International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME AND TECHNOLOGY (IJMET)
ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 2, March - April (2013), pp. 134-140 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

IJMET
IAEME

INVESTIGATING THE EFFECT OF MACHINING PARAMETERS ON SURFACE ROUGHNESS OF 6061 ALUMINIUM ALLOY IN END MILLING
U. D. Gulhane*, M.P.Bhagwat, M.S.Chavan ,S.A.Dhatkar, S.U.Mayekar Department of Mechanical Engineering, Finolex Academy of Management and Technology, Ratnagiri, Maharashtra 415612, India *Corresponding author- Associate Professor, Dept. of Mechanical Engineering, Finolex Academy of Management and Technology, P-60/61, MIDC, Mirjole Block, Ratnagiri- (M.S.) 415639, India

ABSTRACT Design of experiments is performed to analyse the effect of spindle speed, feed rate and depth of cut on the surface roughness of 6061 Aluminium alloy. The results of the machining experiments were used to characterise the main factors affecting surface roughness by the Analysis of Variance (ANOVA) method. The feed rate was found to be the most significant parameter influencing the surface roughness in the end milling process. Keywords: Surface roughness, DOE, ANOVA, 6061 Aluminium alloy. INTRODUCTION Milling process is one of the common metal cutting operations used for machining parts in manufacturing industry. It is usually performed at the final stage in manufacturing a product. The demand for high quality and fully automated production focuses attention on the surface condition of the product, especially the roughness of the machined surface, because of its effect on product appearance, function, and reliability. In the present work an experimental investigation of milling on aluminium 6061 with HSS tool is carried out and the effect of different cutting parameters on the surface roughness is studied.
134

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

The material used for the analysis is 6061 Aluminium alloy which is widely used in wings of the aeroplane, wheels of the automobiles. In this paper, L9 orthogonal array is employed to analyze experimental results of machining obtained from 9 experiments by varying three process parameters viz. cutting speed (A), depth of cut (B) and feed rate(C). ANOVA has been employed and compared with Taguchi method. METHODOLOGY DOE techniques enable designers to determine simultaneously the individuals and interactive effects of many factors that could affect the output results in any design. There are three input parameters and three level. Full factorial experimental design will give rise to total 33=27 experiments which is time consuming and lengthy procedure.

Fig 1: End- milling operation Taguchi found out new method of conducting the design of experiments which are based on well defined guidelines. This method uses a special set of arrays called orthogonal array. This standard array gives a way of conducting the minimum number of experiments which could give the full information of all the factors that affect the response parameter instead of doing all experiments. ANOVA was developed by Sir Ronald Fisher in 1930 and can be useful for determining influence of any given input parameter for a series of experimental results by design of experiments for machining process and it can be used to interpret experimental data. ANOVA is statistical based objective decision making tool for detecting any differences in average performance of groups of items tested. While performing ANOVA degrees of freedom should also be considered together with each sum of squares. In ANOVA studies a certain test error, error variance determination is very important. Obtained data are used to estimate F value of Fisher Test (F-test). Variation observed (total) in an experimental attributed to each significant factor or interaction is reflected in percent contribution (P), which shows relative power of factor or interaction to reduce variation.

135

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

MATERIALS AND METHOD The Rectangular 25 X 25 X 100 mm 6061 Aluminium Alloy specimens were used for experimentation. Table 1 and 2 shows properties and composition of 6061 Aluminium Alloy used for the study. Milling operation was carried out on SINGER UNIVERSAL MILLING MACHINE by using HSS tool. Table 1 Properties of 6061 Al TENSILE TEST Ultimate Yield Modulus Of Stress Stress Elasticity (N/mm2) (N/mm2) (GPa) 251.66 202.92 56.1

BHN For 500 Kg

79.57

Table 2 Composition of 6061 Al

Elements Al Si Fe Mg Ti Ca Cd B P Na Mn

98.81

0.475

0.178

0.49

0.0135

0.0027

0.001

0.0015

0.0014

0.0043

0.0005

Work piece was inserted in the jaw on the work bed and was tightened in the jaws until they fixed the work piece such that top surface of the work piece will be perfectly perpendicular to the tool axis. The milling was carried out for 9 different work pieces. For each workpiece, all the three parameters, viz. cutting speed, depth of cut and feed rate, were varied as shown in Table 3. Table 3: Machining parameters and levels: Machining Parameters Cutting speed (Rev/min) Depth of cut (mm) Feed rate (mm/min) Level 1 58 0.4 15.31 Level 2 220 0.8 41.84 Level 3 500 1.2 104.56

The surface roughness of each specimen was tested on the surface roughness tester (Mitutoyo Roughness tester SJ-400) for cut off value of 4.0 mm distance. The Ra value was generated by the tester for each work piece.

136

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

RESULTS AND DISCUSSION Table 4 shows experimental design matrix and surface roughness value (Ra) for 6061 Al, S/N ratio is calculated using Lower the better characteristics.

where, n = No of measurements in a trial/row Yi = ith measured value in a run/row Table 4 Experimental Design Matrix and Results EXPT NO. MILLING SPEED (RPM) 1 2 3 4 5 6 7 8 9 58 58 58 220 220 220 500 500 500 PARAMETERS DEPTH FEED S/N OF CUT RATE SURFACE RATIO (mm) (mm/min) ROUGHNESS (m) 0.4 15.32 2.54 -8.0967 0.8 41.84 2.78 -8.8809 1.2 104.56 2.97 -9.4551 0.8 15.32 2.06 -6.2773 1.2 41.84 2.86 -9.1273 0.4 104.56 3.4 -10.6296 1.2 15.32 1.58 -3.9731 0.4 41.84 1.81 -5.1536 0.8 104.56 2.54 -8.0967

MEAN

2.54 2.78 2.97 2.06 2.86 3.4 1.58 1.81 2.54

Responses for Signal to Noise Ratios of Smaller is better characteristics is shown in Table 5. Significance of machining parameters (difference between max. and min. values) indicates that feed is significantly contributing towards the machining performance as difference gives higher values. Plot for S/N ratio shown in Figure 1 explains that there is less variation for change in depth of cut where as there is significant variation for change in feed rate. Table 5-Response Table for a) Signal to Noise Ratios and (b) means (a) (b) A B C Level A B C -8.811 -7.96 -6.116 1 2.763 2.583 2.06 -8.678 -7.752 -7.721 2 2.773 2.46 2.483 -5.741 -7.519 -9.394 3 1.977 2.47 2.97 3.07 0.441 3.278 Delta 0.797 0.123 0.91 2 3 1 Rank 2 3 1

Level 1 2 3 Delta Rank

137

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

M a in E ff e c ts P lo t f o r S N r a tio s
D a ta M e a n s
Speed -6 -7 Fe e d

Mean of SN ratios

-8 -9 58 -6 -7 -8 -9 0 .4 0 .8 1 .2 220 Depth 500 1 5 .3 3 4 1 .9 2 1 0 4 .9 0

S ig n a l - to - n o is e : S m a l le r is b e tte r

M a in E f f e c t s P l o t f o r M e a n s
Da ta M e a n s
3 .0 0 2 .7 5 2 .5 0 Speed Fe e d

Mean of Means

2 .2 5 2 .0 0 58 3 .0 0 2 .7 5 2 .5 0 2 .2 5 2 .0 0 0 .4 0 .8 1 .2 220 De pth 500 1 5 .3 3 4 1 .9 2 1 0 4 .9 0

Fig. 2 Effect of cutting speed, Depth of cut and Feed rate on surface finish Taguchi method cannot judge and determine effect of individual parameters on entire process while percentage contribution of individual parameters can be well determined using ANOVA. MINITAB software of ANOVA module was employed to investigate effect of process parameters cutting speed, Depth of Cut and Feed rate. Table 6-Analysis of Variance for S/N ratios Adj MS 9.0334 0.1463 8.0605 1.6549

Source A B C Residual error Total

DF 2 2 2 2 8

Seq SS Adj SS 18.0668 18.0668 0.2926 0.2926 16.121 16.121 3.3098 37.7902 3.3098

F 5.46 0.09 4.87

P 0.155 0.919 0.17

138

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Table 7-Analysis of Variance for Means Source Speed Feed Depth Residual Error Total DF 2 2 2 2 8 Seq SS Adj SS Adj MS 1.25362 1.25362 0.62681 1.24416 1.24416 0.62208 0.02816 0.02816 0.01408 0.23209 0.23209 0.11604 2.75802 F 5.4 5.36 0.12 P 0.156 0.157 0.892

Table 6 and 7 shows Analysis of variance for S/N ratio and mean. F value (5.46) of parameter indicates that feed rate is significantly contributing towards machining performance. F value (0.09) of parameter indicates that depth of cut is contributing less towards surface finish. It can be observed rough surface for the specimen No. 6 (cutting speed, 220 rev/min; depth of cut, 0.4 mm; feed, 104.90 mm/min.) and smooth surface for the specimen No. 7 (cutting speed, 500 rev/min; depth of cut, 1.2 mm; feed, 15.33 mm/min.)

Fig3: Surface texture for the test (cutting Fig 4: Surface texture for the test (cutting speed 500 rev/min, depth of cut 1.2 mm, speed 220 rev/min, depth of cut 0.4 mm, feed 15.33 mm/min) feed 104.90 mm/min)

Fig5: Surface Roughness Profile For specimen 1 Cut off length = 4.0 mm, Ra= 2.54 m The pattern of impressions left by tool after the machining of workpiece is called as a lay pattern and it is circular in end milling process. When the feed is high the pattern is more prominent as the time available for traversing is less. When the feed is low the lay pattern is not much emphasized as more time available for traversing. Hence we observed in our experimentation that the contribution of feed is dominant amongst all three parameters in surface roughness.

139

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

CONCLUSION Taguchi method of experimental design has been applied for investigating the effect of machining parameters on surface roughness. Results obtained from Taguchi method closely matches with ANOVA. Best parameters found for finish machining are: cutting speed, 500 rev/min; depth of cut, 1.2 mm; feed, 15.33 mm/rev. The parameters found for rough machining are cutting speed, 220 rev/min; depth of cut, 0.4 mm; feed, 104.90 mm/min. Feed is most influencing parameters corresponding to the quality characteristics of surface roughness. ACKNOWLEDGEMENT Quality control department of Adler Mediequit PVT.LTD, Ratnagiri are gratefully acknowledged. REFERENCES
1. Gulhane U. D., et. al.(2012), Improvement in surface roughness of 316 L Stainless Steel and Ti-6Al-4V: DOE Appproach International Journal of Mechanical Engineering and Technology, 2012, Volume 3, Issue 1, pp. 150 - 160, ISSN Print: 0976 6340, ISSN Online: 0976 6359. 2. Patel K.P. (2012) Experimental analysis on surface roughness of CNC end milling process using taguchi design method International Journal Of Engineering Science And Technology (IJEST) Vol-4 No.02 ISSN:0975-5462. 3. Mohammed T., et. al. (2007) A Study of the effects of machining parameters on the surface roughness in the end milling process., Jordan Journal Of Mechanical And Industrial Engineering.(JJMIE) Vol-1No-1. ISSN-1995-665. 4. Kuttolamadom M. A., et. al (2010), Effect Of machining feed on surface roughness in cutting 6061 aluminum 2010-01-0218. 5. Kakati A., et. al. (2011), Prediction of optimum cutting parameters to obtain desired surface in finish pass end milling of aluminium alloy with carbide tool using ANN World Academy Of Science And Engineering and Technology 81. 6. Gopalsamy B. M., et. al. (2009), taguchi method and Anova : An Approach for process parameters optimisation of hard machining while machining hardened steel Journal of Scientific and Industrial research, vol.68, pp.686-695. 7. Julian J. Faraway, Practical Regression and ANOVA using R, July 2002, pp 168-200. 8. Phillip J. Ross Taguchi Techniques for Quality Engineering Printed and bounded by R.R. Donnelley and sons company 2nd edition. 9. Gulhane U. D. , et. al. (2012), Optimization of process parameters for 316L stainless steel by using Taguchi method and ANOVA International Journal of Mechanical Engineering and Technology(IJMET). Volume 3, Issue 2, pp. 67-72, ISSN Print: 0976 6340, ISSN Online: 0976 6359. 10. P.C. Sharma A text book of production engineering ISBN: 81-219-0111, Code:10A 038A. 11. N.B.Doddapattar and N Lakshmana swamy, An Optimization of Machinability of Aluminium Alloy 7075 and Cutting Tool Parameters by using Taguchi Technique International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp. 480 - 493, ISSN Print: 0976 6340, ISSN Online: 0976 6359

140