IJIRST International Journal for Innovative Research in Science & Technology| Volume 3 | Issue 11 | April 2017
ISSN (online): 2349-6010
Optimization of CNC End Milling Process
Parameters for Aluminium 6061 Alloy using
Carbide Tool Material by Design of Experiments
Hemantsinh Pratapsinh Rao Prof. Rajat Dave
Student Assistant Professor
Department of Mechanical Engineering Department of Mechanical Engineering
S V B I T, Gandhinagar-382650 S V B I T, Gandhinagar-382650
Prof. Riddhish Thakore
Assistant Professor
Department of Mechanical Engineering
S V B I T, Gandhinagar-382650
Abstract
Quality and productivity play important role in todays manufacturing market. Now a days due to very stiff and cut throat
competitive market condition in manufacturing industries. The main objective of industries reveal with producing better quality
product at minimum cost and increase productivity. CNC end milling is most vital and common operation use for produce
machine part with desire surface quality and higher productivity with less time and cost constrain. To obtain main objective of
company regards quality and productivity. In the present research project an attempt is made to understand the effect of
machining parameters such as cutting speed (m/min), feed rate (mm/min),depth of cut (mm) that are influences on responsive
output parameters such as Surface Roughness(Ra) and Material Removal Rate(MRR) by using optimization philosophy. The
effort to investigate optimal machining parameters and their contribution on producing better Surface quality and higher
Productivity. Thus by Analysing experimental and theoretically data optimization of process parameters are to be carried out.
Keywords: CNC end milling, Optimization, Surface roughness (Ra), Material removal rate(MRR), Carbide tool material,
Alluminium alloy
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I. INTRODUCTION
Milling is the process of machining flat, curved, or irregular surfaces by feeding the work piece against a rotating cutter
containing a number of cutting edges. The milling machine consists basically of a motor driven spindle, which mounts and
revolves the milling cutter, and a reciprocating adjustable worktable, which mounts and feeds the work piece. Among several
CNC industrial machining processes, milling is a fundamental machining operation. End milling and face Milling is the most
common metal removal operation encountered. It is broadly used in a variety of manufacturing industries including the
aerospace, automotive sectors, where quality is vital factor in the production of slots, pockets, precision moulds and dies.
Fig. 1.1: Milling Operation
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Optimization of CNC End Milling Process Parameters for Aluminium 6061 Alloy using Carbide Tool Material by Design of Experiments
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Fig. 1.2: End Mill
The end mill has edges in the side surface and the bottom surface. The fundamental usage is that the end mill is rotated, and
makes a plane of a material in the right-and-left direction or a plane of a bottom side of the end mill. We can make various
shapes of mechanical parts with the end mill. The edge of the end mill is very weak. In case beginning of cuttings, we have to
take care so that the end mill may touch to a material as slowly as possible A large variety of cutter materials has been developed
to meet the required conditions in milling operation the common materials used for making of milling cutters are carbon steel,
high speed steel, sintered carbides, ceramics and satellites.
The mechanism behind the formation of surface roughness is very dynamic, complicated, and process dependent. Several
factors will influence the final surface roughness in a CNC end milling operation such as controllable factors (spindle speed, feed
rate and depth of cut) and uncontrollable factors (tool geometry and material properties of both tool and work piece). Milling is
one of the most common process in manufacturing and is very commonly employed in numerical control machines for material
removal operations.
II. END MILLING OPERATION
End milling is the most common metal removal operation encountered. It is widely used to mate with other part in die,
aerospace, automotive, and machinery design as well as in manufacturing industries. The cutter called end mill has diameter less
than the work piece width.
III. LITERATURE REVIEW
Many investigators have suggested various methods to explain the effect of process parameter on surface roughness and MRR in
CNC end milling process.
B. Ramesh, et al [1] were carried out Determination of optimum parameter levels for multi performance characteristics in
conventional milling of beryllium copper alloy by using response surface methodology. They described that the utilization of
Replication Surface Methodology (RSM) to investigate the relative influence of milling process parameters (spindle celerity,
victual and depth of cut) on quality characteristics (surface roughness and material abstraction rate), adequacy analysis of
replication surface models and to procure optimal process parameter levels in the culled range which leads to procure high
machining quality and productivity in conventional milling of beryllium copper alloy plate utilizing 6 mm carbide end mill.
Predicated on the experimental results and methodology utilized, the conclusions can be drawn for straight grooving operation
are that Surface roughness and material abstraction rate increases as speed and victual increases.
K.D Theja, et al [2] were carried out Prediction & Optimization of End Milling Process Parameters Using Artificial Neural
Networks. They described that on a potent and precise 3-axis CNC vertical machining centre, mode employing a perpetually
variable spindle expedite to a maximum of 6000 rpm and with a maximum spindle power of 5.5kW. The victual rates can be set
up to a maximum of 10m/min. Experiments were conducted as per the deign matrix. Cutting haste, Victual and Depth of cut
were taken as the process parameters and the output replications i.e. Material abstraction rate and Implement wear resistance
were taken as the output replications. Full factorial design was acclimated to carry out the experimental design. Artificial Neural
networks (ANN) program available in Matlab software is utilized to establish the relationships between the input process
parameters and the output variables. The developed ANN model can be further integrated with optimization algorithms like GA
to optimize the End milling parameters.
Dimple Rani, et al [3] were carried out Optimization and Modelling of End Milling Process Parameters by Using Taguchi
Method. They described that an integrated optimization approach utilizing Taguchi method. The average value of surface
roughness and S/N ratio were calculated and were found to be within the range. Taguchi parameter design can provide a
systematic procedure that can efficaciously and efficiently identify the optimum surface roughness in the process control of
individual end milling machines. As speed increases surface roughness decreases and victual increases surface roughness
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Optimization of CNC End Milling Process Parameters for Aluminium 6061 Alloy using Carbide Tool Material by Design of Experiments
(IJIRST/ Volume 3 / Issue 11/ 016)
additionally increases. For achieving good surface finish on the D2 work piece, higher cutting haste, lower aliment and lower
depth of cut are preferred.
P. M. Thakur, R. Rajesh [4] were carried out Optimal selection of process parameters in CNC end milling of Al-7075-T6
aluminium alloy using a Taguchi-Fuzzy approach. They described that integrated Taguchi-Fuzzy for optimization of process
parameters of CNC end milling of Al-7075 T6 alloy with multiple performance characteristics. A fuzzy reasoning of multiple
performances has been performed by fuzzy logic unit and a multi replication performance index (MRPI) was developed for each
run. Predicated on experimental results and corroboration tests the conclusion can be drawn that the following parameter setting
has been identified as to yield the best cumulation of parameters: A3B1C3D2. The experimental results showed that there was
consequential amelioration in surface roughness and MRR. The most paramount parameters affecting replications have been
identified as nasal perceiver radius and depth of cut.
Amit Joshi, Pradeep Kothiyal [5] were carried out Investigating Effect of Machining Parameters of CNC Milling on Surface
Finish by Taguchi Method. They described from the graph of S-N ratio it can be observed that optimal value of surface finish is
obtained at first level of factor A third level of factor B and second level of factor C. Optimal value of surface finish is
3.0723m. From the ANOVA it can be visually perceived that percentage contribution of aliment rate is maximum and it
signifies Victual rate is the most dominating factor for modelling surface finish. Taguchi robust design is opportune for
modelling surface finish in CNC milling.
Abhishek Kumbhar, et al [6] were carried out Multi-objective Optimization of Machining Parameters in CNC End Milling of
Stainless Steel 304. They described that the effects of cutting speed, feed rate and depth of cut on surface roughness and
material removal rate during end milling of Stainless steel 304 were investigated utilizing Taguchi's experimental design method
coalesced with Grey relational analysis. The conclusions can be made from performed experimental research that based on Grey
Relational Grade analysis, the optimal process parameters for multi-objective optimization are as follows: Cutting speed at level
2 (75 m/min), feed rate at level 1 (0.15 mm/rev) and depth of cut at level 3 (1.5 mm) i.e. v2-f1-d3. Confirmatory test result was
copacetic and has yielded reduction in surface roughness by 24.86 % and increment in material removal rate by 23.99 %. Thus
we can observe amendment in performance characteristic. It has been established that Taguchi predicated Grey Relational
Analysis is an efficacious multi-objective optimization implement.
On the basis of the above Literature Review paper, we finds the several research gap in the following segment of End Milling.
So selected of workpiece material as an Aluminium 6061 Alloy and Carbide End Mill with different angle Cutting insert.
IV. EXPERIMENTAL SETUP AND DATA COLLECTION
Workpiece Material
Fig. 3.1: Aluminium 6061 alloy
Table - 3.1
Physical Properties of Al 6061
Density 2.7 g/cm
Melting Point Approx. 580C
Modulus of Elasticity 70-80 GPa
Poisson's Ratio 0.33
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Optimization of CNC End Milling Process Parameters for Aluminium 6061 Alloy using Carbide Tool Material by Design of Experiments
(IJIRST/ Volume 3 / Issue 11/ 016)
Table - 3.2
Chemical Composition of Al 6061
Component Amount (wt %)
Aluminium 97.610
Magnesium 0.890
Silicon 0.570
Iron 0.352
Copper 0.219
Zinc 0.093
Titanium 0.019
Manganese 0.037
Chromium 0.114
Other 0.05
Advantages of Al 6061 Alloy
Light in weight and resistance to oxidation
Corrosion less
Low density material
Good Surface finish
Medium to High Strength
Widely Availability
Good corrosion resistance to sea water
Can be anodized
Good weldability and brazability
Application of Al 6061 Alloy
The demand for high strength and low weight material in aerospace is found to be increasing in fabrication of structures
and equipment's of Aircraft.
Aluminium alloys possess the characteristics of light weight and high strength.
Marine fittings
Transport, Bicycle frames
Camera lenses
Drive shafts
Electrical fittings and connectors
Brake components
Valves, and Couplings
Selected Process & Response Parameters are
Table - 3.3
Process Parameters Response Parameters
Cutting Speed (Vc) m/min Surface roughness (m)
Feed Rate (Fd) mm/rev Material Removal Rate (mm/min)
Depth of Cut (Ap) mm
Cutting Inserts and Cutters Specifications
Table - 3.3 for 10 Carbide Insert
Table - 3.4
Cutter 210 Code:- Insert 210 Code:-
(R210-020A16L-09M050) (R210-090408-NL1025)
Specifications Specifications
R=Style(Right Hand Rotating) R=Style (Right/ Left Hand)
210=Main Code (Coro mill) 210=Main Code (Coro mill)
020=Cutter Diameter (mm) 09=Insert Size (mm)
A=Types of coupling, Cylindrical (mm) 04=Insert Thickness (mm)
16=Coupling Size (mm) 08=Corner Radius (mm)
L=Extra Long N=Main ISO Application Area For Aluminium
12=Insert Size (Ia) L=Operation (Light Cutting)
M=Close Pitch 1025=Wiper (W)
050=Length (mm)
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Optimization of CNC End Milling Process Parameters for Aluminium 6061 Alloy using Carbide Tool Material by Design of Experiments
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V. RESULT AND DISCUSSION
Design of Experiment
In industry, designed experiments can be used to systematically investigate the process or product variables that influence
product quality.
After you identify the process conditions and product components that influence product quality, you can direct
improvement efforts to enhance a product's manufacturability, reliability, quality, and field performance.
Designed experiments are often carried out in four phases: planning, screening (also called process characterization),
optimization, and verification.
DOE is considered as one of the most comprehensive approach in product or process developments.
It is a statistical approach that attempts to provide a predictive knowledge of a complex, multi-variable process with few
trials.
Taguchi Method Steps:-
1) Identified the main function and its side effects
2) Identified the noise factors, testing condition and quality characteristics
3) Identified the objective function to be optimized
4) Identified the control factors and their levels
5) Select a suitable Orthogonal Array and Construct the matrix
6) Conduct the matrix experiment
7) Examine the data, predict the optimum control factor levels and its performance
8) Conduct the verification experiment
9) Selected levels of DOE
Table 4.1
Factor level of DOE
Factors Level Factors Value
Cutting Speed(rpm) 3 120, 235, 380
Feed Rate(mm/rev) 3 0.08, 0.14, 0.20
Depth of Cut(mm) 3 1, 3 , 6
Table 4.2
DOE
Serial No Cutting Speed (rpm) Feed Rate (mm/rev) Depth of Cut (mm)
1 120 0.08 1
2 120 0.14 3
3 120 0.20 6
4 235 0.08 3
5 235 0.14 6
6 235 0.20 1
7 380 0.08 6
8 380 0.14 1
9 380 0.20 3
Table 4.3
Measured Surface Roughness and MRR
Serial No Cutting Speed (rpm) Feed Rate (mm/rev) Depth of Cut (mm) SR (m) MRR (mm/min)
1 120 0.08 1 1.35 36.68
2 120 0.14 3 2.40 192.60
3 120 0.20 6 3.10 550.31
4 235 0.08 3 2.45 215.53
5 235 0.14 6 3.15 754.39
6 235 0.20 1 1.40 179.61
7 380 0.08 6 3.20 697.06
8 380 0.14 1 1.45 203.31
9 380 0.20 3 2.70 871.33
Taguchi Orthogonal Array Design
In this experimental work, we have taken L9 orthogonal array design i.e. L9 (3^3) means that Factors are 3 & Runs are 9, and
Columns of L9 (3^4) Array.
Analysis: SR, MRR versus Cutting Speed, Feed Rate, Depth of Cut
Response Table for Means
Table 4.4
Nominal is best (10Log10 (Ybar^2/s^2))
Level Cutting Speed Feed Rate Depth of Cut
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Optimization of CNC End Milling Process Parameters for Aluminium 6061 Alloy using Carbide Tool Material by Design of Experiments
(IJIRST/ Volume 3 / Issue 11/ 016)
1 131.07 159.38 70.63
2 192.76 192.88 214.50
3 296.51 268.07 335.20
Delta 165.44 108.70 264.57
Rank 2 3 1
Fig. 4.1: Means Plot for 10 Insert
Response Table for Signal to Noise Ratios
Table - 4.5
Nominal is best (10Log10 (Ybar^2/s^2))
Level Cutting Speed Feed Rate Depth of Cut
1 -2.692 -2.705 -2.711
2 -2.875 -2.873 -2.854
3 -2.924 -2.915 -2.927
Delta 0.232 0.210 0.216
Rank 1 3 2
Fig. 4.2: S/N Ratio for 10 Insert
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Optimization of CNC End Milling Process Parameters for Aluminium 6061 Alloy using Carbide Tool Material by Design of Experiments
(IJIRST/ Volume 3 / Issue 11/ 016)
The study proposes an integrated optimization approach using Taguchi method. In this research work, the average value of
surface roughness and S/N ratio were calculated and were found to be within the range.
Taguchi parameter design can provide a systematic procedure that can effectively and efficiently identify the optimum
surface roughness in the process control of individual end milling machines.
It also allows industry to reduce process or product variability and minimize product defects by using a relatively small
number of experimental runs and costs to achieve superior-quality products. This research only demonstrates how to use
Taguchi parameter design for optimizing machining performance with minimum cost.
This approach can be recommended for continuous quality improvement and off-line quality of any production process. As
speed increases surface roughness decreases and feed increases surface roughness also increases. For achieving good surface
finish on the Al 6061 alloy work piece, higher cutting speed, lower feed and lower depth of cut are preferred. And Cutting
Insert 210 consider as a high cutting speed.
VI. CONCLUSION
In this study, the effects of cutting speed, feed and depth of cut on surface roughness and material removal rate during end
milling of Aluminium 6061 alloy were investigated using Taguchi's experimental design method by Design of Experiment.
From the experimental analysis, we can see that the Surface Roughness and Material Removal Rate (MRR) are mainly affected
by the process Parameters of Cutting Speed, Feed Rate and Depth of Cut.
Response table of S/N Ratio concludes that Cutting speed has great impact on SR and MRR, and Means Plot and Standard
Deviations Plot mainly affect the Depth of Cut.
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