Surface Roughness Prediction in End Milling of Machinable Glass Ceramic and Optimization by Response Surface Methodology

Abstract:

This paper presents the prediction of a statistically analyzed model for the surface roughness,R_a of end-milled Machinable glass ceramic (MGC). Response Surface Methodology (RSM) is used to construct the models based on 3-factorial Box-Behnken Design (BBD). It is found that cutting speed is the most significant factor contributing to the surface roughness value followed by the depth of cut and feed rate. The surface roughness value decreases for higher cutting speed along with lower feed and depth of cut. Additionally, the process optimization has also been done in terms of material removal rate (MRR) to the model’s response. Ideal combinations of machining parameters are then suggested for common goal to achieve lower surface roughness value and higher MRR.

• Periodical: Advanced Materials Research (Volumes 189-193)
• Pages: 1376-1381
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.189-193.1376
• Online since: February 2011
• Authors: Moola Mohan Reddy, Alexander Gorin, Khaled A. Abou El Hossein
• Keywords: End Milling, Machinable Glass Ceramic, Response Surface Method (RSM), Surface Roughness (SR)

References

[1] Hock in HK Xu, Jahanmir S. Micro fracture and material removal in scratching of Alumina. Journal of materials science 1995; 2235-47.

[2] Malkin S. Ritter JE, Grinding mechanisms and strength degration for ceramics ASME, Journal of engineering for Industry 1989; 111: 2111-18.

[3] Malkin S. Ritter JE, Grinding mechanisms and strength degration for ceramics ASME, Journal of engineering for Industry 1989; 111: 2111-18.

[4] Kovach.J. A, Laurich.M. A, Malkin. S, Srinivasan. S, Bandyopadyay. B, Ziegler.K. R, A feasibility of investigation of high speed, low damage grinding for advanced ceramics, SME fifth international grinding process conference, Vol. 1, SME, (1993).

DOI: 10.2172/755533

[5] Hwang.T. W, Evans.C. J, Whitenon.E. P, Malkin. S, High speed grinding of silicon nitride with electroplated diamond wheels. 1. wear and wheel life, Manufacturing science and engineering, MED-Vol. 10, ASME, 1999 , 431-441.

DOI: 10.1115/imece1999-0701

[6] Hwang.T. W, Evans.C. J, Whitenon.E. P, Malkin. S, High speed grinding of silicon nitride with electroplated diamond wheels. 2. Wheel topography and grinding mechanisms , Manufacturing science and engineering, MED-Vol. 10, ASME, 1999 , 443-452.

DOI: 10.1115/imece1999-0702

[7] Hwang. H, Liu.Y. C, Experimental investigation of machining characteristics and removal mechanisms of advanced ceramics in high speed grinding, International Journal of Machine Tools and Manufacture 43, 2003, 811-823.

DOI: 10.1016/s0890-6955(03)00050-6

[8] Chwan-Huei Tsai, Hong-Wen Chen, Laser cutting of thick ceramic substrates by controlled fracture technique, Journal of Materials Processing Technology 136 (2003), 166–173.

DOI: 10.1016/s0924-0136(03)00134-1

[9] Rajurkar.K. P, Wang.Z. Y, Kuppattan. A, Micro removal of ceramic material (AL2O3) in the precision ultrasonic machining, Precision Engineering 23, 1999, 73-78.

DOI: 10.1016/s0141-6359(98)00026-9

[10] Yang.J. L, Chen.J. C, A systematic approach for identifying optimum surface roughness performance in end milling operations, Industrial Technology 17(2)(2001).

[11] Suresh.P. V, Venkateswara Rao.P., Deshmukh.S. D, A genetic algorithm approach for optimization of surface roughness prediction model, International Journal of Machine tool and Manufacture, Vol. 42, p.675 – 680, (2002).

DOI: 10.1016/s0890-6955(02)00005-6

[12] Bernados.P. G, Vosniakos.G. C, Predicting surface roughness in machining: a review, International Journal of Machine Tools and Manufacture 43(8) (2003) 833-844.

DOI: 10.1016/s0890-6955(03)00059-2