Optimization of Axial Rake Angle for Face Milling Using Taguchi Method and Finite Element Analysis

Abstract:

This study employed the Taguchi approach in combination with finite element analysis (DEFORM3D) to investigate face milling process onto AL6061. The factors studied in this investigation were cutting speed, feed rate, and axial rake angle. The simulation of flank wear was generated according to Usuis wear model though the L₉ (3⁴) of the orthogonal array experiment. ANOVA analysis and F test were conducted to find the significant factor that contributes to tool wear in the signal to noise ratio. Finally, the confirmation test has been carried out at optimal parameter.

• Periodical: Applied Mechanics and Materials (Volumes 465-466)
• Pages: 746-750
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.465-466.746
• Online since: December 2013
• Authors: Mohd Riduan Ibrahim*, A.R. Abd. Kadir, M.S. Omar, M.H. Osman, S. Sulaiman, M.A. Razak, A.B. Abdullah
• Keywords: ANOVA, Axial Rake Angle, Cutting Speed, Deform 3D, Face Milling, Feed Rate, Taguchi Method

References

[1] Yung-Chang Yen, Jörg Söhner, Blaine Lilly, Taylan Altan, Estimation of tool wear in orthogonal cutting using the finite element analysis, Journal of Materials Processing Technology 146 (2004) 82–91.

DOI: 10.1016/s0924-0136(03)00847-1

[2] P.S. Sivasakthivel, V. Vel Murugan, R. Sudhakaran Prediction Of Tool Wear From Machining Parameters By Response Surface Methodology In End Milling. International Journal of Engineering Science and Technology Vol. 2(6), 2010, 1780-1789.

[3] G. Taguchi, E.A. Elsayed and T.C. Hsiang, Quality Engineering in Production Systems, McGraw-Hill, (1989).

[4] A study of Taguchi optimization method for identifying optimum surface roughness in CNC face milling of cobalt-based alloy (stellite 6), Eyup Bagci · S¸ eref Aykut, Int J Adv Manuf Technol (2006) 29: 940–947.

DOI: 10.1007/s00170-005-2616-y

[5] J.A. Ghani, I.A. Choudhury∗, H.H. Hassan, Application of Taguchi method in the optimization of end milling parameters, Journal of Materials Processing Technology 145 (2004).

DOI: 10.1016/s0924-0136(03)00865-3

[6] M.S. Phadke, Quality Engineering Using Robust Design, Prentice-Hall, Englewood Cliffs, NJ, (1989).

[7] Ross PJ (1996) Taguchi techniques for quality engineering. McGraw–Hill Int Edn, Singapore.

[8] Serope Kalpakjian and Steven R. Schmidz Manufacturing Engineering and technology in 6th Ed, Prentice Hall 2010, Illinios Institute of Technology, pp.591-71.