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Assessment of surface roughness and MRR while machining brass with HSS tool
and carbide inserts
K Arun Vikrama*, Ch Ratnamb, K Sankara Narayanac & B Satish Bend
a
Department of Industrial Engineering, GITAM Institute of Technology, GITAM University, Visakhapatnam 530 045, India
Department of Mechanical Engineering, Andhra University College of Engineering (AUCE), Visakhapatnam 530 003 , India
c
Department of Mechanical Engineering, GITAM Institute of Technology, GITAM University, Visakhapatnam 530 045, India
d
Department of Mechanical Engineering, National Institute of Technology, Warangal 506 004, India
b
322
323
324
SS Between
n1
(1)
& DF = N 1
( X ) + ( X )
=
n2
( X ) ( X )
+ .. +
AC
nAC
(2)
SSC =
( X )
SS A =
( for
n
each column )
( for
each row )
( X )
( X )
(3)
(4)
(5)
%Contribution = MS
(6)
MSTotal
Ra = C*fk*vh
(7)
(8)
(9)
325
1
2
3
4
5
6
7
8
9
Control factors
A
B
1
1
1
2
2
2
3
3
3
1
2
3
1
2
3
1
2
3
560
900
1250
0.14
0.17
0.20
0.14
0.17
0.20
0.14
0.17
0.20
Table 2Experimental values of turning brass using TiN-Al2O3-TiCN-TiN carbide insert and HSS Tools
Exp
No.
A:
Speed
(rpm)
B:
Feed
Ra (microns)
(mm/rev)
1.43
1.47
1.48
1.66
1.65
1.69
1.97
2.10
1.99
1.41
1.45
1.44
1.62
1.66
1.67
1.98
1.99
2.00
1.44
1.42
1.39
1.60
1.55
1.60
1.95
1.99
1.94
Carbide insert
MRR
S/N ratio
(mm3/min)
(Ra)
5732.2
5729.7
5734.6
6960.5
6957.3
6963.5
8188.8
8185.3
8192.3
9212.4
9208.5
9216.4
11186.5
11181.7
11191.3
13160.6
13155.0
13166.3
12795.1
12789.6
12800.6
15536.9
15530.2
15543.5
18278.7
18270.8
18286.5
S/N ratio
(MRR)
Ra
(microns)
-3.29
75.35
-4.44
77.04
-6.11
78.45
-3.13
79.47
-4.35
81.16
-5.98
82.57
-3.03
82.33
-3.99
84.01
-5.85
85.42
2.99
2.81
2.98
3.12
3.14
3.10
3.40
3.39
3.43
2.44
2.50
2.48
2.68
2.65
2.71
2.76
2.78
2.74
2.40
2.36
2.34
2.65
2.61
2.60
2.67
2.69
2.64
HSS Tools
MRR
S/N
(mm3/min) Ratio (Ra)
5855.3
5852.8
5857.8
7110.0
7107.0
7113.0
8364.7
8361.2
8368.2
9410.3
9406.3
9414.3
11426.8
11422.0
11431.6
13443.3
13437.6
13448.9
13069.9
13064.4
13075.4
15870.5
15863.9
15877.2
18671.2
18663.4
18679.1
S/N ratio
(MRR)
-9.33
75.17
-10.00
76.85
-10.72
78.26
-7.87
79.29
-8.56
80.97
-8.80
82.39
-7.48
82.14
-8.44
83.83
-8.77
85.24
326
Table 3Two-way ANOVA for carbide inserts: roughness versus speed, feed including interactions
Source
DF
SS
MS
FCritical
A
B
A*B
Error
Total
2
2
4
18
26
0.018
1.416
0.002
0.019
1.455
0.009
0.708
0.001
0.001
0.719
8.4
675
0.54
0.003
0.000
0.712
3.55
3.55
2.93
% Contribution Remarks
1.25
98.5
0.13
Less significant
Highly significant
Not significant
100
DF
SS
MS
FCritical
% Contribution Remarks
1.893
0.946
547
0.00
3.55
75.6
Highly Significant
B
A*B
Error
Total
2
4
18
26
0.578
0.059
0.031
2.56
0.289
0.015
0.002
1.252
167
8.5
0.00
0.00
3.55
2.93
23.1
1.19
Significant
Less significant
100
DF
SS
MS
FCritical
A
B
A*B
Error
Total
2
2
4
18
26
345385938
73735563
7170666
469
426292636
172692969
36867781
1792667
26
211353443
6633796
1416232
68863
0.00
0.00
0.00
3.55
3.55
2.93
% Contribution Remarks
81.7
17.5
0.85
Highly Significant
Highly Significant
Significant
100
DF
SS
MS
FCritical
A
B
A*B
Error
Total
2
2
4
18
26
331021594
70670039
6871609
471
408563713
165510797
35335020
1717902
26
202563745
6320606
1349390
62604
0.00
0.00
0.00
3.55
3.55
2.93
% Contribution Remarks
81.7
17.5
0.85
100
Highly Significant
Highly Significant
Significant
327
DF
SS
MS
FCritical
Regression
Error
2
24
1.39
0.06
0.69
0.003
280
0.00
3.44
% Contribution Remarks
99.5
Highly significant
DF
SS
MS
FCritical
% Contribution
Remarks
Regression
Error
2
24
419121501
7171135
209560750
298797
701
0.00
3.44
99.86
Highly significant
DF
SS
MS
FCritical
Regression
Error
2
24
2.18
0.38
1.09
0.02
68.0
0.00
3.44
% Contribution Remarks
98.19
Highly significant
DF
SS
MS
FCritical
% Contribution
Regression
Error
2
24
401691633
6872080
200845817
286337
701.4
0.00
3.44
99.86
Remarks
Highly significant
328
Feed (mm/rev)
Predicted (microns)
Error %
4
6
0.17
0.17
560
1250
1.67
1.58
1.69
1.68
1.51
5.93
3.11
2.62
6.17
0.00
0.14
0.17
560
1250
2.93
2.62
Fig. 4Main effects and interactions of parameters on surface roughness S/N ratio while machining with carbide
Fig. 5Main effects and interactions of parameters on MRR S/N ratio while machining with carbide
Fig. 6Main effects and interactions of parameters on surface roughness S/N ratio while machining with HSS
329
Fig. 7Main effects and interactions of parameters on MRR S/N ratio while machining with HSS
Fig. 8Surface plots of parameters on surface roughness and MRR while machining with carbide inserts
Fig. 9Surface plots of parameters on surface roughness and MRR while machining with HSS tools
330
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