Research Papers

Multiresponse Optimization of Al Alloy-SiC Composite Machining Parameters for Minimum Tool Wear and Maximum Metal Removal Rate

[+] Author and Article Information
Rajesh Kumar Bhushan

Assistant Professor
Shri Mata Vaishno Devi University,
Katra, Jammu, Jammu and Kashmir,
182320, India e-mail: rkbsmvdu@gmail.com

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received June 25, 2012; final manuscript received January 3, 2013; published online March 22, 2013. Assoc. Editor: Robert Landers.

J. Manuf. Sci. Eng 135(2), 021013 (Mar 22, 2013) (15 pages) Paper No: MANU-12-1186; doi: 10.1115/1.4023454 History: Received June 25, 2012; Revised January 03, 2013

Optimization in turning means determination of the optimal set of the machining parameters to satisfy the objectives within the operational constraints. These objectives may be the minimum tool wear, the maximum metal removal rate (MRR), or any weighted combination of both. The main machining parameters which are considered as variables of the optimization are the cutting speed, feed rate, depth of cut, and nose radius. The optimum set of these four input parameters is determined for a particular job-tool combination of 7075Al alloy-15 wt. % SiC (20–40 μm) composite and tungsten carbide tool during a single-pass turning which minimizes the tool wear and maximizes the metal removal rate. The regression models, developed for the minimum tool wear and the maximum MRR were used for finding the multiresponse optimization solutions. To obtain a trade-off between the tool wear and MRR the, a method for simultaneous optimization of the multiple responses based on an overall desirability function was used. The research deals with the optimization of multiple surface roughness parameters along with MRR in search of an optimal parametric combination (favorable process environment) capable of producing desired surface quality of the turned product in a relatively lesser time (enhancement in productivity). The multi-objective optimization resulted in a cutting speed of 210 m/min, a feed of 0.16 mm/rev, a depth of cut of 0.42 mm, and a nose radius of 0.40 mm. These machining conditions are expected to respond with the minimum tool wear and maximum the MRR, which correspond to a satisfactory overall desirability.

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Fig. 1

CNC turning machine

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Fig. 2

Central composite rotatable design in 3X variables

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Fig. 3

Normal probability of residuals flank wear

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Fig. 4

Effect of cutting speed and feed on flank wear

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Fig. 5

Effect of cutting speed and depth of cut on flank wear

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Fig. 6

Effect of cutting speed and nose radius on flank wear

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Fig. 7

Normal probability of residuals crater wear

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Fig. 8

Variation of crater wear with feed and cutting speed

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Fig. 9

Variation of crater wear with depth of cut and cutting speed

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Fig. 10

Effect of cutting speed and nose radius on crater wear

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Fig. 11

Normal probability of residuals MRR

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Fig. 12

Variation of MRR with depth of cut and cutting speed

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Fig. 13

Variation of MRR with nose radius and cutting speed

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Fig. 14

Variation of MRR with nose radius and depth of cut

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Fig. 15

Contour graph at maximum desirability value

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Fig. 16

Contour graph flank wear-cutting speed

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Fig. 17

Contour graph at maximum desirability value

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Fig. 18

Contour graph crater wear-cutting speed

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Fig. 19

Contour graph at maximum desirability value

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Fig. 20

Contour graph MRR-cutting speed

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Fig. 21

Ramp function graph for overall desirability

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Fig. 22

Individual desirability value of each response



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