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Abstract Increasing the productivity with quality is the 2. EXPERIMENTAL PROCEDURE
main key areas focused in the present scenario of
manufacturing. Various techniques have been implemented to In this study, Design Expert 7.0.0 (dx7) software was used
improve the machining processes to increase the productivity. and by using Central Composite Design (CCD) approach the
And Turning is one of the most important manufacturing experimental plan was developed for single response
techniques because of its simplicity and effectiveness. The main optimization. In this study, Response Surface Methodology
aim of this study is to optimize the understudy parameter was used to optimize the Surface Roughness. Response
specially the surface roughness (Ra) in turning of EN 18 Steel surface methodology (RSM) is a collection of mathematical
work piece by using three input parameters i.e. spindle speed, and statistical techniques used for empirical model building.
feed rate and depth of cut. Experimental work was done using Where a response of interest is influenced by several
Design Expert 7.0.0 (dx7) software with Central Composite variables and the objective is to optimize the response. To
Design (CCD) approach. The input parameters were varied at find relation between input and response variable, usually
three different levels. And turning was done using CNC lathe first order model is used, as given in equation below
machine and surface roughness was measured with the help of
portable Mitotoyo Surftest-4 tester. This study uses Response y 0 i xi i i xi i ..... kxi k
surface methodology to find the optimum machining
parameters to produce minimum surface roughness possible in Where, y is the response understudy, is regression
turning process. Regression Equations were developed for coefficient and is error. If the result can still be improved,
Surface Roughness. Confirmation experiments were conducted then the Second order model is applied, as given below
in end to validate the results of experimental work.
k k
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 613
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
2.2 Flow Process Chart Table 3: Results of main experiments for average Ra
Response
Factor 1 Factor 2 Factor 3
Surface
Run A: Speed B: Feed C: DOC
Roughness
rpm mm/min mm
Ra
1 1500 1.02 2.5 3.02
2 2500 0.915 1.85 1.4
3 2500 0.915 1.85 1.98
4 2500 0.915 2.5 2.01
5 3500 0.81 2.5 2.97
6 2500 1.02 1.85 2.4
7 2500 0.915 1.2 1.24
8 3500 0.915 1.85 3.05
9 2500 0.915 1.85 1.99
10 2500 0.81 1.85 0.18
11 1500 0.81 1.2 0.15
12 2500 0.915 1.85 1.51
13 1500 0.915 1.85 1.58
14 3500 1.02 1.2 2.84
15 2500 0.915 1.85 1.86
2.3 Process Variables and their levels Source Sum of df Mean F p-value Remarks
Squares Square Value Prob >
F
The process variables working ranges was selected by Model 10.80 4 2.70 26.10 < significant
performing pilot study. In the present experimental study 0.0001
spindle speed, feed rate and depth of cut has been A-Speed 2.82 1 2.82 27.20 0.0004
considered as process variables. The process variables with B-Feed 4.10 1 4.10 39.62 <
their units (and notations) are listed in Table 2 0.0001
Table 2: Process Variables C-DOC 2.37 1 2.37 22.89 0.0007
A2 1.52 1 1.52 14.67 0.0033
Factors Units Level 1 Level 2 Level 3 Residual 1.03 10 0.10
Spindle
rpm 1500 2500 3500 Lack of 0.73 6 0.12 1.61 0.3350 not
Speed (N)
Fit significant
Feed (F) mm/min 0.81 0.91 1.02
Pure 0.30 4 0.076
Depth of Error
mm 1.20 1.85 2.50 Cor Total 11.84 14
Cut
Std. Dev. 0.32 C.V. % 17.12
R- 0.9126 Pred R- 0.767
2.4 Experimental Results for Surface Roughness Squared Squared 1
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 614
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 615
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
3.4 Response Optimization for Minimum Surface Table 5: Optimal parameters for Surface Roughness (Ra)
Roughness Ra.
Parameters Units Optimal Parameters
Speed rpm 1740.68
Feed mm/min 0.82
Depth of Cut mm 1.27
Here, Fig. 3. Shows Response optimization diagrams and the
value of Desirability comes out to be 0.991 and Table 5.
Shows the optimum process parametric setting where
spindle speed is 1740.68 RPM, feed rate is 0.82 mm/min. and
depth of cut is 1.27 mm.
Surface
0.147096 0.150512 2.32%
Roughness
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 616
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
REFERENCES
2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 617