International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue: 03 | Mar 2024
p-ISSN: 2395-0072
www.irjet.net
Parametric Optimization of CNC End Milling Process Using Taguchi Method T. Nishkala1*, K. Sai Sowmya1, C. Gnana Prasad1, K. Jagdeesh1, N. Narasimha Mohith1, CH. Shyam Sai1 1Department of Mechanical Engineering, Annamacharya Institute of Technology & Sciences, Tirupati, India
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Abstract - Selection of optimum process cutting conditions
helps to improve the performance of any manufacturing process. In the present work, a study was made to know the impact of cooling method type and process parameters on milling process performance during NC machining of Al 5082 material using Taguchi technique. In milling process, cutting speed, feed rate and depth of cut were taken as milling process variables and cutting temperature (CT), surface roughness (Ra) and material removal rate (MRR) were considered as outputs. Taguchi L9 orthogonal array (OA) experimental design plan was consider for carrying out the experiments. From, the obtained results, optimum process variables were selected for all the output characteristics and observed substantial improvement in the milling process performance at the Taguchi determined optimum conditions respectively. Key Words: Al 5082 Material; Milling Process; Taguchi Method; Cutting Temperature; Surface Roughness; Material Removal Rate
1. INTRODUCTION In today's manufacturing market, quality and productivity are crucial factors. From the perspective of the consumer, quality is crucial since it impacts how satisfied the consumer will be. In addition to quality, productivity is another crucial factor that exists and is closely linked to both the growth and profitability of an industry. Every manufacturing company wants to produce more goods within a shorter time. Productivity can be maximized by having sound knowledge of all the optimization techniques for machining. Among various types of milling processes, end milling is one of the most important and common metal cutting techniques used for machining parts because of its capability to remove materials quickly with a decent good surface quality. Also, it is capable of producing a variety of configurations using milling cutter. Additionally, it may use a milling cutter to produce a range of designs. Computer numerically controlled (CNC) machine tools have been used recently to automate the milling operation completely. It reduces the need for operator input, boosts production, and improves the quality of machined products. These factors have led to the recent discovery that the CNC end milling technique is a very flexible and useful machining operation in the majority of modern manufacturing industries. The © 2024, IRJET
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Impact Factor value: 8.226
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automation of the final milling process is not the only accomplishment. For machining to be effective and to meet industry needs, it is also essential to continuously enhance the machining process and machining performances. Surface roughness is a key factor in the machining process while considering machining performance and that is why in many cases, industries are looking for maintaining the good surface quality of the machined parts. Surface roughness is a major determinant of production cost and quality and a gauge of a product's technological quality. It explains the geometry of the machined surface and, when paired with surface texture, can significantly impact the operational characteristics of the part. On the other hand, another crucial element that significantly affects production rate and cost is material removal rate (MRR), which shows the work piece's processing time. Therefore, a tool that will enable the assessment of the material removal rate (MRR) and surface roughness prior to part machining is required. This tool should also be simple to use on the production floor, helping to reduce time and expense requirements while producing the desired surface quality. Changes in the cutting process parameters result in significant variations in both surface roughness and material removal rate. For this reason, accurate process parameter selection is also important with its prediction to obtain good surface finish (lower Ra value) and higher material removal rate in CNC end milling process. Liao et al. (2007) found that MQL is the feasible cooling technique while high speed milling of NAK80 hardened steel over dry and wet condition. Da Silva et al. (2011) performed milling experiments on AISI 1047 steel with coated tungsten carbide tools under flood, reduced fluid flow rate (250 ml/min) and MQL. It was reported that reduced fluid flow rate significantly increased the cutting length and MRR due to the prevention of chipping tool wear mechanism when compared to other conditions respectively. Asiltürk and Akkuş ( 2011) determined the optimum cutting condition for achieving low Ra and Rz using Taguchi optimization techniques while dry turning of AISI 4140. Zhang et al. (2012) while end milling Inconel 718, used MQCL hybrid cooling approach. MQCL involves a combination of micro droplets of vegetable-based coolant along with cryogenic compressed air. Tool life and cutting force were taken as investigative outputs under MQCL and dry cutting conditions. Experimental results showed that
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