ACKNOWLEDGEMENT

We are extremely grateful to our guide Miss. N.KEERTHI Assistant Professor in

Mechanical Engineering Department of Annamacharya Institute of Technology and Sciences,
Rajampet, for her valuable support and guidance throughout this project and we are very
thankful for her association with us and for her constant encouragement, accessibility and
valuable suggestions. we would also like to thank Mr. V.VENKATESH Assistant Professor in
mechanical engineering department for helping in conducting the experiments in CNC milling
machine.
We express our in deep sense of gratitude to our Head of the Department, Prof.
N.SIVARAMI REDDY, for the support extended to us during this project work.
We take

immense

pleasure

in

thanking

Dr. A.SUBRAMANYAM,Principal,

Annamacharya Institute of Technology and Sciences, Rajampet, for providing necessary

facilities to carry our project.
We wish to express our sincere gratitude to Dr.G.PRABHAKARA RAO, Director,
Annamacharya Institute of Technology and Sciences, Rajampet, for providing necessary
facilities to carry our project.
Finally we would like to express our sincere thanks to faculty members of mechanical
engineering department, lab technicians, one and all who has helped us to complete the project
work successfully.

ABSTRACT

Milling is the machining process of using rotary cutters to remove material from a work
piece advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide
variety of different operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations. It is one of the most commonly used processes in industry
and machine shops today for machining parts to precise sizes and shapes.
A metal matrix composite (MMC) is composite material with at least two
constituent parts, one being a metal necessarily, the other material may be a different metal or
another material, such as a ceramic or organic compound when at least three materials are
present, it is called a hybrid composite. in our project the matrix material is aluminium and
reinforcements are magnesium and zinc.
The project is divided into three phases. First the experimental data is collected by
conducting the experiments. In the first phase artificial neural network (ANN) has been
developed to predict the responses. The developed model was trained and tested with
experimental data. The predicted results were compared with experimental results.
In second phase the ANN predicted results were analyzed by performing taguchi S/N
ratio analysis. In the third phase analysis of variance (ANOVA) is employed to analyze the
effects of process parameters and output responses. This work is useful in predicting the
responses while milling the aluminium metal matrix composites.

CONTENTS
CHAPTER

TITLE

Page No.

ACKNOWLEDGEMENT
ABSTRACT
LIST OF TABLES

(i)

LIST OF FIGURES

(ii)

LIST OF ABBREVIATIONS

(iii)

INTRODUCTION

1-19

1.0

composite material

1.1

matrix selection

1.2

aluminum alloy matrix

1.3

machining of metals

11

1.4

aspects of machining

12

1.

stir casting process

13

16

composite material preparation

15

1.7

heat treatment

17

1.8

cutting parameters

17

1.9

response parameters

18

1.10

CNC milling

19

1.11

overview of CNC milling

19

LITERATURE REVIEW

2.0

Introduction

21

2.1

literature review

21

2.2

objective of present work

25

2.3

scheme of investigation

21-25

METHODOLOGY

26-38

3.0

Introduction

26

3.1

neural network

26

3.2

design of experiments

34

3.3

orthogonal array

35

3.4

signal to noise ratio

37

3.5

analysis of variance

38

EXPERIMENTAL WORK

4.0

Introduction

40

4.1

experimental setup

40

4.2

specification of CNC milling machine

41

4.3

work material preparation

42

4.4

surface finish measurement

44

4.5

experimental procedure

44

4.6

orthogonal array table creation

45

RESULTS AND DISCUSSION

5.0

results from ANN

48

5.1

results from taguchi

50

5.2

results from ANOVA

51

40-45

48-51

CONCLUSION

52-53

6.0

conclusion

52

6.1

future scope

52

REFERENCES

53