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Optimization of Cutting Parameters To Minimize The
Optimization of Cutting Parameters To Minimize The
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Luís Queijo
Instituto Politécnico de Bragança
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research article Received 23 February 2016; accepted after revision 21 September 2016
Abstract 1 Introduction
This paper presents a study of the Taguchi design application The machining is one of the most important manufacturing
to optimize surface quality in a CNC end milling operation. processes in the industry today. This is usually defined as the
The present study includes feed per tooth, cutting speed and process of removing material from a workpiece or part in the
radial depth of cut as control factors. An orthogonal array form of chips. A mechanical part could be machined using dif-
of L9 was used and the ANOVA analyses were carried out to ferent techniques without major differences in the final results.
identify the significant factors affecting the surface roughness. However, the efficiency is not the same for all techniques. In
The optimal cutting combination was determined by seeking other words, to obtain the same part, there is a machining tech-
the best surface roughness (response) and signal-to-noise nique most appropriate that gives the best quality for the lower
ratio. The study was carried-out by machining a hardened machining time and energy consumption. The choice of the tech-
steel block (steel 1.2738) with tungsten carbide coated tools. nique depends on the goal to be achieved and, for machining, is
The results led to the minimum of arithmetic mean surface related to the part material and its geometry, as well as, machines
roughness of 1.662 µm, being the radial depth of cut the most and tools available. According to the machining goal and the
influent parameter, with 64% of contribution for the workpiece choice of cutting tool, there are different combinations of param-
surface finishing. eters, like feed rate, spindle speed, axial or radial depth of cut to
obtain different results in terms of quality of machined surface
Keywords and tool wear [1-3]. Each cutting parameters combination will
milling, cutting parameters, optimization, surface roughness, result in a different surface roughness and tool life. However, for
Taguchi method many different parameters to control with several levels for each
one is very difficult to define the best combination that provides
the lower surface roughness and maximum tool life. The most
important features in the manufacturing industry is to predict the
surface quality, tool life and the manufacture costs for a particu-
lar combination of machining parameters.
The quality of machined surface is evaluated by the surface
roughness of the machined part, being the most critical qual-
ity characteristic. Some researchers tried to predict the surface
roughness of machining process through mathematical algo-
rithms [4-6], but those studies are very slow and expensive
since they required a large number of experimental tests, using
several parameters combinations. Nevertheless, an interesting
1
Department of Mechanical Technology
solution to minimize the combinations number of experimental
Polytechnic Institute of Bragança, ESTIG/IPB
Campus Sta. Apolónia, 5301-857 Bragança, Portugal tests could be the implementation of optimization techniques.
2
Department of Mechanical Engineering
In the last two decades were instigated many numerical tech-
Polytechnic Institute of Porto, DEM/ISEP, niques applied to the optimization of machining parameters [7]
R. Dr. António Bernardino de Almeida, 4200-072 Porto, Portugal being the most frequently used the fuzzy logic [8], the genetic
3
Development Department, Palbit, Hardmetals Tools Solutions, algorithms [9] and the Taguchi method [10-12]. In this work is
R. das Tílias, 3854-908 Branca Alb.-a-Velha, Portugal implemented the Taguchi method for surface roughness opti-
*
Corresponding author, e-mail: jribeiro@ipb.pt mization in an end-milling operation.
one. In this analysis, a three-level process parameter counts for Ni 0.90 – 1.20
two degrees of freedom, being the interaction between the cut- Mo 0.15 – 0.25
ting parameters neglected. As a result, there are six degrees of
freedom with three cutting parameters. The degrees of freedom
for the orthogonal array must be equal or greater to those for The tests were carried out on a Deckel Maho DMC 63V ver-
the process parameters. In the present study, was used an L9 tical machining centre using WC coated tools. The tool inserts
orthogonal array. This array has 26 degrees of freedom and it were WNHU 04T310 manufactured by Palbit®. The milling
allows combining three-levels of process parameters. So, the operations were around a circular path with a constant axial
analysis of all parameter position using the L9 orthogonal depth (0.3 mm) in one way until 50 mm of vertical length. In
array will require twenty seven experiments. The experimental Fig. 1 is presented the workpiece on the milling machine table
design for the three cutting parameters using the L9 orthogonal after the machining tests and during roughness measurements.
array is presented in Table 2. There is several surface roughness amplitude param-
eters employed in industry, being the most common the
Fig. 2, using the Mitutoyo SJ-301 Portable Surface Roughness Test Ra_P1 Ra_P2 Ra_P3 S/N ratio
A B C
Tester. The average surface roughness was measured within the Number [µm] [µm] [µm] [dB]
sampling length of 2.5 mm. For each orientation were taken 1 1 1 1 1.92 2.16 2.08 -6.264
five vertical measurements and neglected the lowest and the 2 1 2 2 2.04 1.97 1.95 -5.969
highest result. Final average Ra value is taken by considering 3 1 3 3 1.99 1.78 1.89 -5.523
the average value of the whole measurements. 4 2 1 2 1.63 1.84 1.63 -4.641
5 2 2 3 1.95 1.79 1.87 -5.443
6 2 3 1 2.41 2.31 2.48 -7.608
7 3 1 3 1.72 1.57 1.70 -4.421
8 3 2 1 2.22 1.84 2.06 -6.376
9 3 3 2 1.86 1.79 1.82 -5.208