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Parag V. Bute
Assistant Professor
Department of Mechanical Engineering
Suman Ramesh Tulsiani Technical Campus-Faculty of
Engineering, Khamshet, Pune, India
Rohit R. Patil
Assistant Professor
Department of Mechanical Engineering
Suman Ramesh Tulsiani Technical Campus-Faculty of
Engineering, Khamshet, Pune, India
Jitendra B. Satpute
Assistant Professor
Department of Mechanical Engineering
Suman Ramesh Tulsiani Technical Campus-Faculty of
Engineering, Khamshet, Pune, India
Abstract
The present work highlights the optimization of Computerized Numerical Control (CNC) milling Process Parameters to provide a
better surface finish and high Material Removal Rate (MRR). As Taguchis method reduces the number of experiments, it is used
for optimization of machining parameters. It is applied to find out the influence of various machining parameters like Speed, Feed
rate, Depth of cut on Surface finish and MRR. The material used in this experiment is Al 7075 of size 100mm*100mm*10mm and
the pocketing operation of size 20mm*20mm is carried out on vertical CNC milling machine by 12 mm carbide tool. L9 Orthogonal
Array (OA) is used to carry out the experimentation. MINITAB-14 Software is used to analyse the result. Surface roughness (Ra)
was measured and the MRR values were calculated to determine optimum levels. Results obtained were plotted for Ra, MRR v/s
Speed, feed rate, depth of cut. In this Study, it is observed that the order of Significance of the main Variable for Surface Roughness
(Ra) is Speed; Feed & Depth of Cut (DOC) whereas for MRR, the Order of Significance is DOC, Feed rate & Speed.
Keywords: ANOVA; Milling; MRR; Ra; Taguchis method
________________________________________________________________________________________________________
I.
INTRODUCTION
In machining of parts, surface quality or surface roughness is one of the most specified customer requirements. It is major concern
to decide the acceptance and quality of product along with improved or maximum tool life as an economical constraint. In many
actual machining applications, the maximum production rate, minimum operational cost and the quality of machining objectives
are frequently considered.
The surface roughness mainly depends on work piece hardness, tool geometry, and process parameters such as feed rate, depth
of cut, cutting speed etc. In order to maximize the gain from machining, accurate predictive models for surface roughness must be
constructed. In order to address these issues, this study proposed methodical approach that integrates optimization concept, with
statistically robust design technique.
Milling is the important machining operation, widely used in most of the manufacturing industries due to its capability of
producing complex geometric surfaces with reasonable accuracy and surface finish. However, with the inventions of CNC milling
machine, the flexibility has been adopted along with versatility in end milling process. In the manufacturing industries, side milling,
end milling machining processes are adopted for removing the material from the workpiece for a better product. Out of these, end
milling process is one of the most vital and common metal cutting operations used for machining parts because of its ability to
remove materials faster with a reasonably good surface quality. In recent times, CNC machine tools have been implemented to
realize full automation in milling since they provide greater improvements in productivity, quality of the machined parts with less
operator input. The surface finish of the machined surface has been identified as quality attribute whereas MRR has been treated
as performance index directly related to productivity.
The new development of optimization of the machining process in soft computing approaches such as Geometric Algorithm
(GA) to be the alternative technique in estimating the optimal result of the cutting parameters, particularly for the Ra value in the
end milling machining process.
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Optimization of Process Parameters in Milling Operation by Taguchis Technique using Regression Analysis
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Optimization of Process Parameters in Milling Operation by Taguchis Technique using Regression Analysis
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Azlan Mohd Zain et al.[9] carried out study to observe the optimal effect of the radial rake angle of the tool, combined with
speed and feed rate cutting conditions in influencing the surface roughness result. In machining, the surface roughness value is
targeted as low as possible and is given by the value of the optimal cutting conditions. They attempt the application of GA to find
the optimal solution of the cutting conditions for giving the minimum value of surface roughness. They developed the regression
model. They conclude that the GA technique is capable of estimating the optimal cutting conditions that yield the minimum surface
roughness value.
From the literature it is seen that enormous research was carried out by the researchers either experimentally or theoretically in
the optimisation of process parameters. Various methods were introduced to study dominance of parameters in milling operation.
For the present study the control factors considered are Speed, Feed and DOC. Three levels for each control factor are used.
Experiments are conducted on CNC milling machine with uncoated carbide tool and Al 7075 as work material to optimize the
milling parameter. Based on the above said number of control factors and their levels, L9 orthogonal array is selected from the
Standard orthogonal array table to conduct the matrix experiment. The work piece used for the experiment is
100mm*100mm*10mm.
III. METHODOLOGY
The methodology adopted for this work is as follows:
1) Selection of work material and tool material from the literature survey.
2) Next conduction of the preliminary experiment.
3) Analysis of the obtained data from experimentation using ANOVA and Regression analysis. From this experimentation,
significant factors and insignificant factors are identified, and then insignificant factors are neglected.
4) Then experiment is designed by taking speed, feed, DOC as a significant factors into consideration.
5) Responses are measured using surf test machine & weighing machine.
6) Optimization of speed, feed, and depth of cut parameters performed using Taguchis technique.
7) Creating a model using Minitab software.
8) Confirmation test.
9) Correlation of data obtained from optimization of parameters and predicted values through model.
IV. EXPERIMENTAL SETUP
Work Material and Tool :
Al 7075 is an aluminium alloy, with zinc as the primary alloying element. It is strong, with strength comparable to many steels,
and has good fatigue strength and average machinability, but has less resistance to corrosion than many other Al alloys.
------------------------
0.40 %
0.50 %
1.2-2.0 %
0.30 %
2.1-2.9 %
0.18-0.28 %
Zinc
----Titanium
----Others, each ----Others,
----Balance, Aluminum
5.1-6.1%
0.20 %
0.5 %
0.15 %
Table 1
Machining Parameters and Their Levels
Levels
Parameters
1
2
3
Speed (rpm)
1600 3200 4800
Feed (mm/min) 165
320
475
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Optimization of Process Parameters in Milling Operation by Taguchis Technique using Regression Analysis
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DOC (mm)
0.6
0.8
Speed (rpm)
1600
1600
1600
3200
3200
3200
4800
4800
4800
Feed (mm/min)
165
320
475
165
320
475
165
320
475
DOC(mm)
0.6
0.8
1
0.8
1
0.6
1
0.6
0.8
In this investigation, the response surface Ra is measured by MITUTOYO SJ210 SURFTEST, a stylus type profilometer and
the response MRR is calculated by using following mathematical equation with time consideration
MRR =
(WiWf)1000
(Dwt)
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Optimization of Process Parameters in Milling Operation by Taguchis Technique using Regression Analysis
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EXPT.NO
SPEED (rpm)
1
2
3
4
5
6
7
8
9
1600
1600
1600
3200
3200
3200
4800
4800
4800
Table 4
surface Roughness for Al 7075 material
Surface Roughness (Ra) m
FEED (mm/min) DOC (mm)
Ra 1
Ra 2
Ra 3 Mean (Ra)
165
0.6
1.082 1.023 1.403
1.169
320
0.8
1.614 1.068 0.978
1.220
475
1
1.073 1.221 1.466
1.253
165
0.8
0.609 0.626 0.903
0.712
320
1
1.059 0.937 1.315
1.104
475
0.6
1.376 1.145 1.009
1.176
165
1
0.967 1.010 0.835
0.937
320
0.6
0.872 0.862 0.868
0.867
475
0.8
0.882 1.261 0.995
1.046
Taguchi Analysis:
Ra versus Speed (A), Feed (B) and DOC(C)
Main Effects Plot (data means) for SN ratios
M a i n E f f e c ts P l o t ( d a ta m e a ns ) f o r S N r a ti o s
sp e e d
fe e d
0 .5
0 .0
Me a n of SN ra t ios
-0 . 5
-1 . 0
-1 . 5
1600
3200
4800
165
320
475
dco
0 .5
0 .0
-0 . 5
-1 . 0
-1 . 5
0 .6
0 .8
1 .0
S ig n a l- to - n o is e : S m a lle r is b e tte r
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Optimization of Process Parameters in Milling Operation by Taguchis Technique using Regression Analysis
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Table 5
Result from ANOVA
FACTOR
D.O.F
Sum of Square
Mean of Square
F calculated
F tabulated
P%
Speed (rpm)
Feed (mm/min)
Depth of cut(mm)
(ERROR)
TOTAL
2
2
2
3
9
8.333755
5.90205
1.734417
5.161296
15.97022
4.1668776
2.9510249
0.8672086
1.720432
2.421994863
1.71528128
0.504064428
1
5.64134057
5.28
5.28
5.28
42.93297
30.40556
8.935189
17.72628
100
Rank
1
2
3
Regression Analysis:
Ra versus Speed, Feed, DOC, The regression equation is
Ra = 1.04 - 0.000083 speed + 0.000706 feed + 0.068 doc
From the Regression analysis, it is found that the factor Speed is having more significance on surface roughness (Ra) which is
followed by the feed rate and depth of cut (DOC), which is shown in table-6
Predictors
Constant
Speed
Feed
DOC
Coefficients
1.0370
-0.00008250
0.0007065
0.0683
Table 6
Response table of Regression Analysis for Ra
Sum of Error Coefficients
T
P
Rank Sum of Square Error
0.2671
3.88 0.012
0.00003343
-2.47 0.057
1
0.131031
0.0003451
2.05 0.096
2
0.2365
0.26 0.809
3
R^2
Adj R^2
67.4%
47.9%
Table 7
confirmation experiment for Ra
Level
Value
Trial no
Ra(m)
3
4800rpm
1
0.916
1
165mm/min
2
0.829
2
0.8mm
3
0.805
Mean Ra=0.850
SPEED (rpm)
FEED (mm/min)
DOC (mm)
1
2
3
4
5
6
7
8
9
1600
1600
1600
3200
3200
3200
4800
4800
4800
165
320
475
165
320
475
165
320
475
0.6
0.8
1
0.8
1
0.6
1
0.6
0.8
Taguchi Analysis:
MRR versus Speed (A), Feed (B) and DOC(C)
Main Effects Plot (data means) for SN ratios
From graph, it is clear that;
- By increasing the speed value from 1600 rpm to 4800 rpm, the S/N ratio is increasing.
- By increasing the feed from 165 mm/min to 475 mm/min the S/N ratio is decreasing.
- By increasing the DOC from 0.6 mm to 1 mm the S/N ratio is increasing.
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Optimization of Process Parameters in Milling Operation by Taguchis Technique using Regression Analysis
(IJSTE/ Volume 2 / Issue 11 / 020)
M a i n E f f e c ts P l o t ( d a ta me a ns ) f o r S N r a ti o s
sp e e d
fe e d
26
M e a n o f SN r a t io s
24
22
20
1600
3200
4800
165
320
475
doc
26
24
22
20
0 .6
0 .8
1 .0
S ig n a l- to - n o is e : La r g e r is b e tte r
Table 9
Results of confirmation experiment
Level
Value
Trial no.
MRR(mm3/sec)
3
4800rpm
1
24.82
2
320mm/min
2
21.27
3
1mm
3
25.85
Mean MRR=23.98
VI. CONCLUSION
In present study, experiments were conducted to measure response variable such as surface roughness, material removal rate using
Hartford LG800 VMC Milling. The Taguchi method and Statistical MINITAB-14 software were used for analysis. Based on this
analysis, process parameters were optimized. After the process parameters optimization, ANOVA was performed to determine the
relative magnitude of the each factor on objective functions. Taguchis OA was used for optimization of process parameters in
milling. The confirmation experiment was conducted using the optimized process parameters and the performance characteristics
were measured and compared with the results obtained from the initial set of readings. Finally it is concluded that for the Ra; the
factor speed should be at level 3(4800 rpm), feed at level 1(165 mm/min) and DOC at level 2(0.8 mm) and also for better MRR;
the factors speed should be at level 3(4800 rpm), feed at level 2(320mm/min) and DOC at level 1(1mm).
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