AIJREAS VOLUME 3, ISSUE 12 (2018, DEC) (ISSN-2455-6300)ONLINE
Anveshana’s International Journal of Research in Engineering and Applied Sciences
OPTIMIZATION OF PROCESS PARAMETERS IN MACHINING OF 6063
ALUMINIUM ALLOY USING RSM
SHAIK MD ADIL HUSSIAN [Link],
Master of Technology in CAD/CAM Asst. Professor
Indira Institute of technology and science Indira Institute of technology and science
Abstract: Turning is the process whereby a single
Due to global competition in manufacturing point cutting tool is parallel to the surface.
industries scenario the conventional machining It can be done manually, in a traditional
processes have been replaced by advanced non-
form of lathe, which frequently requires
conventional machining process. Several advanced
non-conventional machine tools are available continuous supervision by the operator,or
specifically computer numerical control (CNC) by using a computer controlled and
turning is the major used machine tool in metal automated lathe which does not. This type
based industries. Now days, due to the increasing of machine tool is referred to as having
demand of the higher precision components for its
computer numerical control, better known
functional aspect, surface roughness of a machined
part plays an important role in the modern as CNC, and is commonly used with many
manufacturing process. To get the minimum other types of machine tool besides the
surface roughness various turning parameter like lathe. When turning, a piece of material
cutting speed, depth of cut, feed rate, metal (wood, metal, plastic even stone) is rotated
removal rate (MRR) and tool geometry etc. are
and a cutting tool is traversed along 2 axes
required among all these parameter optimal
parameter are determined by using various of motion to produce precise diameters
optimization techniques. Productivity as well as and depths.
quality both has a similar impact on final product. Overview of Wire
This paper describes various optimization studies EDM Wire EDM (Vertical EDM's kid
and the literature review for the influence of CNC
brother), is not the new kid on the block. It
turning parameter on surface roughness as well as
other response variables.
was introduced in the late 1960s', and has
1.0 Introduction revolutionized the tool and die, mold, and
Aluminum alloys are contains the typical metalworking industries. It is probably the
alloy elements such as copper, magnesium, most exciting and diversified machine tool
manganese, silicon and zinc and in which developed for this industry in the last fifty
aluminum is the predominant metal. Here years, and has numerous advantages to
aluminum 6063 is the work piece material offer. WEDM is a spark erosion process
and CCMT is cutting tool. The main used to produce complex two and three
properties of aluminum are light weight, dimensional shapes through electrically
strength, recyclability corrosion resistance, conductive work pieces. The wire does not
durability, formability, ductility and touch the work piece, so there is no
conductivity which make them valuable physical pressure imparted on the work
material. Surface roughness is one of the piece compared to grinding wheels and
importantrequirements in milling cutters.
machiningprocess. 2.0 literature review
Turning P. Saha, D. Tarafdar, (2009)In this paper,
an attempt has been made to machine Al
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6063/ ZrSiO4 (p) metal matrix composite machined parts/components. So, it
using wire electric discharge machining. required focusing on material removal rate
The objective is to investigate the and surface roughness .Critical quality
influence of process parameters namely measure and surface roughness in
pulse on time, pulse off time, peak current mechanical parts depends on process
and servo voltage on dimensional parameter during machining parameter.
deviation. A Box-Behnken design E. Hamed, A. Sarkar (2001) This paper
approach of response surface methodology presents the effect of process parameter in
(RSM) is used to plan and analyze the turning operation to predict surface
experiments. roughness. The turning process by using
N.G. Patil, P.K. Brahmankar CNC turning lathe is widely used in
(2010)Every manufacturing industry aims industry because of its versatility and
at producing a large number of products efficiency. Applications of the turning
within relatively lesser time. This study process can be found in many industries
applies Taguchi design of experiment ranging from large engine manufactures to
methodology for optimization of process small die shops. The parameters that affect
parameters in turning of Aluminium Alloy the turning operation are vibration, tool
7075 using tungsten coated carbide tool. wear, surface roughness etc
Experiment have been carried out based on 3.0 Methodology
L27 standard orthogonal array design with A wire EDM machine (Sprintcut 734) was
three process parameters namely Cutting utilized for test examination. This machine
Speed, Feed, Depth of Cut for Material gives full scope of adaptability to the
removal rate and Machining time. administrator in choosing parameters
A. Shah, N.A. Mufti, (2010)Wire- esteems. The settled procedure parameters
Electrical Discharge Machining (WEDM) are: Workpiece: Aluminum amalgam
is an extremely accurate machining 6063, Cathode: 0.25mm Ø metal wire,
process. It can produce a smooth surface workpiece tallness: 15mm, cutting length:
finish as the wire is able to go through the 100mm, dielectric conductivity: 20mho,
entire part and the accuracy can be dielectric temperature: 20- 24°C. Table 1
achieved until ×0.0001 inches. WEDM is demonstrates the huge control factors,
also very effective in machining of small their units and breaking points.
holes, blind holes, inclined holes, irregular
holes and deep holes. Aluminium 6063 is Table Optimal Ranges of Significant
perhaps the most widely used workpiece Process Parameters
because of its extrudability. Real Unit Paramete Lowe Uppe
S.K. Garg, A. Manna, A. Jain (2016) facto r Name r r
Turning is one of the widely used r Limit Limit
machining processes for various purposes. Ton Pulse µs 100 104
The purpose of turning operation is to on
produce low surface roughness of the Time
parts. In a global competitive environment Toff Pulse µs 40 60
every industry are trying to reduce the off
cutting cost and improved the quality of time
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Anveshana’s International Journal of Research in Engineering and Applied Sciences
WF Wire m/min 6 12 The work material used as the test
Feed specimen was Aluminium 6063. A
SV Servo V 45 75 cylindrical bar of Aluminium alloy
Voltag (320mm long 60 mm diameter) was used
e for the tests.
Tool Material
Experimental set-up: Tungsten carbide inserts were used for the
A Kistler force three component turning tests. These inserts are
dynamometer (Type 9215A1, calibrated manufactured by Sandvik. Uncoated
range: Fx.0±5000 N,Fy.0±5000 N, and carbide inserts as per ISO specification
Fz.0±3000 N) in conjunction with three THN SNMG 08 were clamped onto a tool
Kistler charge amplifiers (Type 5070), holder with a designation of DBSNR
used to convert the dynamometer output 2020K 12 for turning operation. The
signal into a voltage signal appropriate for parameter levels were chosen within the
the data acquisition system, and a intervals based on the recommendations by
computer were used to measure and record the cutting tool manufacturer.
the cutting forces. The instrument shown Design of Experiment
in figure 1 is a Kistler three component A commercial statistical analysis software
dynamometer and the figure is a multi- “Design Expert” was employed for design
channel charge amplifier. of experiment. In Design Expert, RSM is
used to find a combination of factors
which gives the optimal response. RSM is
actually a collection of mathematical and
statistical technique that is useful for the
modeling and analysis of problems in
which a response of interest is influenced
by several variables and the objectives is
to optimize the response. Three process
Figure:Kistler Three component parameters at three levels led to a total of
Dynamometer 27 tests for turning operation. Three levels
were specified for each of the factors as
Thermocouples are known to be very indicated in Table. The standard
popular transducers for measuring orthogonal array chosen was L27, which
temperature. The k-type thermocouple was has 27 rows and 26 degrees of freedom.
chosen for measuring the temperature in Table Factors and Levels
this work. This technique was preferred as Factor Assignme Levels
it is inexpensive, easy to calibrate, has a nt Lev Lev Lev
quick response time and good repeatability el 1 el 2 el 3
during experiments. A mineral insulated, Speed(N) A 100 150 200
metal sheathed, k-type thermocouple with m/min
Digital micro voltmeter of ranges between Depth of B 0.25 0.5 1
-200°C and 1200°C. cut(d)mm
Work Material Feed C 0.05 0.07 0.1
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rate(f)mm/r 5
ev
Taguchi Approach
Taguchi method uses a loss function to
determine the quality characteristics. Loss
function values are also converted to a
signal-to-noise (S/N) ratio η. The term
“signal” represents the desirable value
(mean) for output characteristic and the
term “noise” represents the undesirable
value for the output characteristic.
Usually there are three categories of the
performance characteristic in the analysis
of the S/N ratio, that is, the lower-the-
better, nominal-the-better and the Figure Aluminium 6063T6 after
higher-the-better. The S/N ratio for each machining
level of process parameters is computed 4.0 Analysis of micro-hardness
based on the S/N analysis. The optimal The micro-hardness testing as carried out
level of the process parameters is the level on different welded specimens. Figure 2
having highest S/N ratio. and table 4 showing that the most
influencing factor for the hardness
property is welding voltage at higher level
(50 V) of voltage. The second affecting
factor is root gap at its first level i.e. 0.5
mm, third affecting factor is welding
current at its second level (70 A), and
finally the last affecting factor is gas flow
rate at its first level (16 litter/min). To
validate the above result analysis of
variance (ANOVA) was applied which is
Aluminium 6063T6 before machining
presented in table.
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V 1 42.94 42.93 6.44 0.02
6 6
R 1 37.95 37.94 5.69 0.03
8 4
G 1 0.44 0.440 0.07 0.80
2
Squa 4 1316. 329.2 49.3 0.00
re 81 04 7 00
A series of experiments have been carried
out with variation of different parameters.
After completing the experiments
according to design of experiment a
Graph: Main effects plot for SN ratios statistical analysis was done for the
for hardness property experimental data obtained which are
R 2 (Coefficient of determination) shown in table from the L27 experiments.
is used to check the goodness of the The average performance and S/N ratio
model; it determines how close the were calculated for surface roughness.
predicted values with the experimental Analysis of variance (ANOVA) was
values [6,14]. The values of R 2 are performed to identify the most significant
mentioned in Table, for the hardness value control parameter and to quantify their
R-sq = 97.13 and R- sq (adj) = 96.27. This effects on surface roughness.
value indicates the goodness of designed Table Surface Roughness and S/N ratio
model at states that designed model is according to Design of Experiment
valid for the further investigation. Spee Feed Dept Ra S/N
Table Response table for S/N ratio of d (mm/rev h of (µm) Ratio
hardness value (rpm) ) Cut
Level Current Voltage Root Gas (mm)
Gap flow 1500 0.15 0.1 2.495 -
rate 4 7.942
1 40.72 39.96 42.14 41.12 8
2 41.36 41.30 40.38 41.07 1500 0.15 0.3 1.050 -
3 41.08 41.92 40.68 40.87 7 0.429
Delta 0.64 1.95 1.77 0.25 6
Rank 3 1 2 4 1500 0.15 0.6 1.109 -
Table Analysis of variance Hardness 9 0.905
Sour DO Adj Adj F- P- 7
ce F SS MS Valu Valu 1500 0.25 0.1 2.430 -
e e 7 7.714
Line 4 2851. 712.8 106. 0.00 6
ar 57 9 91 1500 0.25 0.3 2.444 -
I 1 102.1 102.1 15.3 0.00 0 7.762
5 54 2 2 0
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AIJREAS VOLUME 3, ISSUE 12 (2018, DEC) (ISSN-2455-6300)ONLINE
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Table ANOVA for surface roughness
Sour D Se Ad Adj F P %
ce O q j MS contr
F SS SS ibuti
on
Spe 2 2.9 2.6 1.3 2. 0. 6.66
ed 65 68 341 7 1 376
1 2 1 2
6
Fee 2 22. 21. 10. 2 0. 50.9
d 68 14 573 1. 0 7953
38 63 15 4 0
8 1
Doc 2 0.1 0.1 0.0 0. 0. 0.25
11 06 533 1 8 0585
5 7 5 1 9
9 4.1.3 Graph S/N Response Graphs for
spee 4 7.4 5.6 1.4 2. 0. 16.6 Surface Roughness
d*fe 17 74 185 8 0 7008 Conclusion:
ed 5 0 8 9 The revelations from the past data for over
5 two decades prove that Computer
spee 4 3.2 3.6 0.9 1. 0. 7.20 Numerical Controlled (CNC) machine
d*d 07 38 096 8 2 8305 plays an important role in advanced
oc 4 6 5 5 1 manufacturing industries. Productivity as
3 well as product quality also plays a vital
role in competitive manufacturing. After
literature review major three factors like
cutting speed, depth of cut and feed rate
are more responsible for surface roughness
because finally that parameter gives the
surface quality of CNC turning work-
piece. In this situation the selection of
optimization method and determination of
optimum machining parameter condition is
very crucial. Hence this paper provide a
package round study about the effect of
turning process parameter on surface
roughness of CNC turning work-piece and
their measurement methods as well as
process parameters optimization
techniques (Taguchi techniques has been
used regularly to optimize the process
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parameter). The analysis has highlighted
certain point: Genesis of analysis points
out that the following techniques have
been adopted for optimization of turning
process parameter:
References:
[1] P. Saha, D. Tarafdar, S.K. Pal, Modelling of
wire electrodischarge machining of Tic/Fe in situ
metal matrix composite using normalized RGFN
with enhanced K-means clustering technique, Int.
J. Adv. Manuf. Technol. 43 (2009) 107–116.
[2] N.G. Patil, P.K. Brahmankar, Some studies
into wire electro-discharge machining of alumina
particulate reinforced aluminium matrix
composites, Int. J. Adv. Manuf. Technol. 48 (2010)
537–555.
[3] A. Shah, N.A. Mufti, D. Rakwal, E. Bamberg,
Material removal rate, kerf, and surface roughness
of tungsten carbide machined with wire electrical
discharge machining,J. Mater. Eng. Perform. 20
(1) (2010) 71–76.
[4] S.K. Garg, A. Manna, A. Jain, Experimental
investigation of spark gap and material removal
rate of Al/ZrO2 (P)- MMC machined with wire
EDM, J. Braz. Soc. [Link]. Eng. 38 (2) (2016)
481–491.
[5] R.T. Yang, C.J. Tzeng, Y.K. Yang, M.H. Hsieh,
Optimization of wire electric discharge machining
parameters for cutting tungsten, Int. J. Adv. Manuf.
Technol. 60 (2011) 135–147.
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