Documenti di Didattica
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11 (2012)
Research India Publications;
http://www.ripublication.com/ijaer.htm
INTRODUCTION
Increasing the productivity and the quality of the machined
parts are the main challenges of metal-based industry. There
has been increased interest in monitoring all aspects of the
machining process. Quality of machining can be judged by
surface roughness. Higher the surface finish higher will be the
quality. Surface finish depends on 1.Cutting speed 2. Depth of
cut 3 Feed mostly. Speed, Feed and Depth of cut are the
parameters that can be adjusted in machining operation. Most
of the operators use trial and error method to find the
appropriate cutting condition. It is not the effective way to
find out optimal cutting parameters. So the main objective of
the study is to find the optimum parameters (speed, feed,
depth of cut) so that surface roughness is optimized.
Aluminum has much application in industries. Also
automotive aircraft and train companies need to replace steel
and cats iron with lighter metal like aluminum. So it is
important to know the machining behavior of aluminum.
There are various optimization techniques like genetic
algorithm, artificial neural network, grey analysis , utility
concept , response surface methods, taguchi technique etc. to
find out optimum cutting condition.Taguchi technique is easy
LITERATURE REVIEW
Uros and Franc et al (2000): In this paper, a neural network
approach to multiple-objective optimization of cutting
parameters is proposed. The procedure should be used for
the fast approximate determination of optimum cutting
conditions on the machine, when there is not enough time for
deep analysis. Suresh et al (2002) focused on machining mild
steel by TiN-coated tungsten carbide (CNMG) cutting tool for
developing a surface roughness prediction model by using
Response Surface Methodology (RSM). Genetic algorithms
(GA) is used to optimize the objective function and compared
with RSM results. Pal and Chakraborty et al (2005) studied on
development of a back propagation neural
Network model for prediction of surface roughness in turning
operation and used mild steel work-pieces with high speed
steel as the cutting tool. Doniavi et al. (2007) used response
surface methodology (RSM) in order to develop empirical
model for the prediction of surface roughness by deciding the
optimum cutting condition in turning. The authors showed
that the feed rate influenced surface roughness remarkably.
H.-S.Lu, J.-Y. Chen et al (2008): This paper presents an
application of the Taguchi method with grey-fuzzy logics for
optimizing the cutting parameters of rough cutting process in
side milling operation for SKD61 tool steel. The results reveal
that the proposed method provides a systematic and efficient
methodology for the optimization design of the cutting
parameters. Show-Shyan Lin, Ming-Tsan Chuang, Jeong-Lian
Wen, and Yung-Kuang Yang (2009): The GRA based on an
orthogonal array of the Taguchi method was a way of
optimizing the CNC boring operations for aluminum alloy
6061T6. Sanjit Moshat, Saurav Datta, Asish Bandyopadhyay
and Pradip Kumar Pal (2010) in the study, the use of PCA
based hybrid Taguchi method has been proposed and adopted
for solution of multiobjective optimization, along with a case
study, in CNC end milling operation. The proposed method
has been found efficient for solving multi-attribute decision
making problem i.e., for multiobjective product as well as
process optimization. Shutong XIE1,, Yinbiao GUO2 (2011)
: To tackle the optimization problem of machining parameters
in multi-pass turnings, a new approach was proposed, which
combines the pass enumerating method with genetic
algorithm (GA). J.Pradeep Kumar1 K.Thirumurugan2 (2012):
Taguchis robust design method is suitable to optimize the
surface roughness in milling CP Ti Grade 2. The significant
factors for the surface roughness in milling CP Ti Grade 2
were the spindle speed and the tool grade, with contribution
of 30.347 and 29.933 respectively. Nitin agarwal (2012) has
International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.7 No.11 (2012)
Research India Publications;
http://www.ripublication.com/ijaer.htm
prepared surface roughness model with machining parameter
in CNC milling.
Taguchi Method
Taguchi Method is developed by Dr. Genichi Taguchi, a
Japanese quality management consultant. The method
explores the concept of quadratic quality loss function and
uses a statistical measure of performance called Signal-toNoise (S/N) ratio. The S/N ratio takes both the mean and the
variability into account. The S/N ratio is the ratio of the mean
(Signal) to the standard deviation (Noise). The ratio depends
on the quality characteristics of the product/process to be
optimized. The standard S/N ratios generally used are as
follows: - Nominal is Best (NB), Lower the Better (LB) and
Higher the Better 68 (HB). The optimal setting is the
parameter combination, which has the highest S/N ratio. In
this study lower the better is used.
Actual Workpiece
EXPERIMENTAL DETAIL
Workpiece Material: Aluminum (50mm x 65mm)
Tool Material: HSS milling cutter (10 mm Dia)
The test is performed on Aluminum workpiece of 50mm x 65
mm. A groove of 10mm x 15mm is cut on wokpiece using
10mm dia HSS milling cutter. The Figure of workpiece is
shown below.Surface roughness measurement is done offline
with SJ201 roughness tester.
EXPERIMENT PROCEDURE
Dimensions of workpiece
International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.7 No.11 (2012)
Research India Publications;
http://www.ripublication.com/ijaer.htm
3 Stat DOE Taguchi Predict Taguchi results
SOURCE
A
B
C
RESIDUAL ERROR
TOTAL
DF
2
2
2
2
8
Seq SS
2.47278
0.59397
0.17594
0.03946
3.28215
Adj SS
2.47278
0.59397
0.17594
0.03946
Adj MS
1.23639
0.29699
0.08797
0.01973
62.67
15.05
4.46
0.02
0.06
0.18
From above table it can be seen that all the three factors are
significantly affects the response. Speed has highest effect on
response, feed has second highest effect on response and
depth of cut has least effect on output response.
Speed
800
1000
1200
Feed
200
400
500
Depth of cut
0.25
0.5
0.75
-2
-4
Mean of SN ratios
Parameters
-6
-8
1
2
C
-2
-4
-6
-8
X1
X2
X3
Y1
Y2
Y3
800
200
0.25
2.566
2.783
2.534
800
400
0.5
2.546
2.765
2.654
800
500
0.75
2.342
2.134
2.145
1000
200
0.5
2.456
2.546
2.559
1000
400
0.75
1.786
1.699
1.7
1000
500
0.25
1.556
1.456
1.442
1200
200
0.75
1.423
1.456
1.5
1200
400
0.25
1.119
1.187
1.139
1200
500
0.5
1.101
1.002
1.001
A
-7.923
-5.408
-1.599
6.324
1
B
-6.572
-4.815
-3.542
3.03
2
C
-4.347
-5.607
-4.975
1.26
3
2.4
2.1
1.8
Mean of Means
1.5
1.2
1
2
C
2.4
2.1
1.8
1.5
1.2
International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.7 No.11 (2012)
Research India Publications;
http://www.ripublication.com/ijaer.htm
The above graph represents the main effect plot for
means.
Level
1
2
3
Delta
Rank
A
2.497
1.911
1.214
1.282
1
B
2.203
1.844
1.575
0.627
2
C
1.754
2.07
1.798
0.316
3
CONCLUSIONS
Taguchis robust design method is suitable to optimize the
surface roughness in milling Aluminum. The optimal
condition for surface roughness in milling Aluminum was
resulted at level 3 for spindle speed and it was 1200 rpm, at
level 3 for feed rate and it was 500 rpm, at level 2 for depth of
cut and it was 0.5 mm. The corresponding surface roughness
is 1.034 m.
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International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.7 No.11 (2012)
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http://www.ripublication.com/ijaer.htm
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