Optimal Selection of Process Parameters in CNC End Milling of Al 7075-T6 Aluminium Alloy

Using a Taguchi-fuzzy
Thakur Paramjit Mahesha, , , R. Rajeshb
This paper describes the application of the fuzzy logic integrated with Taguchi method for
minimizing the surface roughness and maximizing the material removal rate simultaneously, in
CNC end milling of Al 7075 T6 aerospace aluminium alloy. The input parameters taken into
consideration are speed, feed, depth of cut and nose radius. Al 7075 T6 is one of the highest
strength aluminium alloys in 7000 series family. In Taguchi method, L27 orthogonal array with 4
factors and 3 levels are chosen and S/N ratios are calculated. The S/N ratios of roughness and
material removal rate are fed as inputs to fuzzy logic system and output received is Multi
response performance index (MRPI). With application of ANOVA, the nose radius and depth of
cut are identified as the most significant parameters contributing about 31% of the variance.
Further a confirmation test showed that, there was a significant improvement in MRPI of optimal
process parameters as compared to MRPI of initial process parameters.

Multi-objective optimization using Taguchi based grey relational analysis for micro-milling of
Al 7075 material with ball nose end mill
Emel Kuram, , Babur Ozcelik
This study was carried out to understand micro-milling of aluminum material with ball nose end
mill and consisted of four stages: experimental work, modelling, mono and multi objective
optimization. In the first stage (experimental work), micro-milling experiments were carried out
using Taguchi method. The effects of spindle speed, feed per tooth and depth of cut on tool wear,
force and surface roughness were investigated. Cutting tools and workpiece surfaces were also
inspected via scanning electron microscope. Adhesion and abrasion wear mechanisms during
micro-milling of aluminum were observed. Workpiece surfaces had the accumulations of
plastically deformed workpiece material due to the high ductility of aluminum. In the second
stage (modelling), all data gathered in the experimental works were utilized to formulate first-
order models with interaction. These first-order models with interaction could be used to predict
responses in micro-milling of aluminum with a minor error. In the third stage (mono-objective
optimization), responses were used alone in optimization study as an objective function. To
minimize all responses, Taguchis signal to noise ratio was used. The effect of control factors on
responses was determined by analysis of variance. In the fourth stage (multi objective
optimization), responses were optimized simultaneously using grey relational analysis.
Influence of Cutting Parameters in Face Milling Semi-Solid AA 7075 Using Carbide Tool
Affected the Surface Roughness and Tool Wear
Surasit Rawangwonga,* Jaknarin Chatthonga, Worapong Boonchouytana.Romadorn Burapaa
The purpose of this research was to investigate the effect of the main factors on the surface
roughness in semi-solid AA 7075 face milling. The results of the research could be applied in the
manufacture of automotive components and mold industry. The study was conducted by using
computer numerical controlled (CNC) milling machine with 63 millimeter diameters fine type
carbide tool with twin cutting edge. The variable factors were the speed, feed rate and depth of
cut which the bite cutter was not over 1 mm. For this experiment we used factorial designs. The
result revealed that the factors affected the surface roughness were the feed rate ratio and the
speed, while the depth of cut unaffected the surface roughness. Furthermore, the result of the test
showed that the surface roughness was likely to reduce when using the speed 3,800 rpm and the
feed rates was 1,000 mm/min. The result of the research led to the linear equation measurement
value which was Ra = 0.156 - 0.000024 Speed + 0.000047 Feed rate. The equation formula
should be used with the speed in the range of 2,600-3,800 rpm, feed rate in the range of 1,000-
1,500 mm/min and the depth of cut of not over 1 mm. When the equation was used to confirm
the research results, it was found that the mean absolute percentage error (MAPE) of the surface
roughness obtained from the predictive comparing to the value of the experiment was 3.62
percent, which was less than the specified error it was acceptable. Pattern of wear was similar to
mechanical fatigue cracking. It may be due to the very tip of the cutting tool or an impact as
cutting tool materials resistant to wear less.

Effect of machining parameters on output characteristics of CNC milling using Taguchi

optimization technique, Jatin and Pankaj Sharma.
This paper gives the effect of different machining parameters (cutting speed, feed, and depth of
cut) on Surface Roughness in end milling. Taguchi technique is being used for the various
calculations. The study was conducted in machining operation for hardened die steel H-13. The
processing of the job was done by solid carbide four flute end-mill tool under finishing
conditions. L-9 standard orthogonal array is used for calculation of no. of variables and no. of
levels. Signal to Noise Ratio and ANOVA are calculated to draw the graphs and come to the
results.
Effect of machining parameters on output characteristics of CNC milling using Taguchi
optimization technique,
Jatin and Pankaj Sharma.
This paper gives the effect of different machining parameters (cutting speed, feed, and depth of
cut) on Surface Roughness in end milling. Taguchi technique is being used for the various
calculations. The study was conducted in machining operation for hardened die steel H-13. The
processing of the job was done by solid carbide four flute end-mill tool under finishing
conditions. L-9 standard orthogonal array is used for calculation of no. of variables and no. of
levels. Signal to Noise Ratio and ANOVA are calculated to draw the graphs and come to the
results.

Optimization of Machining Parameters in End Milling of AISI H11 Steel Alloy by Taguchi
based Grey Relational Analysis,
Nikhil Aggarwal and Sushil Kumar Sharma..
This study investigated the effects of the machining parameters by end milling operation on the
AISI H11 steel alloy. Metal machining has been a very significant activity in manufacturing.
Surface quality is one of the most common concern is to satisfy customer needs in which the
major indication of surface quality on machined parts is surface roughness. It has long been
recognized that the machining conditions, such as cutting speed, feed and depth of cut affect the
performance of the operation to a high extent. Surface roughness and material removal rate
should be taken into consideration. This can be achieved using design of experiments (DOE). It
is used in the manufacturing industries for making die casting moulds, extrusion dies, moulds for
glass industry, punches, etc. In the present study the machining experiments were conducted on
CNC vertical milling machine whose maximum speed was 6000 RPM. Design of experiments
based on Taguchi grey relational analysis with three independent factors (cutting speed, feed rate
and depth of cut), three levels L27 orthogonal array has been used to develop relationships for
predicting surface roughness and metal removal rate. The surface roughness was measured using
surface roughness tester and the averages were calculated to obtain the surface roughness of the
samples. Material removal rate was calculated using the formula in terms of width of cut, depth
of cut and table feed rate.
Chemical Composition
The following table shows the chemical composition of the aluminum 7075
alloy.

Element Content (%)

Aluminum, Al 90

Zinc, Zn 5.6

Magnesium, Mg 2.5

Copper, Cu 1.6

Chromium, Cr 0.23

Physical Properties
The physical properties of aluminum 7075 alloy are tabulated below.

Properties Metric Imperial

Density 2.8 g/cm3 0.101 lb/in3

Melting point 483C 900F

Mechanical Properties
The mechanical properties of aluminum 7075 alloy are outlined in the
following table.

Properties Metric Imperial

Tensile strength 220 MPa 31909 psi

Yield strength 95 MPa 13779 psi

Shear strength 150 MPa 21756 psi

Fatigue strength 160 MPa 23206 psi

Elastic modulus 70-80 GPa 10153-11603 ksi

Poisson's ratio 0.33 0.33

Elongation at break 17% 17%

Hardness 60 60

Thermal Properties
The thermal properties of aluminum 7075 alloy are given in the following table.

Conditions
Properties
T (C) Treatment

Thermal expansion 23.2 (10-6/C) 20-100 -

Thermal conductivity 130 W/mK 25 T6

Other Designations
Other designations that are equivalent to aluminum 7075 alloy include:

AMS 4044 ASTM B209 ASTM B468 QQ A-200/15

AMS 4045 ASTM B210 DMS 2233 QQ A-225/9

AMS 4049 ASTM B211 MIL A-12545 QQ A-250/13

AMS 4131 ASTM B221 MIL A-22771 QQ A-250/24

AMS 4147 ASTM B241 MIL F-18280 QQ A-367

AMS 4154 ASTM B247 MIL F-5509 QQ A-430

AMS 4323 ASTM B316 QQ A-200/11 QQ WW-T-700/7

SAE J454