Papers by Keyword: Metal Removal Rate

Abstract: In machining process, surface roughness and material removal rate have a vital importance since they affect mass production, consumption of energy, force, and tool life and product quality. In this study, Taguchi-Grey Relation Method (TGRM) is applied to AISI 1040 mild steels in the hardened form when machined with ceramic inserts using response surface methodology for multi-objective optimization. Grey-Relation Method and Pareto chart reveal that feed rate, depth of cut, speed besides square effect of speed/feed rate are effective parameters on the response. Among all eighteen experiments, trial twelfth provides the best multi-performance characteristics while the first experiment shows the worst performance. Optimal levels are determined at higher speed, higher feed rate associated with higher depth of cut. It is concluded that quadratic regression model and reduced quadratic regression model are developed. The correlation coefficients range from 98.3% to 96.89%, respectively. As a result, TGRM has an efficient to provide a good modelling in combination of surface roughness and metal removal rate.

Abstract: The aim of this research work is identification of optimum drilling parameters to increase material removal rate, dimensional and profile accuracy during drilling. ASTM A516 (Grade70) which is a boiler quality plate of 12 mm thickness was considered as the specimen for conducting the experiments. The experiment was done based on full factorial design using 18 experiments generated using Minitab Software. Two levels for tool material and three levels for feed-speed combination and cutting environment were considered. Two runs were carried out for each trial. The metal removal rate was calculated for each hole drilled. The mean result of the two runs of a trial was taken as the result of the trial. The drilled holes were then tested for their dimensional, profile accuracies. With these results in hand the Artificial Neural Network software was trained to predict the optimized input parameters for drilling a hole of required dimensional and profile accuracies and with required metal removal rate.

Abstract: Wire Electric Discharge Machining is one of the non-traditional machining process to develop and generate many complicated shapes with very much accuracy. Improper selection of cutting parameters may result in erroneous configuration and shapes. When cutting curve profile in WEDM process, it has been found out that the magnitude of corner inaccuracy in terms of uncut area at the corner of the die is much higher than the corner inaccuracy at the corner of the punch due to the excess material removal. In this study entropy based grey relation analysis has been used to identify the optimal cutting parameter for WEDM process. ANOVA has been adopted to distinguish the most consequential factors. Inconel 718 has been used as a work-piece material which is a new advance material and it has wide range of industrial application. The characteristics of the machined surfaces of Inconel 718 alloy have also been analyzed through scanning electron microscope (SEM).