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1. Mr.B.Radhakrishnan
Assistant professor, Mechanical department 4. Mr.P.Ramakrishnan
K.Ramakrishnan College of engineering UG scholar Mechanical Engineering
Trichy, Tamilnadu, India. K.Ramakrishnan College of engineering
Email-radhakrishnankrce@gmail.com Trichy, Tamilnadu, India.
Email-sivajiram95@gmail.com
3. Mr.P.Sankarlal
UG scholar Mechanical Engineering
K.Ramakrishnan College of engineering
Trichy, Tamilnadu, India.
Email-sankarlalpulivalam@gmail.com
of significance ANOVA is a separation of variance and genetic data. They concluded that maximum cutting
ascribable to one prove of process of the variance speed and minimum feed is best solution independently
ascribable to other groove. of the criterion used bring analysis except for robustness
coefficients.
Response surface methodology (RSM) is a
collection of mathematical and statistical techniques for chandra shekar et al [4] optimized the
empirical model building. By careful design of machining parameters speed, feed, depth of cut, nose
experiments, the objective is to optimize a response radius in turning of Al 6063 T6 in CNC machine through
(output variable) which is influenced by several design of experiments by taguchi method. They
independent variables (input variables). An concluded that low surface roughness obtain for the
experiment is a series of tests, called runs, in which parameter setting of nose radius value 0.8mm ,feed of
changes are made in the input variables in order to 10mm/min, speed of 500 rpm, depth of cut 0.8mm.
identify the reasons for changes in the output response. Highest material removal rate for nose radius value
An important aspect of RSM is the design of experiments 0.4mm, feed 70 mm/min, speed 1500 rpm.
usually abbreviated as DOE. These strategies were
originally developed for the model fitting of physical P. Jayaraman et al [5] researched on multi
experiments, but can also be applied to numerical response optimization of machining parameters such as
experiments. The objective of DOE is the selection of the cutting speed, feed rate, and depth of cut in turning of
points where the response should be evaluated. AA 6063 T6 using grey relational analysis in Taguchi
Most of the criteria for optimal design of method. They conclude from this analysis it is revealed
experiments are associated with the mathematical model that feed rate, depth of cut are the prominent factors
of the process. The choice of the design of experiments which affect the aluminium alloy and feed rate (57.365
can have a large influence on the accuracy of the %) , depth of cut (25.11%) , speed (17.35%) gives the
approximation and the cost of constructing the response optimal surface roughness value.
surface.
R. Rudrapathi et al [6] investigated on the
II. LITERATURE REVIEW optimization the process parameters using the spindle
speed, feed rate, depth of cut, in CNC turning of
V. Devkumaret al [1] investigated the optimal aluminium alloy using RSM and Teaching Learning
cutting conditions for attaining the better surface Based Optimization. From this analysis they concluded
roughness using the mathematical modeling and analysis that second order mathematical model is developed for
of machining response and tool wear in the turning of surface roughness by RSM. It is found that hybrid RSM
aluminum alloy 6061. There was process parameters such cum TLBO is very useful to optimize surface roughness
as spindle speed, depth of cut and feed rate used to in CNC turning of aluminium alloy.
determine the quality of surface roughness. Experiments
were conducted as per central composite face centered Doreswamy Deepaket al [7] studied the multi
design. Analysis of variance is used for the comparison response optimization of process parameters speed, feed,
study on tabulated values and experimental values for and depth of cut in CNC turning of aluminium 6061
surface roughness. using grey relational analysis in taguchi L9 array method.
From this analysis they concluded that high feed rate
J.Paulo davim et al [2] studied the effects of leads to broken chips and burrs in the surface of the job
turning parameters such as cutting velocity, feed rate on and high cutting speed gives more MRR and low feed
surface roughness of glass fiber reinforced plastics by and depth of cut gives good surface finish.
statistical analysis. They concluded that this cutting
parameters is possible to obtain surface with 0.80 to 1.75 Rohit angris et al [8] analyzed surface roughness
µm. arithmetic average roughness (Ra) 4.9 to 9.3 µm of in CNC turning of aluminium 6063 using various
maximum peak to valley height (Rt, R max). They also parameters speed, feed, depth of cut by taguchi approach.
founded surface roughness increases with feed rate and From this analysis they concluded that feed has more
decreased with cutting velocity. They used two methods significant effect on surface roughness (50.9%) and MRR
HLU and FW. They found HLU is possible to obtain is maximum at the parametric condition 2500rpm, 50 mm
smaller values of surface roughness than FW. per rev and 0.1 mm depth of cut.
C.A.Conceicao Antonio et al [3] investigated the M.S. Ranganath et al [9] inspected on Surface
optimal machining parameters cutting speed, feed, and Roughness Prediction Model for CNC Turning of EN-8
depth of cut for attaining better surface roughness when Steel Using RSM for various parameters speed, feed, and
turning free machining steel 9SMnPb28K with cutting depth of cut. They form the quadratic equation to
tool made of cemented carbide using experimental data conclude that the cutting speed has the strongest effect on
the surface roughness and it also inversely proportional to Aluminium 6063T6 contains Si, Fe, Cu, Mn,
depth of cut. Mg, Zn, Ti, Cr, Al in following percentage represented in
table 2.
B.Radha Krishnan [10] Review of prediction of
surface roughness in machine vision system by using Table 3 CHEMICAL COMPOSITION OF
various parameters like speed , feed rate, depth of cut . in ALUMINIUM 6063T6
this paper as detailed explanation about measuring
objective parameters these are surface roughness , peak Element (%)
to valley, root mean square and list out the methodology
Si 0.2 to 0.6
for the machine vision system.
Fe 0.0 to 0.35
III.MATERIALS AND EQUIPMENTS
Cu 0.0 to 0.1
A) MATERIALS PROPERTIES
Mn 0.0 to 0.1
1) Work piece material:
Mg 0.45 to 0.9
In this experiment work Al6063 is used as a material. It
has generally good mechanical properties and is heat Zn 0.0 to 0.1
Al Balance
soft. A common drawback of this approach is the small Processor With Siemens 802D SI control with
standard equipments
area using which the roughness is evaluated at any one
time and also the transducer is very sensitive and the Power supply 3 phase 415 volt AC 12 KVA
stylus tip is fragile. Therefore, the instrument must be
Axis travel Length –x –axis-190 mm
handled carefully in a fairly, clean environment. Another
problem with the stylus measurement technique is the Z – axis- 210 mm
size of the stylus radius and the crevices of the surface. If
the crevices are narrow such that the stylus cannot Total cost Rs 913943
1.78
2 1300 0.2 0.6 6.9
0.85
3 1400 0.1 0.7 4.14
1.62
4 1500 0.2 0.8 6.65
0.87
5 1600 0.1 0.9 4.47
1.93
7 1800 0.1 1.1 7.24
1.41
8 1900 0.2 1.2 7.45
1.18
9 2000 0.1 1.3 5.38
1.44
10 1200 0.2 1.4 5.96
0.96
11 1300 0.1 1.5 4.8
1.67
12 1400 0.2 1.5 6.56
1.103
13 1500 0.1 1.4 5.486
1.24
14 1600 0.2 1.3 6.32
Fig.4.Aluminium 6063T6 after machining
1.21
15 1700 0.1 1.2 5.96
1.84
16 1800 0.2 1.1 7.33
ANOVA for Response Surface Linear ModelAnalysis of variance table [Partial sum of
squares] on Ra :
P – value > F
Source Sum of squares Df Mean square F – value
0.0425
Model 0.93 3 0.31 3.71
A – Speed 0.2454
0.12 1 0.12 1.49
0.0084
B – Feed 0.83 1 0.83 9.91
0.5613
C - Depth of cut 0.030 1 0.030 0.36
Final Equation in Terms of Coded Factors: dimensional contour plots. The analysis values on the
data of Ra as plotted as per the given values and
Ra =+1.41+0.15 * A+0.23* B-0.072* C shown in the following diagrams. The residual graph
indicates that the decreases of the feed and depth of
Final Equation in Terms of Actual Factors: cut with the increase of speed will get the high
surface finish.
Ra=+0.26631+3.77608E-004*S+4.56384*F-
0.14438*D Design-Expert® Software
Ra Normal Plot of Residuals
Color points by value of
The Model F-value of 3.71 implies the model is Ra:
P r o b a b ility
1.93
significant. There is only a 4.25% chance that 0.85a 99
10
Response surfaces were developed for the empirical 5
In te r n a lly S tu d e n tiz e d R e s id u a ls
Design-Expert® Software Design-Expert® Software
Ra Residuals vs. Run Factor Coding: Actual Ra
Ra 0.20
Design Points
Color points by value of 3.00 1.93
Ra:
1.93 0.85
1.6
0.85
2.00 0.18
X1 = A: Speed
B : F e e d R a te
X2 = B: Feed Rate
Actual Factor
1.00 C: Depth of Cut = 1.00
0.15 1.4
0.00
-1.00
0.13
1.2
-2.00
0.10
-3.00 1200 1400 1600 1800 2000
1 4 7 10 13 16 A: Speed
0.85
The figure explains that the feed rate and speed on 1.5
Ra
1
the surface roughness of turning process has a
0.5
significant effect on Ra. It has been concluded that
higher feed rate and speed was increase the surface 0.20 2000
0.18 1800
ANOVA for Response Surface Linear ModelAnalysis of variance table [Partial sum of
squares] on Rz :
0.0006
B – Feed 10.29 1 10.29 20.98
0.8429
C - Depth of cut 0.020 1 0.020 0.041
Design-Expert® Software
Factor Coding: Actual Rz
Rz 0.20
Design Points
7.79
7
X1 = A: Speed 0.18
B : F e e d R a te
significant.There is only a 0.20% chance that a X2 = B: Feed Rate
Actual Factor
C: Depth of Cut = 1.00
Model F-Value" this large could occur due to noise. 0.15
4.15
8
X1 = A: Speed
Color points by value of X2 = B: Feed Rate
Rz:
Actual Factor 7
P r o b a b ility
Rz
95 5
90
4
80
70
0.20 2000
N o rm a l %
0.18 1800
50 0.15 1600
0.13 1400
B: Feed Rate A: Speed
30 0.10 1200
20
10
5
Fig.11.Feed rate vs. speed for Rz data on 3d view
1
VI. CONCLUSION
-2.00 -1.00 0.00 1.00 2.00 3.00 The operational design was carried out using
response surface methodology to reduce the number
Internally Studentized Residuals
of experiments and to achieve high accuracy results.
This process has been conducted to optimize the
Fig.9.Nominal plot residuals graph for Rz cutting parameters for turning of aluminium alloy
Al6063T6 on a CNC machine.
Surface interaction dimensional views and direct
effect views of feed rate and speed over surface In RSM following parameters like surface roughness,
roughness of Rz: peak to valley was determined by the optimum
The figure explains that the feed rate and machining parameters setting in the statistical
speed on the surface roughness of turning process has analysis we can conclude that
a significant effect. It has been concluded that
increases of feed rate and speed was increase the The lowest surface roughness value is optained for
surface roughness whereas decreases of feed rate and a parameter setting of speed 1400rpm, feed rate 0.1
speed was decrease the surface roughness. mm/min and depth of cut 0.7 mm (Ra=0.85)
The worst surface roughness value is optained for a
parameter setting of speed 1800 rpm, feed rate 0.2
mm/min, depth of cut 1.1 mm (Ra=1.84)
The lowest Rz value optained for a parameter 7. Doreswamy deepak, rajendra beedu,, multi
setting of speed 1400rpm, feed rate0.1mm/min, response optimization of process parameters
depth of cut 0.7 mm(Rz=4.14) using grey relational analysis for turning of al-
The highest Rz value is optained for a parameter 6061
setting of speed 1400 rpm, feed rate 0.2 mm/min,
depth of cut 0.1 mm (Rz=7.79) 8. Rohit angiras, onkar singh bhatia,, analysis of
surface roughness during turning operation of
VII. REFERENCES aluminium-6063 using taguchi approach,
international journal of advance research in
1. V. Devkumar, e. Sreedhar, m.p. Prabakaran ,
science and engineering, ijarse, vol. No.4, issue
optimization of machining parameters on al
06, june 2015
6061alloy using response surface methodology ,
ijar 2015; 1(7): 01-04 9. Ranganath m. S, vipin, r. S. Mishra, prateek,
nikhil, optimization of surface roughness in
2. J. Paulo davim and francisco mata , influence of
CNC turning of aluminium 6061 using taguchi
cutting parameters on surface roughness in
techniques, ijmer / issn: 2249–6645 /vol. 5 /iss.
turning glass-fiber-reinforced plastics using
5 / May 2015 / 42.
statistical analysis, industrial lubrication and
tribology volume 56 · number 5 · 2004 · pp. 270– 10. B.Radha Krishnan, Dr.G.Senthilkumar, Review
274 of prediction of surface roughness in machine
vision system by using various parameter.
3. C.a. Conceicao antonio, andj.p. Davim, optimal
machining parameters based on
surface roughness experimental data and genetic
search, industrial lubrication and tribology 57/6
(2005) 249–254