International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-10, Oct.

-2016

PROCESS PARAMETERS OPTIMIZATION FOR BETTER SURFACE

ROUGHNESS AND MATERIAL REMOVAL RATE OF ALUMINUM
ALLOY
1
SILUVERI.SRAVANTHI, 2T.NIRANJAN REDDY, 3E.SURENDAR
1
M.Tech (Student), Dept of ME, WITS, Oorugonda(V), Atmakur(M), Warangal District, T.S, India.
2
Assistant Professor, Dept of ME, WITS, Oorugonda(V), Atmakur (M), Warangal District, T.S, India.
3
Associate Professor, H.O.D, Dept of ME, WITS, Oorugonda(V), Atmakur (M), Warangal District, T.S, India.

Abstract— In this paper experiments are conducted to improve the surface finish quality and material removal rate of a
component by using carbide tips. The optimized parameter values are determined using Taguchi Method and Regression
Analysis. The machining parameters used for roughing operation are Spindle Speed – 1000rpm, 1500rpm, 2000rpm, Cut
Feed – 2000mm/min, 2500mm/min, 3000mm/min , Step Over – 20mm, 25mm, 30mm and depth of cut – 0.5mm. The
machining parameters used for finishing operation are Spindle Speed – 2000rpm, 2200rpm, 2500rpm, Cut Feed –
1000mm/min, 1200mm/min, 1500mm/min , Step Over – 5mm, 10mm, 12mm and depth of cut – 0.3mm. The milling process
is conducted on a CNC Vertical milling machine.

I. INTRODUCTION cutter used is carbide tool. The surface roughness and

MRR are investigated by performing the machining
Milling is the machining process of using process on 36 pieces. The machining parameters
rotary cutters to remove material from a work piece Spindle Speed, Cut Feed and Step over are varied and
by advancing (or feeding) in a direction at an angle depth of cut is kept constant.
with the axis of the tool. It covers a wide variety of The following image is the component to be
different operations and machines, on scales from machined.
small individual parts to large, heavy-duty gang
milling operations. It is one of the most commonly
used processes in industry and machine shops today
for machining parts to precise sizes and shapes.
Choice of Operating Conditions
 Cutting speed parameter
 Feed rate parameter
 Engagement parameter

II. LITERATURE REVIEW

In the work done by Drazen Bajic[1], examines the

influence of three cutting parameters on surface Fig.1. The component in consideration for experiment
roughness, tool wear and cutting force components in
face milling as part of the off-line process control. IV. EXPERIMENTAL INVESTIGATION
The experiments were carried out in order to define a CNC MACHINING DATA FOR ROUGHING
model for process planning. Cutting speed, feed per The following is the table specifying machining
tooth and depth of cut were taken as influential types done on the components, machining
factors. In the work done by B. Sidda reddy[2], The parameters used and no. of inserts changed in
experiments were conducted using Taguchi’s l50 roughing operation.
orthogonal array in the design of experiments (doe) Component 1
by considering the machining parameters such as
nose radius (r), cutting speed (v), feed (f), axial depth Type of operation Facing
of cut (d) and radial depth of cut(rd). A predictive Cutter 50r6
response surface model for surface roughness is Work piece Mn steel
developed using RSM. The response surface (rs) Material
Cutter Carbide
model is interfaced with the genetic algorithm (ga) to Time (hrs) 9
find the optimum machining parameter values. No.of inserts changed 9
Spindle speed (rpm) 1000
III. EXPERIMENTAL SETUP & PROCEDURE Feed (mm/min) 2000
Step over (mm) 20
In this project, roughing and finishing operations are
Depth of cut (mm) 0.5
done on a work piece made of manganese steel. The

Process Parameters Optimization For Better Surface Roughness and Material Removal Rate of Aluminum Alloy

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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-10, Oct.-2016

Table –I Machining Parameters used for facing No.of inserts

operations for component 1 - Roughing 7
changed
Spindle speed
CNC MACHINING DATA FOR FINISHING 2000
(rpm)
Component 1 Feed (mm/min) 1000
Type of Step over (mm) 5
Facing
operation Depth of cut
Cutter 50r0.8 0.3
(mm)
Work
Mn steel
Material piece Table –II Machining Parameters used for facing
Cutter Carbide operations for component 1 - Finishing
Time (hrs) 5

OBSERVATION
The following tables shows the surface roughness and MRR values determined after machining.
Roughing operation
Step over Surface finish Mrr
Spindle Feed rate (mm) (ra) (mm3/sec)
Component
speed (rpm) (mm/min)
1 1000 2000 20 0.705 1.512
2 1000 2500 25 1.454 1.723
3 1000 3000 30 2.55 2.05
4 1500 2000 25 1.67 2.47
5 1500 2500 30 2.17 2.78
6 1500 3000 20 2.39 2.69
7 2000 2000 30 2.25 1.94
8 2000 2500 20 1.86 1.85
9 2000 3000 25 2.41 2.88
Table –III Surface Roughness and MRR values observed for roughing operations
Finishing operation
Step over Surface finish Mrr
Spindle speed Feed rate (mm) (ra) (mm3/sec)
Component
(rpm) (mm/min)
1 2000 1000 5 2.25 0.149
2 2000 1200 10 2.64 0.155
3 2000 1500 12 3.36 0.331
4 2200 1000 10 2.71 0.448
5 2200 1200 12 2.89 0.617
6 2200 1500 5 3.15 0.553
7 2500 1000 12 2.97 0.273
8 2500 1200 5 2.81 0.21
9 2500 1500 10 3.32 0.671
Table – IVSurface Roughness values observed for finishing operations

Main Effects Plot for SN ratios

OPTIMIZATION OF MACHINING Data Means
PARAMETERS SPINDLE SPEED CUT FEED STEP OVER

TAGUCHI METHOD -3
Roughing operation
-4
M ean of S N ratio s

-5

-6

-7

-8
1000 1500 2000 2000 2500 3000 20 25 30

Signal-to-noise: Smaller is better

Process Parameters Optimization For Better Surface Roughness and Material Removal Rate of Aluminum Alloy

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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-10, Oct.-2016

Fig.2. Effect of milling parameters on surface finish Surface Plot of SURFACE ROUGHNESS vs CUT FEED, SPINDLE SPEED
for S/N ratio Hold Values
STEP OVER 25

Main Effects Plot for SN ratios

Data Means
SPINDLE SPEED CUT FEED STEP OVER
8.5
2.5
8.0
UR FACE R O UGHNESS
2.0
Mean of SN ratios

7.5 1.5 300 0

7.0 1.0 2 500

CUT FEED
1 00
10
6.5 15 00 20 00
2000
S PIN DLE SPEED
6.0

5.5

5.0
Fig.5. Surface Plot of Surface Roughness vs Cut
1000 1500 2000 2000 2500 3000 20 25 30
Feed, Spindle Speed
Signal-to-noise: Larger is better
By observing above graph, to minimize surface
Fig.3. Effect of milling parameters on MRR for S/N roughness, the Cut Feed should be set at
ratio 2000mm/min and Spindle Speed to 1000rpm.
REGRESSION ANALYSIS Surface Plot of MRR vs STEP OVER, CUT FEED
Roughing Hold Values
SPINDLE SPEED 1500

Surface Plot of SURFACE ROUGH NESS vs STEP OVER, CUT FEED

Hold Values
SPINDLE SPEED 1500

2.5 0

MR R 2.25
2.5 30
2 .00
R FACE R O UGH NES2S.0
25
STEP OV ER
1.5 30 2 00 0
25 0 0 20
1.0 25
ST EP O VER 3 00 0
CUT FEED
2000
2500 20
300 0
CUT FEED

Fig.7. Surface Plot of Surface Roughness vs Step

over, Cut Feed
Fig.4. Surface Plot of Surface Roughness vs Step
over, Cut Feed By observing above graph, to maximize MRR, the
Cut Feed should be set at 3000mm/min and Step
By observing above graph, to minimize surface Over at 30mm.
roughness, the Cut Feed should be set at
2000mm/min and Step Over at 20mm. Surface Plot of MRR vs CUT FEED, SPINDLE SPEED
Hold Values
Surface Plot of SURFACE ROUGHNESS vs STEP OVER, SPINDLE SPEED STEP OVER 25

Hold Values
CUT FEED 2500

2 .8

2.4
2.5 MR R

URFA CE RO UGHNESS 2.0 300 0

2.0

30 2 5 00
1.5 CUT FEED
1 00 0
25 15 0 0 2000
S TEP OVER
2 00 0
1 00
10 SPINDLE SP EED
15 00 20
200 0
SPINDLE SPEED

Fig.8. Surface Plot of Surface Roughness vs Cut

Fig.6. Surface Plot of Surface Roughness vs Step Feed, Spindle Speed
over, Spindle Speed By observing above graph, to maximize MRR, the
By observing above graph, to minimize surface Cut Feed should be set at 2000mm/min and Spindle
roughness, the Spindle Speed should be set at Speed at 2000rpm.
1000rpm and Step Over at 20mm.
Process Parameters Optimization For Better Surface Roughness and Material Removal Rate of Aluminum Alloy

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International Journal of Mechanical And Production Engineering, ISSN: 2320-2092,
Surface Plot of MRR vs STEP OVER, SPINDLE SPEED
2. 6
2. 4
M RR
2.2
2. 0
100 0
1500
20 00
SPINDLE SPEED
Fig.9. Surface Plot of Surface Roughness vs Step
Over, Spindle Speed
By observing above graph, to maximize MRR, the
Step Over should be set at 30mm and Spindle Speed
at 2000rpm.
CONCLUSION
From the Taguchi Method, the following
conclusions can be made:
 In roughing operations, to minimize surface
roughness, the optimized values are spindle
speed 1000 rpm, Cut Feed 2000 mm/min,
Step Over 20 mm. To maximize MRR,
spindle speed 1500 rpm, Cut Feed 3000
mm/min, Step Over 25 mm.
 In finishing operations, to minimize surface
roughness, the optimized values are spindle
speed 2000 rpm, Cut Feed 2000 mm/min,
Step Over 5 mm. To maximize MRR,
spindle speed 2200 rpm, Cut Feed 1500
mm/min, Step Over 12 mm.
From the Regression Analysis, the following
conclusions can be made:
 In roughing operations, to minimize surface
roughness, the optimized values are spindle
speed 1000 rpm, Cut Feed 2000 mm/min,
Step Over 20 mm. To maximize MRR,
spindle speed 2000 rpm, Cut Feed 3000
mm/min, Step Over 30 mm.
 In finishing operations, to minimize surface
roughness, the optimized values are spindle
speed 2000 rpm, Cut Feed 1000 mm/min,
Step Over 5 mm. To maximize MRR,
spindle speed 2400 rpm, Cut Feed 1400
mm/min, Step Over 12.5 mm.
Volume- 4, Issue-10, Oct.-2016
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Siluveri. Sravanthi
M.Tech, Department of Mechanical Engineering,
Warangal Institute of Technology & Science,
Oorugonda(V), Atmakur (M), Warangal District, T.S,
India.

REFERENCES
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influence of cutting parameters on the surface roughness,
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Process Parameters Optimization For Better Surface Roughness and Material Removal Rate of Aluminum Alloy

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