Application of Taguchi technique for Analysis of Forces and surface finish during Hard Machining of Steel EN-24 using Ceramic tool insert

The objective of this paper is to obtain optimal setting of turning process parameters cutting speed, feed rate and depth of cut resulting in an optimal value of Feed force, Tangential force & Surface roughness while machining hardened EN-24 steel with ceramic tool insert. The effect of the selected process parameters on the feed force, tangential force and surface roughness have been accomplished using Taguchi’s design of experiments approach. The results indicate that the selected process parameters significantly affect the mean & variance of feed force, tangential force and surface roughness. The percent contributions of parameters in the ANOVA table for Feed force (Fx) for Depth of cut (86.67%) has a major contribution than that of cutting speed (2.29%) and Feed rate (0.89%). Tangential force (Fy), Depth of Cut (81.47%) has a major contribution than that of Feed rate (15.24%) and Cutting speed (0.96%). Similarly the Surface roughness (Ra), has Depth of cut (58.97%) has a major contribution than that of Cutting speed (24.85%) and Feed rate (13.21%). In all these cases the interactions are not having any major contributions. The predicted optimum Feed force, Tangential force and Surface roughness are-100N, 230N and 0.96 μm. The results have been validated by the confirmation of experiment and found to be with in the range of these values

Optimization of feed force, tangential force and surface roughness by using grey based Taguchi method

This study investigated the optimization of turning process parameters such as cutting speed, feed rate and depth of cut on EN-19 material using the Grey Relational Analysis (GRA) method. Twenty seven experimental runs based on an orthogonal array of Taguchi method were performed. The feed force (F X), tangential force (FY) and surface roughness (R a) were selected as the quality targets. An optimal parameter combination of the turning operation was obtained using GRA. By analyzing the grey relational grade matrix, the degree of influenced for each controllable process factor onto individual quality targets can be found. The depth of cut is identified to be the most influence on feed force and tangential force, and feed rate is the most influential factor to the surface roughness. Additionally, the analysis of variance (ANOVA) was also applied to identify the most significant factor; the depth of cut is the most significant controlled factor for the turning operation according to the weighted sum grade of the feed force, tangential force and surface roughness

Analysis and Prediction of feed force, tangential force, surface roughness and flank wear in Turning with uncoated carbide cutting tool using both Taguchi and Grey based taguchi method

The aim of the present study is to investigate the effects of process parameters (cutting speed, feed rate and depth of cut) on performance characteristics (tangential force, feed force, surface roughness and flank wear ) in turning of EN-19 steel with uncoated carbide cutting tool. Experiments are designed and conducted based on Taguchi's L27 orthogonal array carried out under dry cutting conditions for tangential force, feed force and surface roughness, whereas for the flank wear the experiments are conducted as per L9 orthogonal array. The responses are feed force, tangential force, surface roughness and flank wear were recorded for each experiment The depth of cut was identified as the most influential process parameters in the responses of both tangential force and feed force. The feed rate was identified as the most influential process parameter on the surface roughness, while the cutting speed has a significant contribution for flank wear. Grey relational analysis is used to optimize the multi-performance characteristics to minimize the tangential force and surface roughness. The feed rate was identified as the most influential process parameter in the responses of both tangential force and surface roughnes

Analysis of Forces and Surface Roughness on Hardened steel with uncoated ceramic insert using Taguchi Technique

The objective of this paper is to analyze the influence of various turning process parameters such as cutting speed, feed rate and depth of cut on the Feed force, Tangential force & Surface roughness while machining hardened EN -353 steel with uncoated ceramic insert. The effect of the selected process parameters on the Feed force (FX), Tangential force (FY) and Surface roughness (Ra) have been accomplished using Taguchi’s design of experiments approach. The results indicate that the selected process parameters significantly affect the mean & variance of Feed force, Tangential force and Surface roughness. The percent contributions of parameters in the ANOVA table for Feed force (FX) for the depth of cut (87.99%) has a major contribution than that of feed rate (2.82 %) and the cutting speed (4.45%). Tangential force (FY), the depth of cut (81.56%) has a majo r contribution than that of cutting speed (3.8%) and feed rate (9.87%). Similarly the Surface roughness (Ra), has depth of cut (59.59%) has a major contribution than that of cutting speed (23.67%) and feed rate (4.64%). In all these cases the interactions are not having any major contributions

Effect of corner radii on the thermal & fluid flow performance of the laminar flow through rectangular micro channel

Metallic micro channels have the advantage of high thermal conductivity to strength ratio. The recent advances in the manufacturing processes, has increased the feasibility of realizing metallic micro channels with close dimensional control. Presently, various types of micro manufacturing processes are available for the realization of the metallic micro channels. However it is not practical to manufacture any dimensional feature with sharp corner. Depending on the choice of the manufacturing process, the corners get rounded to varying degree. When compared with the dimensions of micro channels the magnitude of the corner radius is considerable. In this paper an attempt has been made to study numerically the effect of corner radius on the performance of the micro channels. Commercially available computational fluid dynamics software ANSYS CFX was used for the simulation of micro channels performance. The thermal & fluid flow performance of the micro channel was simulated by varying the corner radius from 50 microns to 200 microns. The coolant flow velocities were varied from 0.48m/s to 1.27m/s. The Temperature dependent material properties have been used in the analysis. The simulation results were validated using published literature

Experimental & numerical study of forced convection laminar flow through copper micro channel heat sink

A rectangular micro channels having 500 microns width & 1500 microns depth have been machined out of Oxygen free high conductivity Copper material on an area of 12.5mm X25mm. De-ionized water was used as a coolant. The thermal & fluid flow performances have been tested for the flow velocities ranging from 0.5m/s to 1.2m/s. Micro channels performances have been numerically simulated using commercially available computational fluid dynamics software ANSYS CFX. The simulated results have been validated with the experimental results and published literature . The effects of Temperature dependent material properties on simulation have been examine

Analysis of Feed force, Tangential Force and Surface Roughness in Turning EN-353 Steel using uncoated ceramic cutting tool using Taguchi Method

The aim of the present paper is to investigate the effects of process parameters (cutting speed, feed rate and depth of cut) on performance characteristics (feed force, tangential force and surface roughness) in turning of EN-353 steel using uncoated ceramic cutting tool inserts. Experiments are designed and conducted based on Taguchi L9 orthogonal array carried out under dry cutting conditions for feed force, tangential force and surface roughness. The responses such as feed force, tangential force and surface roughness were recorded for each experiment. The depth of cut was identified as the most influential process parameters in the responses of both feed force and tangential force. The feed rate was identified as the most influential process parameter on the surface roughness

Experimental and Computational Simulation of producing ultra-fine grain Structure processed by CGP

In this research the constrained groove pressing (CGP) process as a severe plastic deformation (SPD) method was applied on commercially pure aluminum plates. According to the principle of CGP, a material is subjected to repetitive shear deformation by utilizing asymmetrically grooved dies and flat dies which are constrained by a channel. Each complete groove pre ssing pass consists of four pressing operation steps. Considering the geometry of the die, in each complete pass, a large amount of strain is induced into the specimen. In the present research the effects of the deformation passes on the mechanical propert ies of the specimens were tested by micro hardness tests. In addition, in order to investigate the material flow along the grooves in the CGP process, the finite element simulations were carried for one of the process. Our pproach involves computational simulation of the entire synthesis process for the optimization. Results show that the flow stress of the material and its hardness are affected by the number of passes. Post process of the finite element analysis showed that the real state of the CGP process is a combination of plane stress and plane strain conditions