Optimization of Cutting Process Parameters on AL6061 Using ANOVA and TAGUCHI Method

B, Niranjan D; Shivashankar, G.S.; Rao, K. Ramachandra; Praveen, R.

doi:10.1016/j.matpr.2017.08.037

Cited by 23 publications

(11 citation statements)

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“…Similar findings and studies are also conducted by (Ficici 2020) and (Abukhshim, Mativenga, and Sheikh 2006). Likewise, (Niranjan et al 2017) experimental on cylindrical rods using the Taguchi method and Analysis of Variance (ANOVA) eventually found R. Lubin Raj, et al: Innovative optimization of feed and spindle speed levels for surface roughness and cylindricity tolerance of the drilled holes in liquid stir casted Al6061 hybrid composite reinforced with 15% weight fraction of SiC+Fly ash and comparing the above results with as-cast Al6061…”

Section: Discussionsupporting

confidence: 72%

Innovative optimization of feed and spindle speed levels for surface roughness and cylindricity tolerance of the drilled holes in liquid stir casted Al6061 hybrid composite reinforced with 15% weight fraction of SiC+Fly ash and comparing the above results

2022

pnr

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Aim: The motive of this research is to optimize the feed and spindle speed levels based on surface roughness and cylindricity tolerance values of the drilled holes in liquid stir casted aluminium hybrid metal matrix composite reinforced with a 15% weight fraction composed of 7.5% silicon carbide and 7.5% fly ash and compare the results with pure as-cast Aluminium 6061. Materials and Methods: For g power calculations (threshold level: 0.20, confidence interval: 80%) gives a sample size of 39. Samples of dimensions 150mm x 150mm and thickness 10mm are fabricated using the stir casting method under controlled process parameters adhering to standards. On each sample, 13 holes with 13 different combinations of feed and spindle speed derived using the RSM method are drilled using an uncoated HSS drill bit of 10mm diameter. Cylindricity tolerance and Surface Roughness values were taken on the cylindrical inner surface of the holes on samples from both the experimental group (AHMMC) and control group (As-cast AL6061). Results: With the help of Design-Expert, the effect of feed and spindle speed on surface roughness and cylindricity tolerance is examined and the optimum value for feed rate and spindle speed to reduce the surface roughness [6.8%] and cylindricity tolerance [7.2%] of the drilled holes is found with an insignificance level of 0.4485 (p>0.05). Conclusion: Within the limitations of this study, It is revealed that AHMMC with a 15% weight fraction of SiC+Fly ash exhibits optimum surface roughness and cylindricity tolerance for the speed of 945 rpm and feed rate of 0.09 mm/rev.

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Section: Discussionsupporting

confidence: 72%

Innovative optimization of feed and spindle speed levels for surface roughness and cylindricity tolerance of the drilled holes in liquid stir casted Al6061 hybrid composite reinforced with 15% weight fraction of SiC+Fly ash and comparing the above results

2022

pnr

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“…This standard structural alloy is one of the most versatile heat-treated alloys, popular for high and medium impact applications, with good impact resistance. Alloy 6061 has excellent corrosion resistance in ambient conditions and good corrosion resistance in seawater, good finishing characteristics [16], and it reacts well to anodizing, welding, and various commercial methods of coupling. Lazzaro and Atzori [17] demonstrated that Alloy 6061 has adequate machinability characteristics in the heat-treated condition.…”

Section: Introductionmentioning

confidence: 99%

Artificial Intelligence Monitoring of Hardening Methods and Cutting Conditions and Their Effects on Surface Roughness, Performance, and Finish Turning Costs of Solid-State Recycled Aluminum Alloy 6061 Сhips

Abbas

Pimenov

Ердаков

et al. 2018

Metals

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Aluminum Alloy 6061 components are frequently manufactured for various industries-aeronautics, yachting, and optical instruments-due to their excellent physical and mechanical properties, including corrosion resistance. There is little research on the mechanical tooling of AA6061 and none on its structure and properties and their effects on surface roughness after finish turning. The objective of this comprehensive study is, therefore, to ascertain the effects of both the modern method of hardening AA6061 shafts and the finish turning conditions on surface roughness, Ra, and the minimum machining time for unit-volume removal, T m , while also establishing the cost price of processing one part, C. The hardening methods improved both the physical and the mechanical material properties processed with 2, 4, and 6 passes of equal channel angular pressing (ECAP) at room temperature, using an ECAP-matrix with a channel angle of 90 •. The reference workpiece sample was a hot extruded chip under an extrusion ratio (ER) of 5.2 at an extrusion temperature of 500 • C (ET = 500 • C). The following results were obtained: grain size in ECAP-6 decreased from 15.9 to 2.46 µm, increasing both microhardness from 41 Vickers hardness value (HV) to 110 HV and ultimate tensile strength from 132.4 to 403 MPa. The largest decrease in surface roughness, Ra-70%, was obtained turning a workpiece treated with ECAP-6. The multicriteria optimization was computed in a multilayer perceptron-based artificial neural network that yielded the following optimum values: the minimal length of the three-dimensional estimates vector with the coordinates Ra = 0.800 µm, T m = 0.341 min/cm 3 , and C = 6.955 $ corresponded to the optimal finish turning conditions: cutting speed v c = 200 m/min, depth of cut a p = 0.2 mm, and feed per revolution f r = 0.103 mm/rev (ET-500 extrusion without hardening).

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“…This model can be used to accurately measure temperature at the drill point. Niranjan et al [ 16 ] conducted a study to analyse the effect of parameters such as cutting speed, feed rate, and depth of cut on the turning operation of AA6061 T6 rods which are precipitation hardened. The optimum surface completion and material expulsion rate were determined using contour plots.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Cutting Process Parameters in Inclined Drilling of Inconel 718 Using Finite Element Method and Taguchi Analysis

2020

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Nickel-based superalloys are famous in the demanding applications. Inconel 718 is one of the most commonly used nickel-based superalloys due to its extraordinary inherent properties. Inconel 718 is a suitable material for high temperature applications due to the properties such as anti-oxidization, high hot hardness, high creep, and fatigue strength. Drilling operation is one of the most widely used manufacturing operations in almost all industrial sectors. However, drilling operation is very complex in nature due to the presence of intricate geometry of the drill bit. In conventional drilling, cutting is performed by the combined action of the chisel edge and the two or more cutting lips. In depth analysis of the cutting process shows that chisel edge starts with an indentation at the center of the twist drill. Then away from the center, chisel edge performs orthogonal cutting with negative rake angle. Whereas, cutting action at the cutting lip is oblique in nature, and force analysis involves the use of element formulation due to involvement of radius. It is rarely found in the literature where drilling operation at different inclination angles is conducted and analyzed. The presented study numerically investigates the cutting performance of drilling operation, when operated at different inclination angles. The study revealed cutting force variation at different inclination angles due to the different tool workpiece engagement for each inclination. The magnitude of thrust force increased when inclination angle is changed from 30° to 60°. It can be linked with the higher chip load initially in this case as compared to the 30° inclination angle. The cutting temperature was affected by spindle speed (53.7%), followed by feed rate (33.31%) and inclination angle (3.44%).

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Optimization of Cutting Process Parameters on AL6061 Using ANOVA and TAGUCHI Method

Cited by 23 publications

References 0 publications

Innovative optimization of feed and spindle speed levels for surface roughness and cylindricity tolerance of the drilled holes in liquid stir casted Al6061 hybrid composite reinforced with 15% weight fraction of SiC+Fly ash and comparing the above results

Innovative optimization of feed and spindle speed levels for surface roughness and cylindricity tolerance of the drilled holes in liquid stir casted Al6061 hybrid composite reinforced with 15% weight fraction of SiC+Fly ash and comparing the above results

Artificial Intelligence Monitoring of Hardening Methods and Cutting Conditions and Their Effects on Surface Roughness, Performance, and Finish Turning Costs of Solid-State Recycled Aluminum Alloy 6061 Сhips

Optimization of Cutting Process Parameters in Inclined Drilling of Inconel 718 Using Finite Element Method and Taguchi Analysis

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