Abstract
In any machining operations, quality is the important conflicting objective. In order to give assurance for high productivity, some extent of quality has to be compromised. Similarly productivity will be decreased while the efforts are channelized to enhance quality. In this study, the experiments were carried out on a CNC vertical machining center (KENT and INDIA Co. Ltd, Taiwan make) to perform 10mm slots on Al 6351-T6 alloy work piece by K10 carbide, four flute end milling cutter as per taguchi design of experiments plan by L9 orthogonal array was choosen to determine experimental trials. Furthermore the spindle speed (rpm), the feed rate (mm/min) and depth of cut (mm) are regulated in these experiments. Surface roughness and chip thickness was measured by a surface analyser of Surf Test-211 series (Mitutoyo) and Digital Micrometer (Mitutoyo) with least count 0.001 mm respectively. Grey relational analysis was employed to minimize surface roughness and chip thickness by setting of optimum combination of machining parameters. Minimum surface roughness and chip thickness obtained with 1000 rpm of spindle speed, 50 mm/min feed rate and 0.7 mm depth of cut respectively. Confirmation experiments showed that Gray relational analysis precisely optimized the drilling parameters in drilling of Al 6351-T6 alloy.
Highlights
Milling is the most extensively used machining process which may be employed in at least one stage of fabrication in manufacturing industries
Sharma and Mittal (2014) studied the machining parameters like depth of cut, cutting speed, feed rate and tool diameter are optimized with multiple performance characteristics, and concluded that the S/N ratio with Taguchi‟s parameter design is a simple, systematic, reliable and more efficient tool for optimizing multiple performance characteristics of CNC milling process parameters
From the literature it is observed that the parameters such as depth of cut, spindle speed and feed rate are the three predominant cutting parameters influencing on quality and productivity in any machining operation
Summary
Milling is the most extensively used machining process which may be employed in at least one stage of fabrication in manufacturing industries. End milling is one of the important milling operations, which is commonly used in manufacturing industries due to its capability of producing complex geometric surfaces with reasonable accuracy and surface finish. Compared to the sharp angle formed by the rake and flank faces of a typical turning insert, a milling insert’s cutting edge generally has a small chamfer to protect against the shock of repeated material entry. Chips that are too thin indicate that the cutting action and the heat it generates is constrained to a relatively small portion of the insert edge. This can lead to premature cratering, thermal cracking or flank wear. Chips that are too thick indicate high cutting forces that could overwhelm and break the insert
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