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AN EXPERIMENTAL ANALYSIS AND OPTIMISATION OF PROCESS

PARAMETERS IN AJM DRILLING BY USING TAGUCHI METHOD

ME6811 – PROJECT WORK


Project Members

Sl. No Reg. no. Name of the Students


1. 110815114002 M.S.ABEENATH
2. 110815114022 S.LOHITH NARAYAN
3. 110815114026 S.MANIKANDAN

Name of the Supervisor Name of the Co-ordinator


Mr. M.SANTHANAM Dr . P. GURUSAMY
Assistant Professor Professor and Head of the Department
Mr. K. GANESAN
Assistant Professor
Jaya Engineering College
Department of Mechanical Engineering
ABSTRACT

Aluminium6061alloy gained a significant importance because of owing to its light weight and high strength
properties. Basically, this Al6061 alloy is employed in fabricating medical device applications, aircraft industry,
aerospace fasteners, automotive parts, marine applications, and sports equipment. Abrasive Jet Machining (AJM)
process under un-conventional machining process is one such solution which provides the solution for machining
of holes on Al6061 alloy. In the present paper, an effort has been made to optimize machining parameters
employed during drilling on Al6061 alloy using Abrasive Jet Machining. The influence of the various process
parameters, i.e. pressure, nozzle diameter and stand-off distance on the predominant machining criteria on the
metal removal rate , kerf accuracy, surface roughness , taper angle was studied. In this work, repeated number of
experiments was carried out as per the Taguchi experimental design (L27 3 levels, 3 factors). The settings of the
process parameters were determined by using Taguchi’s experimental design method. Confirmation test with the
optimal levels of machining parameters was carried out in order to illustrate the effectiveness of the Taguchi
optimization method . Orthogonal arrays of Taguchi the effect of these parameters on metal removal rate values
and quality of the holes. The SEM are used to identify the micro structure of the machined surface.
INTRODUCTION
 Aluminium6061 has become very potential material in numerous engineering fields such as aerospace, sports,
turbines, nuclear and biomedical .However, these alloys are very difficult to machine by conventional methods
because of the heterogeneous property of Al6061 alloy. Furthermore, it is difficult to make a hole in Al6061 alloy
material by conventional drilling process. The above problems lead to the invention of un- conventional
machining process to machine Al6061 alloy. Hence, in the present study AJM is chosen as an alternative
machining method to drill a hole in Al6061 material.
 Abrasive jet machining is one of the un-conventional machining processes for machining of hard and brittle
materials. The principle parameters during AJM machining that affect the MRR and Kerf accuracy are gas
pressure, velocity of abrasive particles, and size of the abrasive particle, abrasive mass flow rate, mixing ratio,
standoff distance and nozzle diameter.
 The present investigation has been carried out to optimize the process parameters on AJM during drilling of a
hole on Al6061 alloy material. The influence of the various process parameters, i.e. pressure, nozzle diameter and
stand-off distance on the predominant machining criteria on the metal removal rate (MRR) was studied. In this
work, repeated number of experiments was carried out as per the Taguchi experimental design (L27 3 levels, 3
factors).
 The settings of the process parameters were determined by using Taguchi’s experimental design method.
Orthogonal arrays of Taguchi, the signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) are
employed to find the optimal process parameter levels and to analyze the effect of these parameters on metal
removal rate values and the quality of the hole. Confirmation test with the optimal levels of machining parameters
was carried out in order to illustrate the effectiveness of the Taguchi optimization method.
 The SEM are used to identify the micro structure of the machined surface.
LITERATURE REVIEW
 D.V. Srikanth et.al [5] through his experimental studies revealed that, Abrasive Jet Drilling on glass sheets with
different parameters such as air pressure, nozzle diameter and standoff distance influenced the MRR and Kerf
accuracy. Further, it was concluded that the maximum MRR was achieved when the air pressure was maintained
at 8 kg/cm2, standoff distance (SOD) at 10mm and nozzle diameter at 4mm respectively. Better Kerf was noticed
at air pressure 6 kg/cm2, stand of distance at 9 mm, nozzle diameter 3 mm.

 M. Wakuda et.al [6] conducted an experiment and noticed the effect of workpiece properties during machinability
in abrasive jet machining. His study concluded that, the fracture and hardness of the objective materials are
influencing the material expulsion rate in AJM. Further, it was identified that, the impact on the machinability
was proportionality to velocity, diameter and density of abrasive particles.

 Vishal Guptha et. al [7] also revealed through his experiments conducted on marble by using abrasive water jet
machining that, the ideal settings of process parameters influenced the top and bottom width of the Kerf with
water pressure and nozzle transfer speed as 340 MPa and 100 mm/min respectively.

 D.V. Srikanth et.al. [11] in his research, proposed a method of optimization for machining of ceramics with
abrasive jet machining with different parameters like pressure, standoff distance, abrasive flow rate, on the metal
removal rate and Kerf width on ceramic tiles. It was concluded that maximum aching is achieved at optimal
values of pressure 8 kg/cm2, abrasive flow ratio (AFR) 5.5 gm/min, SOD at 20 mm.
OBJECTIVE

 The influence of various process parameter such as Pressure, nozzle diameter and stand-off distance
on the Al6061 alloy is noted.
 Repeated number of experiments was carried out as per the Taguchi experimental design (L27, 3
levels, 3 factors).

Sl. No Machining parameters 1 2 3 Units


1. Air pressure 6 8 10 Bar
2. Nozzle diameter 4 6 8 mm
3. Standoff distance 3 6 9 mm
The results are analyzed using ANOVA technique to know the percentage contribution of each process
parameter like material removal rate(MRR) and surface roughness, air pressure, nozzle diameter and
stand-off distance on drilling process.
Upon conducting the Taguchi and ANOVA techniques, it is observed that, the optimal values of process
parameters identified during AJM of Al6061 alloy.
METHODOLOGY
 ABRASIVE JET MACHINING
 Machining operation - Drilling.
 Work piece material - Aluminium6061alloy.
 Size of the material - 400mm*400mm*10mm.
 Process parameter - Air pressure, nozzle diameter, stand-off distance.
Sl. No Machining parameters 1 2 3 Units
1. Air pressure 6 8 10 Bar
2. Nozzle diameter 4 6 8 mm
3. Standoff distance 3 6 9 mm
 No .of . holes drilled - 27 (By using Taguchi method 3levels,3parts).
 ANOVA for analyzing - for analyzing the MRR , kurf accuracy (using the above parameters).
 Software used - MINITAB16.
 Result - Which of the above parameters have increased MRR and good quality of
kurf accuracy.
FLOW CHART
Analysis and optimisation of process parameter
in AJM drilling by using Taguchi method

Work piece material-Aluminium6061

Machining method-AJM(drilling)

Process parameter-Air pressure, SOD, Nozzle


diameter

No.of.holes drilled-27 (by using Taguchi method


3levels,3parts).

Optimisation tools-MINI TAB18.

Analysis-The influence of process parameters on


MRR,surface finish,kerf accuracy,Taper angle.
SEM are used to identify the micro structure of the
machined surface
MACHINING PARAMETERS CONSIDERED FOR DRILLING

Medium - Air.
Abrasive particle - Aluminium oxide.
Size of abrasive - 50 microns.
Flow rate of abrasive - 2 to 20 grams/min.
Velocity - 150 - 300m/min.
Pressure - 6,8,10 Bar.
Nozzle size - 4,6,8 mm.
Nozzle material - Tungsten carbide.
SOD - 3,6,9 mm.
Part application - Drilling.
Work piece material - Aluminium
Potential - 220V.
Current - 1A.
Power - 0.22KW.
SCHEMATIC DIAGRAM OF AJM
MODEL 2D CATIA DIAGRAM

BEFORE DRILLING DIMENSIONS AFTER DRILLING


EXPERIMENTAL WORK
Work piece material - Aluminium6061.
Size of the material - 400*400*10mm.
Cost of the material - Rs 2400.

ABRASIVE JET MACHINING.

Process parameter - Air pressure, nozzle diameter, stand-off distance

Sl. No Machining parameters 1 2 3 Units


1. Air pressure 6 8 10 Bar
2. Nozzle diameter 4 6 8 mm
3. Standoff distance 3 6 9 mm
No .of . holes to be drilled – 27 (By using Taguchi method 3levels,3parts)
COLUMN FACTORS PROCESS CHARACTERISTICS
A B C
Trail No Air Standoff Nozzle Diameter MRR Kerf Surface Taper angle
Pressure distance (mm) (gram/sec) accuracy roughness
(bar) (mm)
1 6 3 4 0.002421 0.05
2 6 3 6 0.006482 0.25
3 6 3 8 0.012942 0.4
4 6 6 4 0.002260 0.08
5 6 6 6 0.00580 0.26
6 6 6 8 0.012295 0.6
7 6 9 4 0.001994 0.1
8 6 9 6 0.005510 0.3
9 6 9 8 0.011177 0.8
10 8 3 4 0.002825 0.09
11 8 3 6 0.007871 0.14
12 8 3 8 0.015360 0.9
13 8 6 4 0.002421 0.15
14 8 6 6 0.007871 0.3
15 8 6 8 0.014464 0.4
16 8 9 4 0.002260 0.3
17 8 9 6 0.006480 0.4
18 8 9 8 0.012940 0.5
19 10 3 4 0.003390 0.04*
20 10 3 6 0.009183 0.1
21 10 3 8 0.017560* 0.36
22 10 6 4 0.002825 0.12
23 10 6 6 0.007346 0.16
24 10 6 8 0.014460 0.2
25 10 9 4 0.002421 0.15
26 10 9 6 0.006887 0.25
27 10 9 8 0.012940 0.3
 No .of . holes drilled - 27 (Taguchi method3levels,3parts)
 Total hours of machining - 2 hrs 20 min.
 Cost of the machining per hour - Rs 2,500.
 Total cost of the machining process – Rs 5,800.

 METAL REMOVAL RATE (MRR)

MRR = {Total weight of the material – Amount of material removed per drill}
Total time taken for drilling one drill

UNIT – (grams/sec).
KERF ACCURACY
Kerf accuracy = Upper diameter of the hole – lower diameter of hole.
Kerf accuracy is defined as the difference between the upper diameter of the hole to the lower diameter of the hole.

SURFACE ROUGHNESS
Surface roughness is defined as the irregularities in the machined surface , the instrument used to determine surface
roughness is dial indicator.
 TAPER ANGLE
The formula used for calculating the taper angle is,
Tan-1 (D–d)
t
Where, D-upper diameter of the hole.
d-lower diameter of the hole.
t-Thickness of the material.

 SEM TEST
The electron in the beam interact with the sample , producing
Various signals that can be used to obtain information about
the surface topology and composition.
The SEM are used to identify the micro structure of the machined surface.
ANALYSIS
GRAPH

By the experimental work it is noted that the nozzle diameter has the most influencing effect on the metal
removal rate.
In order to achieve the good quality of the hole(kerf accuracy),the most influencing parameter is the standoff
distance.
RESULT

1. Aluminium6061 is effectively machined on abrasive jet machine and effect of their process parameters on the material
removal rate is analysed by using Taguchi and ANOVA.
2. By the experimental work, it is noted and concluded that, nozzle diameter has the most significant effect on the metal
removal rate.
3. Similarly, in order to achieve the quality of the hole (Kerf accuracy), the most influencing parameter is the standoff
distance.
4. Upon conducting the Taguchi and ANOVA techniques, it is observed that, the optimal values of process parameters
identified during abrasive jet machining of Aluminium6061 alloy.
 In order to increase and achieve the metal removal rate,
Air pressure =10 bar
Standoff distance =3mm
Nozzle diameter =8mm

 In order to get good quality of Kerf accuracy,


Air pressure = 10 bar
Standoff distance = 3 mm.
Nozzle diameter = 4 mm.
APPLICATIONS

Aircraft industry.
Marine application.
Automotive parts.
Sports equipments.
Fabricating medical device.
QUERIES?

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