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Nandam, Srinivasa Rao
- Optimization of Process Parameters of End Milling Process Using Factorial Design of Experiments
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Authors
Affiliations
1 Mech Engg Dept, M. V. S. R. Engg., College, Hyderabad, IN
2 Mech Engg. Dept., University College of Engg., Osmania University, Hyderabad, IN
3 Special Fabrication Section, Mech Engg. Group, Kanchanbagh, Hyderabad, IN
1 Mech Engg Dept, M. V. S. R. Engg., College, Hyderabad, IN
2 Mech Engg. Dept., University College of Engg., Osmania University, Hyderabad, IN
3 Special Fabrication Section, Mech Engg. Group, Kanchanbagh, Hyderabad, IN
Source
Manufacturing Technology Today, Vol 12, No 6 (2013), Pagination: 6-14Abstract
Manufacturing managers, schedulers, and engineers constantly try to overcome with the effects of cutting tool selection. Inaccuracy of cutting tool will contribute to poor surface finish, tool damage, chatter, dimensional accuracy and many other problems that contribute to low productivity and much time will be wasted.Some of the important process variables (cutting parameters) that effect the cutting force and surface roughness process are cutting speed, feed depth of cut and nose radius (cutting tool diameter). In order to optimize the output parameters i.e., cutting force, power consumption and surface roughness, the process variables are varied. The design of experiment is the procedure of selecting the number of trails and conditions for running them, essential and sufficient for solving the problem that has been set with the required precision. In the present work two factorial design of experiments (DOE) technique is used in order to find the effect of input parameters on cutting force and surface roughness. In the present work milling process is carried out for the work material EN8 and cutting forces are measured using dynamometers at DMRL. In design of experiments, number of trails to be conducted is determined by factorial method and design matrix is constructed. After getting the design matrix, regression coefficients are calculated. Adequacy of model is tested by fisher test at 5% significance level. Student's t-test is carried out to check the significance of each regression coefficient. Contribution of each factor on output is determined by Analysis of Variance (ANOVA) and using MAT LAB software the optimum values of cutting force and surface roughness corresponding to their process parameters are obtained.Keywords
DOE, ANOVA, Factors, Milling Process, Cutting Force, Surface Roughness.
- Precision Milling of Nickel-Based Single-Crystal Superalloy by TiAlN Coated Small Diameter Solid Carbide End Mill
Abstract Views :56 |
PDF Views:1
Authors
Affiliations
1 Indian Institute of Technology Bombay, Mumbai. Defence Metallurgical Research Laboratory, DRDO, Hyderabad, IN
2 Defence Metallurgical Research Laboratory, DRDO, Hyderabad, IN
3 Indian Institute of Technology Bombay, Mumbai, IN
1 Indian Institute of Technology Bombay, Mumbai. Defence Metallurgical Research Laboratory, DRDO, Hyderabad, IN
2 Defence Metallurgical Research Laboratory, DRDO, Hyderabad, IN
3 Indian Institute of Technology Bombay, Mumbai, IN
Source
Manufacturing Technology Today, Vol 22, No 4 (2023), Pagination: 1-7Abstract
Nickel-based superalloys pose cutting challenges due to their high strength, hot hardness, work hardening, and low thermal conductivity. Precision milling with small cutters is used for complex shapes and intricate profiles, but selecting appropriate machining parameters for these alloys is a challenging task. A set of machining conditions in slot milling with a TiAlN coated 1.5 mm diameter solid carbide end mills are investigated for dimensional accuracy, cutting forces, and specific energy. The dimensional accuracy in depth consists of within 10% of the depth of cut. The axial force and the feed force increase from 20 N to 106 N and from 17 N to 46 N, respectively with an increase in chip area from 0.8E-03 to 1.5E-03 mm 2 /rev. Tool rotation caused a gradual increase of cutting forces in up-milling and decreasing of cutting forces in down-milling. The specific energy increases from 393 to 865 J/mm 2 steeply under higher chip areas.Keywords
Nickel-Based Single-Crystal Superalloy, Precision Milling, Solid Carbide End Mill, Cutting Forces, Specific Energy.References
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- Nandam, S. R., Venugopal Rao, A., Gokhale, A. A., & Joshi, S. S. (2023). Experimental Study on Surface Integrity of Single-Crystal Nickel-Based Superalloy Under Various Machining Processes. Lecture Notes in Mechanical Engineering, 305-317. https://doi.org/10.1007/978-981-19-3866-5_26
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- Varghese, A., Kulkarni, V., & Joshi, S. S. (2021). Monitoring Shearing-Plowing Transitions in Micro-Milling Using Fluctuations in Cutting Forces. Journal of Micro and Nano-Manufacturing, 9(4). https://doi.org/10.1115/ 1.4053696