Optimization of Process Parameters for Superior Surface Roughness and Higher Mrr of Al Alloy by Using Taguchi Technique and Regression Analysis

Abstract

In this thesis experiments are conducted to get the superior surface finish quality and higher material removal rate of a component by using carbide tips. Multiple experiments are performed by varying the milling parameters such as spindle speed, cut feed and step over for roughing and finishing operations. Experiments are performed on 9 components by selecting the parameters as per Taguchi method. After machining, surface roughness values are observed and the parameters are optimized from the observations for the least value for both roughing and finishing operations. Material Removal Rates are also determined and optimized for higher values. Taguchi method and Regression Analysis are used for the optimization of spindle speeds, cut feed and step over.

Cut Feed – 2000mm/min, 2500mm/min, 3000mm/min, Spindle Speed – 1000rpm, 1500rpm, 2000rpm, Step Over – 20mm, 25mm, 30mm and depth of cut – 0.5mm are the machining parameters used in roughing operation. The machining parameters used for finishing operation are Spindle Speed – 2000rpm, 2200rpm, 2500rpm, Cut Feed – 1000mm/min, 1200mm/min, 1500mm/min , Step Over – 5mm, 10mm, 12mm and depth of cut – 0.3mm.

The milling process is conducted on a CNC Vertical milling machine.