Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024.

Raneen Ali,Catalin Pruncu,Munish Gupta,Wenliang Chen,Mozammel Mia,Aqib Khan

doi:10.3390/ma12071013

Abstract

It is hypothesized that the orientation of tool maneuvering in the milling process defines the quality of machining. In that respect, here, the influence of different path strategies of the tool in face milling is investigated, and subsequently, the best strategy is identified following systematic optimization. The surface roughness, material removal rate and cutting time are considered as key responses, whereas the cutting speed, feed rate and depth of cut were considered as inputs (quantitative factors) beside the tool path strategy (qualitative factor) for the material Al 2024 with a torus end mill. The experimental plan, i.e., 27 runs were determined by using the Taguchi design approach. In addition, the analysis of variance is conducted to statistically identify the effects of parameters. The optimal values of process parameters have been evaluated based on Taguchi-grey relational analysis, and the reliability of this analysis has been verified with the confirmation test. It was found that the tool path strategy has a significant influence on the end outcomes of face milling. As such, the surface topography respective to different cutter path strategies and the optimal cutting strategy is discussed in detail.

Highlights

Due to the importance of the finishing stage in the manufacturing processes, the face milling process is the solution that can be used to achieve good surface quality and high accuracy in a short period of time
The results indicated that the use of single insert face milling leads to worsen the surface with increasing the feed per tooth and the decrease in surface roughness about 1.44–7.71 times when the four-insert face milling considered
The results showed that the surface roughness is only influenced by feed per tooth using a response surface methodology and desirability function

Summary

Introduction

Due to the importance of the finishing stage in the manufacturing processes, the face milling process is the solution that can be used to achieve good surface quality and high accuracy in a short period of time. To achieve the high quality for the desired parts, studying the tool path strategies is inevitable too. The most common cutter path strategies in the milling process are zig, zig-zag, and contour, which can be created with the help of a computer-aided manufacturing system (CAM). The tool path generation is the prime issue in the different stages of NC machining that determines the quality of the desired shapes and the performance of the manufacturing process [1,2]. The optimization of tool path would contribute to improving the sufficiency of the milling process [3].

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Discussion

Conclusion