Optimization of Cutting Parameters on High-Speed CNC Milling for Precision parts of Non-ferrous Castings using RSM

Abstract

This research paper analyses the cutting parameter optimisation suitable for precision parts manufacturing units, which mainly uses non-ferrous cast blocks for their job orders using Box-Behnken's response surface method. This solution method developed based on case studies conducted from industrial units involved in precision components manufacturing in 100% export oriented units around Coimbatore. The problem is converted into a simultaneous optimisation model for getting better material removal rate (MRR) on high-speed CNC milling process while maintaining the surface roughness requirements less than 20 microns. The experiments were carried out for different alloy materials of non-ferrous group frequently used for manufacturing precision components aluminium 6,061, brass, gunmetal, phosper bronze. The group of materials is of heterogeneous but they share similar mechanical properties required for a precision component, it is generally difficult to machine these material due to either soft ductile/hard brittle characters. However this research is to give an adaptable solution to the small and medium type job order companies, which struggle to maintain the precision at a minimised cost of manufacturing. The results show that MRR could be maximised by optimisation of input parameters while keeping Ra in the range less than 0.25 microns.