In the present study, response surface methodology (RSM) has been used to optimize roller burnishing process for aluminum alloy 63400 grade. Single roller burnishing tool (carbide) is used to burnish round aluminum alloy. Experiments were performed with Box and Wilson Central Composite Design (CCD). The machining factors controlled during experimentation are speed, feed, force and number of tool passes. The response parameters are surface roughness and microhardness. The most significant control factors on the surface roughness and microhardness were determined by analysis of variance (ANOVA). A controllable process parameter is correlated with surface roughness and microhardness by mathematical model. A quadratic regression analysis is performed to compute the correlation coefficient between the experimental and predicted values. The optimum surface roughness and microhardness foreseen by the model is found to agree well with the results of the experiment. To find the optimum value of both the response, desirability approach was used. The input parameters with most desirability value are selected as the optimum solution. Hence, the most desirable burnished condition desirability value 0.872 is speed 37.9[Formula: see text]m/min, feed 0.5[Formula: see text]mm/rev, force 35.49[Formula: see text]N and number of tool passes four. Surface roughness obtained is 0.524[Formula: see text][Formula: see text] m and microhardness is 125.02[Formula: see text]HV. This is the optimum condition for minimum surface roughness and maximum microhardness. The optimum surface finish and microhardness predicted by the model are found to agree well with the results of the experiment.
Automated Differential Multi-gauging system is a very complicated and critical tool to measure some casting and machining parts. Hypoid pinion assembly has two taper rollers bearing with assembly play or gap. The differential assembly checking will be on three stages as P is housing and Q is hypoid pinion and the gap between both parts. The differential multi-gauging system needs to evaluate and analyse these critical parameters firmly is very important. So, after manufacturing and assembly of these automated differential multi-gauging system analysis confirmed by Gauge repeatability and reproducibility i.e. GRR. For the GRR method, we can take multiple experiments on the machine as many trials with the different number of parts and operator then that data will be analysed through this method. After analysing the result and accuracy of the measurement system by repeatability trials. The GRR results will be below 10 % is required then and then the only gauging system is Acceptable. The GRR will generate proper graphs and report which shows how multigauging system will ready to take thousands of parts checking accurately and precisely in the industry. This research will help anyone to how to analyse and evaluate the multi-gauging system result through GRR.
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