Abstract
Reducing burr formation in machining operations is of vital importance as they can decrease the functionality of components and can cause injuries. Nowadays, additional processes for deburring are often necessary. To avoid deburring, the modification of turning processes is a promising approach. Here, different parameters have a significant influence on burr formation. This paper presents the influence of cutting parameters like cutting speed, feed rate, depth of cut on the burr size of 5A06, 6061 and 6063 aluminum alloy during turning on CNC lathe. A plan of experiments based on Taguchi method has been used to acquire the data. An orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) are employed to investigate machining characteristics using fine turning tool within the domain of experiments considered. Experimental runs were chosen following L9 orthogonal array of Taguchi. Analysis of variance was undertaken to find out the influence of process parameters on the response noted. Predicted values are finally checked for accuracy through a confirmation test. Confirmation tests have been carried out to predict the optimal setting of process parameters to validated the proposed method and obtained the values 0.024 mm, 0.006 mm, and 0.009 mm for burr height of 5A06, 6061 and 6063 aluminum alloy respectively. In this paper, methods for burr minimization in various cutting processes are presented. Burr reduction strategies for turning of different materials are presented.
Highlights
The presence of burrs on the edges of parts is the cause of various problems in manufacturing
Plan of experiments of 5A06, 6061 and 6063 aluminum alloy based on Taguchi orthogonal array and observed responses are shown in Table 4, Table 5, and Table 6, respectively
From main effects plot of signal to noise (S/N) ratio, the optimum parameters combination of 5A06 aluminum alloy for burr height is A3B2C1 corresponding to the largest values of S/N ratio for all control parameters
Summary
The presence of burrs on the edges of parts is the cause of various problems in manufacturing. The deburring processes are included in manufacturing. This, coupled with the deburring cost, increases as the amount of burrs rises [6,7,8,9,10]. Burr sizes must be controlled for the optimal choice of a deburring process or cutting parameters for burr minimization. The metal cutting burr formation and control are studied by the scholars and engineering experts [11,12,13,14]. They got a series of research achievement, improved the metal cutting burr formation theory and putted the deburring technology into machining
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