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Krishnaiah, A.
- Analysis of Machinability on Al6061 using Single Point Cutting Tool
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Authors
Affiliations
1 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad-501510, IN
2 Department of Mechanical Enigneering, Osmania University, Hyderabad, IN
1 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad-501510, IN
2 Department of Mechanical Enigneering, Osmania University, Hyderabad, IN
Source
International Journal of Scientific Engineering and Technology, Vol 6, No 8 (2017), Pagination: 307-312Abstract
The emerging trend of machining to produce low cost and high quality products in least possible time has given a real challenge in machining aluminium and its alloys. The chemical affinity of aluminium to different coating materials and its low melting point made this a critical one for machining. Many researches are still going on to find out the best compatible procedures for machining aluminum and its alloys. The main problem in machining the aluminum is the formation of built-up edge formation due to the adhesion to the tool materials resulting in an adverse effect on surface quality of the work piece. This can be prevented to an extent by giving suitable process parameters. Hence there is a need for optimization of process parameters for optimized production. Cutting parameters such as speed, feed and depth of cut that are significant in machining process are estimated and analyzed. The main objective is to optimize the process parameters namely- cutting speed, feed and depth of cut on machining AL6061 alloy using single point cutting tool. The Experimentation is carried out after choosing a set of trials that are compatible with the lathe machine used. Surface roughness, Material removal rate and cutting forces are measured using instruments and are incorporated into Design Expert software. An equation is generated for each parameter and inputs to achieve better results are estimated. In the present work, Design of Experiments techniques(full factorial&RSM) are used in order to find the effect of input parameters on cutting force and surface roughness and metal removal rate. Contribution of each factor is determined by ANOVA (Analysis of Variance).Keywords
Cutting Force, Surface Roughness, MRR, DOE, RSM, ANOVA.Full Text
References
- i. SohailAkram, Syed Husain Imran Jaffery, Mushtaq Khan, AamirMubashar, and Liaqat Ali.2015,A Numerical Investigation of Effects of Cutting Velocityand Feed Rate on Residual Stresses in Aluminum AlloyAl-6061,International Journal of Materials, Mechanics and Manufacturing, Vol. 3, No. 1, February 2015
- ii. Kannan Nair M R , ShyamSundar V.2015,Optimization Of Tool Chip Contact Area In Turning Operation Using Finite Element Thermal Analysis, International Journal of advanced research in science and Engineering,Vol No 4, Issue 11, Nov 2015.
- iii. NitinSawarkar,.Ghanshyam Boob.2014,Finite Element based Simulation of Orthogonal Cutting Process to Determine Residual Stress Induced,International Journal of Computer Applications (0975 – 8887).
- iv. Meenu Sahu1 and Komesh Sahu.2014, Optimization of Cutting Parameters on Tool Wear,Workpiece Surface Temperature and MaterialRemoval Rate in Turning of AISI D2 Steel,International Journal of Advanced Mechanical Engineering.ISSN 2250-3234 Volume 4, Number 3, pp. 291-298.
- v. Thamizhmanii S. Saparudin S. and Hasan S., 2007, Analysis of Surface Roughness by Using Taguchi Method, Achievements in Materials and Manufacturing Engineering, Volume 20, Issue 1-2, pp. 503-505.
- vi. Singh H. and Kumar P., (2006), “Optimizing Feed Force for Turned Parts through the Taguchi Technique”, Sadhana, Volume 31, Number 6, pp. 671–681.
- vii. Lin W. S., Lee B. Y., Wu C. L., 2001, Modelling the surface roughness and cutting force for turning, Journal of Materials Processing Technology, Volume 108, pp. 286-293.
- viii. Srikanth T. and Kamala V.2008,A Real Coded Genetic Algorithm for Optimization of Cutting Parameters in Turning IJCSNS, International Journal of Computer Science and Network Security, Volume 8 Number 6, pp. 189-193.
- ix. Thamma R., 2008, Comparison between Multiple Regression Models to Study Effect of Turning Parameters on the Surface Roughness. Proceedings of the 2008 96IAJC-IJME International Conference, ISBN 978-1-60643-379-9, Paper 133, ENG 103 pp. 1-12.
- x. Gajanana.S, 2007, Development of Mathematical Model for EDM Using Two Factorial Design of Experiments XXIII National Convention of Mechanical Engineers and National Seminar on „Emerging Trends In Manufacturing Systems and Technologies‟, Hyderabad, September 10-12, 2007.
- Machinability Study of Aluminium 6061 Alloy on End Milling Process
Abstract Views :147 |
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Authors
Affiliations
1 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN
2 Department of Mechanical Enigneering, CoE, Osmania University, Hyderabad, IN
1 Department of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN
2 Department of Mechanical Enigneering, CoE, Osmania University, Hyderabad, IN
Source
International Journal of Engineering Research, Vol 6, No 8 (2017), Pagination: 397-402Abstract
Usage of non-ferrous materials is increasing day-by-day due to its wide variety of applications in many areas because of their properties, availability etc. Hence the study and development of these materials in many aspects is increasing. Of all the non-ferrous metals, Aluminium is one of the most widely used metal. This paper focuses on casting of Al6061 alloy by varying the composition of its alloying elements and also to study the machinability properties of Al 6061 by conducting set of experiments on Al-6061 alloy under vertical milling machine using HSS end mill cutter and finding out the output responses, Metal removal rate, Surface finish, and Cutting forces by varying process parameters speed, feed and depth of cut. Response Surface Methodology (RSM) and Full Factorial Design of Experiments were used to develop the regression equation between input parameters and output responses. Contribution of each factor (Speed, Feed and Depth of Cut) on output parameters (Metal removal rate, Surface finish, and Cutting Force) was determined using ANOVA.Keywords
End Milling, Al6061, Machinability, RSM, Full Factorial Design, ANOVA.Full Text
- Development of Regression Model Using Lasso for End Milling on AL6061 Alloy
Abstract Views :217 |
PDF Views:7
Authors
Affiliations
1 Dept of Mech Engg, MVSR Engg College, Nadergul, Hyderabad, IN
2 Dept of Mech Engg, CoE, Osmania University, Hyderabad, IN
1 Dept of Mech Engg, MVSR Engg College, Nadergul, Hyderabad, IN
2 Dept of Mech Engg, CoE, Osmania University, Hyderabad, IN
Source
Manufacturing Technology Today, Vol 16, No 9 (2017), Pagination: 3-9Abstract
The development of various non-ferrous materials is increasing at an exponential rate as the usage of non-ferrous materials has seen a greater than before preference over the traditional ferrous metals. Al6061 alloy has become the forerunner and is widely used in various industrial applications. This paper includes the study of machinability properties of Al6061 alloy by performing various experiments under vertical milling machine using HSS end mill cutter. Full-factorial approach was used to conduct the experimentation, a regression model was developed using Least Absolute Shrinkage and Selection Operator (Lasso) between the input parameters and output responses.Keywords
Al6061, Design of Experiments, End Milling, Lasso, Machinability, Regression Analysis.
References
- Sivarao, FairuzDimin, T.J.S. Anand, RidzuanJamli and A. Kamely, “Surface Quality Investigation of Al 6061-T6511 Using TiALN Coated Milling Tool”, Inl J of Basic & Applied Sciences IJBAS-IJENS Vol: 10 No: 04.
- Robert Tibshirani, “Regression Shrinkage and Selection via the Lasso”, Journal of the Royal Statistical Society, Series B (Methodological), Volume 58, Issue 1 (1996), 267-288.
- C A Cantrell, “Technical Note: Review of methods for linear least-squares fitting of data and application to atmospheric chemistry problems”, Atmos. Chem. Phys. Vol. 8, 2008.
- Donald W Marquardt and Ronald D Snee, “Ridge Regression in Practice”, The American Statistician, Vol. 29, No. 1, 1975.
- N J D Nagelkerke, “A note on a general definition of the coefficient of determination”, Biometrika, Vol. 78, No. 3, 1991, 691-692.
- Christophe Leys, Christophe Ley, Oliver Klein, Philippe Bernard, Laurent Licata, “Detecting outliers: Do not use standard deviation around the mean, use absolute deviation around the median”, Journal of Experimental Social Psychology, 2013.
- M. K. Pradhan, MayankMeena, ShubhamSen and Arvind Singh, “Multi-Objective Optimization in End Milling of Al-6061 Using Taguchi Based G-PCA”, World Academy of Science, Engg and Technology, Inl J of Mech, Aerospace, Industrial, Mechatronic and Manufacturing Engg Vol: 9, No: 6, 2015.
- Mathew A. Kuttolamadom, Sina Hamzehlouia and M. Laine Mears, “Effect of Machining Feed on Surface Roughness in Cutting 6061 Aluminum”, Clemson University - Int Center for Automotive Research, 2010-01-0218.
- Najiha M.S, M.M. Rahman and A.R. Yusoff, “Modeling of The End Milling Process For Aluminium Alloy Aa6061t6 Using HSS Tool”, Intl Conf on Mech Engg Research (ICMER2013), 1-3 July 2013.
- Prajina N V, T D John, “Multiple Response Optimization of Cutting Forces in End Milling Using Response Surface Methodology and Desirability Function”, Int J of Scientific Research, Vol: 2, Issue: 5, May 2013.
- V. Devkumar, E. Sreedhar, M.P. Prabakaran, “Optimization of machining parameters on AL 6061 alloy using response surface methodology”, Int J of Applied Research 2015; 1(7): 01-04.
- ASM Metals Handbook, Vol: 16.
- S. Madhava Reddy and A. Chennakesava Reddy, “Studies on Process Parameters in End Milling Operations of Aluminium Alloy”, Int J of Engg Research & Technology (IJERT),Vol. 2 Issue 3, March – 2013.
- Gajanana.S (2002), “Development of Mathematical Model for Maximum Punch Force” Proc of National Conf on Advanced Trends in ME Research and Development, JNTU College of Engg, Ananthapur, 21st Dec, 2002.
- Gajanana.S,(2006), “Optimization of Process Parameters for Hero Honda Exhaust Valve using Design of Experiments” Proc of National Conference on Recent Advances in Computer Aided Engg, Osmania University, Hyderabad, March 3rd& 4th , 2006.
- Gajanana.S (2007), “Development of Mathematical Model for EDM Using Two Factorial Design of Experiments” XXIII National Convention of Mech Engineers and National Seminar on ‘Emerging Trends In Manufacturing Systems and Technologies’, Hyderabad, September 10-12, 2007.
- Casting and Metallurgical Analysis of Aluminium-6061
Abstract Views :176 |
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Authors
Affiliations
1 Dept. of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN
2 Dept. of Mechanical Engineering, CoE, Osmania University, Hyderabad, IN
1 Dept. of Mechanical Engineering, MVSR Engineering College, Nadergul, Hyderabad, IN
2 Dept. of Mechanical Engineering, CoE, Osmania University, Hyderabad, IN
Source
Manufacturing Technology Today, Vol 17, No 2 (2018), Pagination: 15-23Abstract
Aluminium alloys are most extensively used Non-ferrous materials in aircraft and automobile industries. Among the aluminium alloys 6000 series are mostly suitable one by virtue its versability is heat treatment and extrusion capabilities. In the present study the influence of various alloying elements in Al 6061 is undertaken keeping in view the mechanical and metallurgical aspects. Experiments are carried by taguchi philosophy of design experiments. L8 orthogonal array is adapted in selection of compositions of alloying elements for casting specimens and testing is carried to study the mechanical and micro structural properties.Keywords
Al6061, L8 Array.- Investigation to Optimize Process Parameters on Mechanical Properties of Aluminium Alloy in Die Casting Using Taguchi Method
Abstract Views :204 |
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Authors
Affiliations
1 Dept of Mech Engg., Nishitha college of Engg. & Technology Hyderabad, IN
2 Dept of Mech Engg., MVSR Engineering College, Hyderabad, IN
3 Dept of Mech Engg.,UCE, Osmania university, Hyderabad, Telangana, IN
1 Dept of Mech Engg., Nishitha college of Engg. & Technology Hyderabad, IN
2 Dept of Mech Engg., MVSR Engineering College, Hyderabad, IN
3 Dept of Mech Engg.,UCE, Osmania university, Hyderabad, Telangana, IN
Source
Manufacturing Technology Today, Vol 17, No 10 (2018), Pagination: 19-27Abstract
Aluminium alloy (7178) of die casting involves process parameters like weight percentage of Zn, Mg, Cu, Cr Si. Fe, Mn and Ti etc. with this Zn, Mg, Cu and Cr are selected as process parameters and other parameters are kept constant. Experiments were conducted Taguchi’s L-9 orthogonal array. Castings were made under the various parameter at three different level. In this investigation, the effect of process parameters on mechanical properties of castings of aluminium alloy (7178) is studied. Taguchi method design of experiments employed to optimize the parameters of process that leads maximum mechanical properties. The investigation has indicated that influence of parameters like Zinc (Zn), copper (Cu) magnesium(Mg) and chromium (Cr) on properties of mechanical like Tensile strength, Hardness and microstructure analysis. Results were analysed by ANOVA Technique. Microstructures were studied under optical microscope. The optimal parameters of process for castings of aluminium alloy for better mechanical properties have been determined.
Keywords
Aluminium Alloy 7178, Die Casting Method, Taguchi Method, Anova.References
- Vivek Bhardwaj, Arunesh Chandhraand NIKHIL Yadav, “Investigating the effect of process parameters on the mechanical properties of A713 sand cast aluminum alloy by using Taguchi Method’ International journal of advances in Engineering $ Technology. Issued Nov 2013.
- P. Shailesh, S. Sundarrajan and M. Komaraiah ‘Optimization of process parameters of Al-Si alloy by centrifugal casting technique using Taguchi design of experiments’ Elsevier (scienceDirec) issued 2014
- Senthiil P. V, M. Chinnapandian and Aakashsirusshti ‘optimization of process parameters in cold chamber Die casting process using Taguchi method’ International journal of innovative science, Engineering $ Technology, vol. 1, no. 6, August 2014.
- M. Thirunmal Azhagan, B.Mohan and A. Rajaadurai ‘Optimization of process parameters to enhance the hardness on squeeze cast Aluminum Alloy AA6061. International journal of Engineering and Technology, issued vol. 6 Feb-March 2014.
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- Mahesh N Adke and Shrikant V Karanjkar ‘Optimization of die casting process parameters to identify optimized level for cycle time using Taguchi method’ international journal of innovative in Engg. and Technology, vol. 4, no. 4 December 2014.
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- Javed Gulab Mulla, Prof V. V potdar and Swapnil S Kulkarni ‘investigating die casting process parameters to identify the optimized levels using Taguchi methods for design of experiment (DOE), International journal of advanced Engineering Research and studies. Issued March 2014.
- Puyush Bhardwaj ‘Die casting process. International journal innovation Research in Techonology, vol. 2, no. 2, December.
- Sharma Sand Rana Rs “Optimization of Mechanical Behavior of AA 5083 Nano Sic composites using Design of Experiment vol. 4, no. 2015.
- Subhibisen, Tejajumale, YogeshMahajan and D.R.Peshwe ‘Study of abrasive wear of Al Zn-Mg alloy by Taguchi Method’ International journal of Engineering Research & Technology, vol. 2, no. 12 December 2013
- Experimental Investigation on Machining Parameters of Al6061-Mgo
Abstract Views :295 |
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Authors
Affiliations
1 MVSR Engineering College, Hyderabad, IN
2 CoE, Osmania University, Hyderabad, IN
1 MVSR Engineering College, Hyderabad, IN
2 CoE, Osmania University, Hyderabad, IN
Source
Manufacturing Technology Today, Vol 19, No 12 (2020), Pagination: 19-26Abstract
The objective of the current paper is, to investigate the machinability on Al 6061-Mgo metal matrix considering machinability parameters like speed, feed, depth of cut. Aluminum is remarkable for its low density and its ability to resist corrosion through the phenomenon of passivation. It is widely used for high performance applications such as automotive, military, electricity and aerospace industries because of their improved physical and mechanical properties such as light weight, high strength, good corrosion resistance, malleability, etc. Al metal matrix is the material. In the present work aluminium is used as the matrix and several reinforced materials are embedded into the matrix. Al 6061 aluminum alloy is reinforced with 1.0 weight percentage of Magnesium Oxide (MgO) particles through stir casting. In the present work, the influence of alloying elements in Al 6061 alloy have been investigated Casting of specimen having mentioned composition were prepared using stir casting method. Experiments were performed machining parameters like speed, feed, depth of cut during the turning operation with rake angle 15o per various trials, by changing the machinability parameters and calculated for all trials resultant force and frictional force with the help of merchant cycle and identified optimized machinability parameters.Keywords
Al6061, Merchant Circle, Machinability, Rake Angle.- Study on influence of process parameters in hot rolling of al 7178 metal matrix materials
Abstract Views :65 |
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Authors
Affiliations
1 1 Maturi Venkata Subba Rao (MVSR) Engineering College, Hyderabad, Telangana, India, IN
2 Maturi Venkata Subba Rao (MVSR) Engineering College, Hyderabad, Telangana, India., IN
3 University College of Engineering, Osmania University, Hyderabad, Telangana, India, IN
4 Brilliant Institute of Engineering Technology, Hyderabad, Telangana, India, IN
5 HCL Technologies, Hyderabad, Telangana, India, IN
1 1 Maturi Venkata Subba Rao (MVSR) Engineering College, Hyderabad, Telangana, India, IN
2 Maturi Venkata Subba Rao (MVSR) Engineering College, Hyderabad, Telangana, India., IN
3 University College of Engineering, Osmania University, Hyderabad, Telangana, India, IN
4 Brilliant Institute of Engineering Technology, Hyderabad, Telangana, India, IN
5 HCL Technologies, Hyderabad, Telangana, India, IN
Source
Manufacturing Technology Today, Vol 21, No 5-6 (2022), Pagination: 3-14Abstract
Aluminium and its alloys are in demand for the manufacturing of components due to their high strength to weight ratio. As the technology is advanced the demand for high strength to weight ratio is increased exponentially. Many researchers are explore alternatives to pure aluminium by way of adding silicon and metal matrix of Mg, SiC and Al2 O3 . The present work aims at preparation of optimized Al7178 by stir casting process and extruding to preparation of aluminium matrix materials consisting silicon carbide and aluminium oxide (Al2 O3 ) powder of 40µm particle size at 6% weight percentage with a objective of investing the influence of process parameters of hot rolling process. Investigation is undertaken in order to minimize the rolling force of Al7178 aluminium metal matrix in hot rolling forming process where in the process parameters inlet thickness, rolling speed, percentage reduction of thickness, rolling temperature are considered as input parameters. Experimentation on hot rolling process concludes that 6% weight percentage of SiC and Al203 needs minimum rolling force 2.6 and 1.3 kN corresponding to 9mm inlet thickness, 15rpm rolling speed, 10% of thickness reduction at rolling temperature of 600ᵒC.Keywords
Al 7178 alloy, Silicon Carbide (SiC), Aluminium Oxide (Al2 O3 ), Taguchi Method.References
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