, pulse off-time, peak current momentum. By adjusting
the input parameters as A2, B1, C1, D2, E2, can achieve the
nominal output response (ie, Max MRR and Min EWR)
.And selecting A2, B2, C2, D1, E1, as input parameters, we
can achieve maximum MRR. Surface roughness decreases
with increasing time and may increase with increasing pulse
peak time. Arjun Singh Rupinder Biloria (2) concluded that
the discharge has a greater effect on the MRR tension
followed. Wire tension had any influence on MRR. The
optional condition of process parameters for optimal
roughness is voltage (150), the discharge current (25), and
the cable tension (1150). Rishu Diwedi Ashutosh Gupta (3)
concluded that the analysis of experimental observations
noted that MRR in CNC turning is strongly affected by the
depth of cut, followed by the speed. It is noted that the
power is mostly influence the Ra followed by nose radius.
For optimization of surface roughness and the material
removal rate depth of cut is the most important parameter
that affects followed by the nose radius. Dhruv H. Gajjar
and PROF. Jayesh V. (4) Desai concluded that Pulse rise
time generates more spark energy as the amount of time that
increases in electricity supply. MRR, cutting width and SR

pulse increases with time. Pulse time is the most significant


parameter. The surface roughness increases with increasing
pulse. Time pulse has an opposite effect on the time.MRR
pulse decrease with increasing in the pulse time, while
reducing the roughness. The surface roughness is reduced by
increasing the value of servo voltage. Rajmohan T. et al. (5)
They have studied the optimization of machining parameters
of electrical discharge machining 304 stainless steel &
experienced the effect of parameters such as pulse time,
pulse time, voltage and current rate material removal was
studied in 304 stainless steel. it was concluded that different
combinations of the EDM process parameters required to
achieve greater MRR. Vishal Parashar et al. (6). From the
experimental results, the surface roughness was determined
for each machining performance criterion. Noise signal was
applied to measure the performance characteristics that
deviate from true value A.Rehman et al. (7) The variation in
kerf width with machining parameters is mathematically
modeled using the regression analysis method. Sivakiran S.
et al.(8) The relationship between the control parameters and
output parameters (RRM) is performed by means of linear
regression. L16 Taguchi (4 * 4) Orthogonal Array (OA)
designs have been used in the EN-31 tool steel for
maximum metal removal rate.
II. MATERIAL USED
Aluminium Alloy (Aluminium 6063). AA 6063 is
Aluminium Alloy , with Magnisium and silicon as the
alloying elements. The standard controlling its composition
is maintained by THE ALUMINIUM ASSOCIATION. It
has generally good mechanical properties and is heat
treatable and weldable. It is similar to the British aluminium
alloy HE9. 6063 is mostly used in extruded shapes for
architecture, particularly window frames, door frames,
roofs, and sign frames. It is typically produced with very
smooth surfaces fit for anodizing.
III. CALCULATION OF MRR
EXPERIMENT
NO.
1
2
3
4
5
6
7
8
9
10
11
12

RPM
45
45
45
45
90
90
90
90
140
140
140
140

FEED
(mm/rev.)
0.1
0.22
0.44
0.68
0.1
0.22
0.44
0.68
0.1
0.22
0.44
0.68

DEPTH OF
CUT (mm)
0.5
1
1.5
2
1
0.5
2
1.5
1.5
2
0.5
1

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458

Evaluation The Effect of Machining Parameters for MRR using Turning of Aluminium 6063
(IJSRD/Vol. 3/Issue 10/2015/092)

13
14
15
16

330
330
330
330

0.1
0.22
0.44
0.68

2
1.5
1
0.5

SPECIMEN

MATERIAL REMOVAL RATE

NUMBER

(Wi- Wf)/st in mm3 / sec

1.

5.634

2.

12.81

3.

32.974

4.

80.186

5.

15.122

6.

20.246

7.

93.981

8.

105.064

9.

18.803

10.

74.44

11.

54.466

12.

111.111

13.

82.687

14.

125.22

15.

151.515

16.

113.96

A. Response Table for Signal To Noise


Ratios
Larger is better
Level
Rpm
Feed (mm)
D.O.C
1
32.90
30.56
48.58
2
58.60
58.18
72.64
3
64.70
83.23
70.52
4
118.35
102.58
82.82
Delta
85.44
72.02
34.25
Rank
1
2
3
IV. CONCLUSIONS
From all the above experiments, observations and
calculations, following conclusions has been drawn;
1) MRR is largely influenced by Speed then Feed then
DOC.
2) MRR shows an increasing trend with increasing Speed.

3) MRR shows an increasing trend with increasing Feed.


4) MRR shows an increasing trend with increasing DOC.
REFERENCES
[1] P. Abinesh, Dr. K. Varatharajan, Dr. G. Satheesh
Kumar, Optimization of Process Parameters
Influencing MRR, Surface Roughness & Electrode
Wear During Machining of Titanium Alloys by
WEDM, International Journal of Engineering Research
& General Science Volume 2, Issue 4, June, 2014
,ISSN 2091-2730.
[2] ArjunBiloria& Rupinder Singh,Optimizing the
Parameters Influence the Performance of Wire cut
EDM Machining, International Journal of Current
Engineering & Technology Vol.4, No.5 (Oct -2014).
[3] Rishu Gupta &Ashutosh Diwedi, Optimization of
Surface Finish & Material Removal Rate with Different
Insert Nose Radius for Turning Operation on CNC
Turning Center, International Journal of Innovative
Research in Science Engineering & Technology, Vol. 3,
Issue 6, June 2014.
[4] Dhruv H. Gajjar & PROF. Jayesh V. Desai ,
Optimization of MRR, Surface Roughness &
KERFWidth in wire EDM Using Molybdenum Wire,/
International Journal for Research in Education, Vol. 4,
Issue:2,February : 2015.
[5] Rajmohan, T., Prabhu R.,Subba Rao G., Palanikumar
K. optimization of machining parameters in electrical
disacharge machining of 304 stainless steel,
International conference on modeling , optimization &
computing,1030-1036.
[6] Parashar, Vishal A. Rehman, J.L. Bhagoria, Y.M. Puri
Investigation & Optimization of Surface Roughness
for Wire Cut Electro Discharge Machining using
Taguchi Dynamic Experiments, International Journal
of Engineering Studies, Volume 1, pp. 257267.
[7] Vishal Parashar, A. Rehman, J.L. Bhagoria, Y.M.
Puri(2010). Kerfs width analysis for wire cut electro
discharge machining using design of experiments,
Indian Journal of Science & Technology, volume 3. PP.
369-373.
[8] Sivakiran, S C. Bhaskar Reddy, C. Eswara Reddy
(2012). Effect of Process Parameters On Mrr in Wire
Electrical Discharge Machining Of En31 Steel,
International Journal of Engineering Research &
Applications (IJERA), VOLUME 2, pp.1221-1226 .
[9] Singaram, Lakshmanan1, PrakashChinnakutti, Mahesh
Kumar Namballa (2013).Optimization of Surface
Roughness using Response Surface Methodology for
Tool Steel EDM Machining, International Journal of
Recent Development in Engineering & Technology,
volume 1, december, pp. 33-37.
[10] Lodhi,
Brajesh
Kumar,
Sanjay
Agarwal
(2014).Optimization of machining parameters in
WEDM of AISI D3 Steel using Taguchi Technique,
6th CIRP International Conference on High
Performance Cutting, HPC. PP.194-199

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