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ABSTRACT
Almost half of the worlds industrial and production is
done by using stainless steel. It is not easy to machine
materials like austenitic stainless steel because of their
high strength, high ductility and low thermal
conductivity. This paper discusses the experimental
study on performance characteristics of AISI 304
stainless steel during CNC drilling process.Factors like
spindle speed, feed rate and point angle affect the
performance parameters such as the surface roughness
and ovality in drilling process. To get minimum surface
roughness and minimum ovality, the best optimal level
of parameters has to be chosen carefully. This paper
presents the multi-objective optimization of drilling
process parameters using Taguchi method in machining
of AISI304 stainless steel. The experiments are
conducted based on Taguchi L16 orthogonal array by
taking point angle, drill diameter, feed rate and spindle
speed at two levels. The Taguchi based signal-to-noise
ratio analysis is used to obtain the relation between the
machining parameters and performance characteristics.
The complete experimental results are discussed and
presented in this paper.
Keywords: CNC drilling, AISI stainless steel, surface
roughness, ovality, signal-to-noise ratio, Taguchi
method, AISI304.
1. INTRODUCTION
Drilling is one of the oldest metal removal processes.
Also, 40% of metal removal processes in industries,
majorly aerospace and automobile are done by drilling.
Bottlenecks were major problem in the drilling of
material using conventional method. However, the use
of CNC, NC machines has made it very easy to drill
without any kind of problem or bottlenecks. Also, the
use of drills all over the industry shows the significance
of drilling of material in each industry. AL-6061, Al6351 and AL-7075 were machined with feed rate,
cutting speed and point angle as the parameters to
optimize the effect on the diameter error and thrust
force. And results showed that the cutting speed and
feed rate both will help in minimising the thrust force
and diameter accuracy [1]. Al-2014 was selected as the
work piece and L18 of the orthogonal array was
selected for several experiments. Control factors were
the spindle speed, feed rate and cutting tool. Not much
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902
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
2. TAGUCHI METHOD
Dr.Genichi Taguchi introduced an optimization method
that helped in making calculations of experiments
easier and rapid. It was originally made to make the
improvement in the quality of goods that were being
made in japan. This technique helped in introducing a
method that only require a specific set of experiments
to find the effectiveness on the response parameters.
Orthogonal Array represents the data structure and the
matrix that it shows contains the data for the
experiments. In addition, the number of runs during
experiment is defined by orthogonal array. In order to
reach maximum quality of product three steps are very
important in Taguchi method which is System Design,
Parameter Design and tolerance design. Taguchi
analysis was done using MINITAB17 software and the
results and graphs were plotted with that. MINITAB17
is software which a brilliant tool for the calculations
and researches using several algorithm. The
experiments were designed using Taguchi orthogonal
array and both the design of experiment follow the
same methodology. The DOE is a L16 orthogonal array
with four process parameters having two levels.
3. EXPERIMENTAL WORK
Table: Selected Parameters with levels
Sr.
Parameters
Level -1
no.
1.
Spindle Speed(rpm) 300
2.
Feed(mm/min)
20
3.
Point Angle
90
4.
Depth of Hole(mm) 15mm
Level +1
CUTTING TOOL
WORKPIECE MATERIAL
500
50
118
18mm
4. MACHINE USED
The experiments were conducted on the VMC-400. It is
a vertical milling/drilling machine, which is
manufactured by HMT. This vertical machining center
is equipped with the Fanuc India series O-M controller
for the execution of programs. The machine is capable
of running at 4000rpm of spindle speed. The maximum
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
5. DESIGN MATRIX
17.50-19.50
Nickel (Ni)
8.00-10.50
Manganese (Mn)
0.0-2.00
Silicon (Si)
0.0-1.00
Sr. No.
Nitrogen (N)
0.0-0.11
Point
Angle
Depth
Of
Hole
Spindle Speed
Feed
1.
90
15
300
20
0.0-0.07
2.
90
15
300
50
3.
90
15
500
20
4.
90
15
500
50
Carbon
Phosphorus (P)
0.0-0.05
Sulphur (S)
0.0-0.03
5.
90
18
300
20
Iron (Fe)
Balance
6.
90
18
300
50
7.
90
18
500
20
8.
90
18
500
50
9.
118
15
300
20
10.
118
15
300
50
11.
118
15
500
20
12.
118
15
500
50
13.
118
18
300
20
14.
118
18
300
50
15.
118
18
500
20
16.
118
18
500
50
OVALITY MEASUREMENT
SR
S/N (SR)
90
90
90
90
90
90
90
90
118
118
15
15
15
15
18
18
18
18
15
15
300
300
500
500
300
300
500
500
300
300
20
50
20
50
20
50
20
50
20
50
3.672
5.662
4.561
5.83
4.013
6.124
4.825
6.94
4.31
5.827
-11.29805345
-15.0593973
-13.18120144
-15.3133711
-12.06938319
-15.74070364
-13.66994635
-16.82718941
-12.6895454
-15.30890036
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
11.
12.
13.
14.
15.
16.
118
118
118
118
118
118
15
15
18
18
18
18
500
500
300
300
500
500
20
50
20
50
20
50
4.868
5.521
4.469
6.448
5.145
6.583
-13.74701139
-14.84035494
-13.00420709
-16.18850058
-14.22770758
-16.3684771
ANOVA
ANOVA means the disintegration of complete
variability into its constituents. Using ANOVA, we can
find the most effective parameters in the study and
name the significant ones very easily and performance
parameter can be optimized successfully. It helps in
understanding the means of groups and the chances of
them being equal. It is a very helpful method in finding
the significance when we have two or more means to
analyse.
Level
1
2
Delta
Rank
A
B
C
D
A*B
A*C
A*D
B*C
B*D
C*D
Residual
error
Total
SS
DF
MS
0.6462
2.7708
2.9041
29.5932
0.0040
0.5012
0.8484
0.1164
0.4056
1.3881
0.2289
1
1
1
1
1
1
1
1
1
1
5
0.6462
2.7708
2.9041
29.5932
0.0040
0.5012
0.8484
0.1164
0.4056
1.3881
0.0458
39.4068
15
RESPONSE
TABLE
ROUGHNESS
Fvalue
14.11
60.51
63.43
646.32
0.09
10.95
18.53
2.54
8.86
30.32
FOR
Pvalue
0.013
0.001
0.001
0.000
0.780
0.021
0.008
0.172
0.031
0.003
Significant
Significant
Significant
Significant
Insignificant
Significant
Significant
Insignificant
Significant
Significant
SURFACE
B
-13.93
-14.76
0.83
3
C
-13.92
-14.77
0.85
2
D
-12.99
-15.71
2.72
1
A
-14.14
-14.55
0.40
4
Sr.
no.
1.
Ovality
S/N (OV)
90
15
300
20
14.235
-23.06714943
2.
90
15
300
50
14.185
-23.0365868
3.
90
15
500
20
14.237
-23.0683697
4.
90
15
500
50
14.343
-23.13279997
5.
90
18
300
20
14.286
-23.09821292
6.
90
18
300
50
14.217
-23.05615927
7.
90
18
500
20
14.457
-23.20156362
8.
90
18
500
50
14.512
-23.23454539
9.
118
15
300
20
14.017
-22.93310147
10.
118
15
300
50
14.147
-23.01328707
11.
118
15
500
20
14.164
-23.02371836
12.
118
15
500
50
14.379
-23.15457367
13.
118
18
300
20
14.082
-22.9732868
14.
118
18
300
50
14.103
-22.98623012
15.
118
18
500
20
14.377
-23.15336545
16.
118
18
500
50
14.414
-23.17569035
SS
MS
0.014528
D
F
1
0.014528
Fvalue
32.17
Pvalue
0.002
Significant
0.012626
0.012626
27.96
0.003
Significant
0.060100
0.060100
133.10
0.000
Significant
0.004594
0.004594
10.17
0.024
Significant
A*B
0.000925
0.000925
2.05
0.212
Insignifica
nt
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Volume 4, Issue 8, August 2015
A*C
0.003088
0.003088
6.84
0.047
Significant
A*D
0.003067
0.003067
6.79
0.048
Significant
B*C
0.006478
0.006478
14.35
0.013
Significant
B*D
0.002990
0.002990
6.62
0.050
Significant
C*D
0.003309
0.003309
7.33
0.042
Significant
Residu
al
error
0.002258
0.000452
Total
0.113962
15
-23.11
-23.05
-23.02
-23.05
-23.11
-23.14
Delta
0.06
0.06
0.12
23.06
23.10
0.03
Rank
INTERACTION PLOT
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
7. CONCLUSION
In this paper, the research has been done to find out the
best optimal conditions for the drilling of AISI 304
stainless steel using HSS twist drills. The analysis of
variance and Signal-to-Noise ratio showed the effect of
factors over the responses in various forms like one
way or with the interaction. Now, we have following
conclusions from our research study:
i.
The feed is the most effective parameter and
that the small variation in feed will show large
increase in surface roughness.
ii.
For better or minimum surface roughness the
feed need to be kept low along with the spindle
speed and depth of hole.
iii.
The surface roughness increases with increase
in feed, depth of hole.
iv.
The ovality increases with the increase in depth
of hole, spindle speed and feed.
v.
The ovality decreases with the increase in point
angle. So, for minimum ovality, point angle
should be high.
REFERENCES
[1] Sreenivaslu Reddy, G. Vijaya Kumar, C.
Thirupathiah Influence Of The Cutting Parameters On
The Hole Diameter Accuracy And The Thurst Force In
Drilling Of Aluminium Alloys, Ijirset, International
Journal Of Innovative Research In Science,
Engineering And Technology, Volume-2, Issue- 11,
November, 2013
[2] Ugur Koklu Influence Of The Process Parameters
And The Mechanical Properties Of Aluminium Alloys
On The Burr Height And The Surface Roughness In
Dry Drilling, Udk, Original Scientific Article,
October, 2011
[3] T. Kartikeya Sharma, A. Navnth A Study Of
Taguchi Method Based Optimization Of Drilling
Parameters In Dry Drilling Ofal-2014 Alloy At Low
Speeds, Ijeset, International Journal Of Engineering
Sciences And Emerging Technologies, Volume- 6,
Issue- 1, August, 2013, Pp. - 65-75
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