Sunteți pe pagina 1din 3

International Journal of Research in Advanced Technology IJORAT

Vol 1, Issue 9, NOVEMBER 2016

OPTIMIZATION OF MATERIAL
REMOVAL RATE IN CNC DRILLING OF
AA6063 USING TAGUCHI METHOD
M.Ravichandran1,M.Meignanamoorthy2 and S.Sakthivelu3
1

Professor, Department of Mechanical Engineering, Chendhuran College of Engineering and Technology,


Pudukkottai, Tamilnadu, India.
2
Research Scholar, Department of Mechanical Engineering, Anna University, Chennai, Tamilnadu, India.
3
Assistant Professor,Department of Mechanical Engineering, M.Kumarasamy College of Engineering, Karur,
Tamilnadu, India.
Abstract: The aim of this research work is to investigate the influence of process parameters in drilling of
AA6063 in a CNC lathe by using high speed steel drill bit. The input parameters namely the spindle speed,
feed rate and depth of cut are wide-ranging to experiment their influence on material removal rate (MRR).
The experiments were conducted using L16 orthogonal array. Consequence of quality of CNC drilling
process was found by Design of Experiments (DOE) and analysis of variance (ANOVA). The investigations
exposes that the material removal rate is directly influenced by the Spindle speed, feed rate and depth of cut.
It was identified that the MRR increase and increases with related to feed rate, spindle speed and frequently
for all depth of cut and also monitor the machining time.
Keywords:AA6063, CNC Lathe, Drilling, MRR, S/N Ratio, DOE, ANOVA, Taguchi Method, MINITAB-16

I.INTRODUCTION
The objective of this paper is to optimize drilling
parameters on CNC lathe of AA6063 using taguchi based
Design of experiments (DOE). Ramesh et al [1]
investigated the Surface roughness (Ra), machining time
and material removal rate (MRR) of EN31affect the
aesthetical aspect of the final product. The experiments
were carried out as per L27 orthogonal array(ANOVA)
was employed by using MINITAB-16 software. The
Taguchi experimental trials, shows that the feed rate was
the most significant factor for improving the Metal
Removal rate with contribution percentage of 85.1% and
85.7% respectively.Kunal Sharma et al [2] discussed about
the performance characteristics of AISI 304 SS during
CNC drilling. Factors like speed, feed and depth of cut
affect the parameters such as surface roughness and
ovality. L16 orthogonal array has been chosen. From the
result it is concluded that feed is most effective parameter.
Surface roughness (SR) increases with increases in feed
and ovality increases with the increase in depth of hole.
Navanth et al [3] studied the drilling parameters of Al2024
alloy at low speeds to obtain minimum surface roughness
and hole diameter. L18 orthogonal array was used to
conduct the experiment. ANOVA was employed to
determine the most significant control factors. It was
identified that a spindle speed of 300rpm, point angle &
helix angle of 1300/200 and a feed rate of 0.15 mm/rev is
the optimal combination of drilling parameters that
produce a high value of S/N ratio. Balakumaran et al [4]
investigated the simultaneous minimization and
maximization of surface roughness, machining time and
material removal rate of EN31 alloy steel. Experiments
were carried out by CNC lathe using chromium nitride tool
bit. In this experimental investigation taguchi and Analysis
of Variance (ANOVA) were used to obtain optimal drilling
parameters in the drilling of EN31 steel under wet
conditions the peck increment 4.5, feed rate 0.04 and
200rpm was the most significant factor for improving the
Metal Removal rate (MRR) with contribution 46%. The
Design of Experiment (DOE) is an influential method to
improve manufactured goods design presentation where it
can be used to decrease cycle time needed to improve new
process.The Analysis of Variance (ANOVA) is a very
All Rights Reserved 2016 IJORAT

powerful statistical tool for test of significance. The


ANOVA is a separation of variance ascribable to one
proves of process of the variance ascribable to the other
groove [5].Ramudu et al [6] the investigations of most
significant variables distressing worth features and a
design for leading such trials are called the Design of
Experiments. In this research work all the experiments
were conducted under dry conditions. Taguchi mentions a
procedure to attain product eminence by design.

II.Experimental Work
A.Work piece Material
In this research work, AA6063 is used as a
material. The chemical compositions and mechanical
properties of AA60663 is clearly shown in the below
table I & II.
TABLE I: CHEMICAL COMPOSITIONS OF
AA6063
Elements

Si

0.3 0.6

Fe

0.15 - 0.35

Cu

0.1

Mn

0.15

Mg

0.6 - 0.9

Zn

0.15

Ti

0.1

Cr

0.05

Al

Balance

International Journal of Research in Advanced Technology IJORAT


Vol 1, Issue 9, NOVEMBER 2016

Work Piece Material : AA6063


Hole Diameter
: 16mm

TABLE II: MECHANICAL PROPERTIES OF


AA6063
Tensile Strength

220 Mpa

Elongation

5%

Proof Stress

190 Mpa

B.Experimental Setup
The experimental work was carried out in CNC
Fig.3 Drilled Work piece
turning center JOBBER XL using high speed steel drill bit.
Figure 1 clearly shows the experimental set up of CNC
turning center. The specifications of CNC turning center D. Process Parameter With Three Levels
In this work each factor has four levels. L16
machine are given in Table III.
orthogonal array has been followed.
Table III: CNC Turning Center Specification
TABLE IV: INPUT PARAMETERS MRR AND S/N
RATIO FOR MRR
Machine Type
JOBBER XL
Year

2012

Supply Voltage

380V/415V

Control Voltage

24V D.C

Back Up Fuse

63 AMPS

Rated Current

AMPS

KVA Rating

KVA

Size of Wire

SQ mm

Cutting Feed Rate Depth of MRR


S/N Ratio
(mm3/
Speed (mm/min)
Cut
for MRR
min)
S.No (rpm)
(mm)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

800

0.1

0.4

46.2

33.29

800
800
800
1000
1000
1000
1000
1200
1200
1200
1200
1400
1400
1400
1400

0.15
0.17
0.2
0.1
0.15
0.17
0.2
0.1
0.15
0.17
0.2
0.1
0.15
0.17
0.2

0.5
0.6
0.8
0.5
0.4
0.8
0.6
0.6
0.8
0.4
0.5
0.8
0.6
0.5
0.4

58.4
63
77.3
49.1
62.2
65.5
79.4
57.3
64.2
66.5
82.7
58.8
65.5
78.8
81.7

35.33
35.99
37.76
33.83
35.88
36.32
38.00
35.16
36.15
36.46
38.35
35.38
36.32
37.93
38.24

TABLE V: PROCESS VARIABLES AND THERE


PARAMETERS

Levels
Fig.1 CNC Turning Center JOBBER XL

C. Drilling Tool
In this work, experiments were conducted using
16 - mm diameter HSS twist drill. Figure 2 clearly shows
the dimensions of the drill bit.

S.No

Parameters
1

1
2
3

Speed (rpm)

800 1000 1200

Feed (mm/min) 0.10 0.15


Depth of Cut
(mm)

0.4

0.5

4
1400

0.17

0.20

0.6

0.8

III.Results and Discussions


In machining process, maximizing the material
removal rate (MRR) is an important objective to increase
Fig.2 HSS 16mm Drill Bit
the productivity. The signal to noiseratiofor material
removal rate also given in the Table IV.The material
D.Drilled Work piece Materials
The drilled AA6063 sixteen samples are clearly removal rate (MRR) was calculated based on the weight
and machining time by using the below formula.
shown in the Figure 3.
All Rights Reserved 2016 IJORAT

International Journal of Research in Advanced Technology IJORAT


Vol 1, Issue 9, NOVEMBER 2016

3.
MRR = /4.d2.L
Where, d= hole diameter
L= length of the workpiece

4.

From Table-VI, Table-VII, and Figure-IV, Feed is the


most influencing parameter for maximum MRR which is
followed by cutting speed and depth of cut.
From Table- IV, best parameters found for maximum
MRR are cutting speed = 1200rpm, feed rate=
0.2mm/minand depth of cut= 0.5mm.

A.ANALYSIS FOR MRR:


REFERENCES
For MRR, Depth of cut is the more influencing
parameter for MRR followed by feed rate and cutting
speed. Plot for S/N ratio shown in figure-4 shows there is
more variation for change in feed rate where as there is less
variation for change in cutting speed for MRR.
Table VI: Response Table For Signal To Noise Ratio
LEVEL

SPEED

FEED

DEPTH

35.59

34.41

35.97

36.01

35.92

36.36

36.53

36.67

36.37

36.97

38.09

36.4

Delta

1.38

3.67

0.43

Rank

[1] Ramesh V, Mohammed Hasian Y, Gopinath T, Taguchi


Method Based Optimization Of Drilling Parameters of EN31
Steel With PVD Coated and Uncoated Drills, Journal of
Manufacturing Engineering, Vol.10, Issue.2, 2015.
[2] Kunal Sharma, AbhishekJatav, Optimization of Machining
Parameters in Drilling of Stainless Steel, International Journal of
Scientific Research Engineering & Technology (IJSRET),
Volume.4, Issue.8, 2015.
[3] A. Navanth, T. Karthikeya Sharma,A Study Of Taguchi
Method Based Optimization Of Drilling Parameter In Dry
Drilling Of Al 2014 Alloy At Low Speeds, International Journal Of
Engineering Sciences & Emerging Technologies, Volume 6,
Issue 1, 2015.
[4] Balakumaran.V, Parthasarathy.C, and J.Chandradass,
Optimization of Drilling Parameters on EN31 Steel with
ChromiumCoated Drill Bit by Using Taguchi Method,
International Journal of Advances in Engineering, Vol.1, Issue.8,
2015.
[5] YogendraTyagi, VedanshChaturvedi, JyotiVimal, Parametric
Optimization of Drilling Machining Process usingTaguchi Design
andANOVA Approach, International Journal of Emerging
Technology and Advanced Engineering,Vol.2, Issue.7, 2012.
[6] Ramudu and
M. Naga PhaniSastry, Analysis and
Optimization of Turning Process Parameters Using Design of
Experiments, International Journal of Engineering Research and
Applications, Vol. 2, Issue.6, 2012.
[7] Kamal Hassana, Anish Kumar, M.P.Garg, Experimental
Investigation of Material Removal Rate in CNC Turning Using
Taguchi Method, International Journal of Engineering Research
and Applications, Vol. 2, Issue.2, 2012.

Fig.4. Main Effects plot for MRR

B.ANOVA
Taguchi method cannot judge effect of individual
parameters on entire process. Contribution of individual
parameters of process can be determined using ANOVA.
Minitab 17 software of ANOVA module was employed to
investigate the effect of machining parameters feed, cutting
speed and depth of cut.
TABLE VII: ANOVA FOR MRR
Square

DOF

Seq SS

Adj SS

Adj MS

Speed

7.23

0.02

3
3

526.5
2
6.98

50.8
1
0.67

Depth

224.7
2
1579.
6
20.95

74.91

Feed

224.7
2
1579.
6
20.95

Error
Total

6
15

62.18
1887.
41

62.18

10.36

0.59
9

IV. CONCLUSION
1.

2.

Taguchi method of experimental design has been


applied for optimizing multi-response process
parameters for CNC Drilling Al 6063 Alloy with L16
orthogonal array.
Results obtained from Taguchi method exactly matches
with ANOVA.

All Rights Reserved 2016 IJORAT

S-ar putea să vă placă și