Process design for minimization of resultant cuttting forces during the machining of heavy-duty piston

Abstract

In this study, machining performance a series of commercially available uncoated carbide inserts with different depth of cut investigated during plunging of aluminum alloy (LM-13) and NI-alloy (MPL-251) of heavy-duty piston. For comparison, different depth of cut with same angle was also tested under the same cutting conditions. Direction of plunging machining operation is perpendicular to the axis of the piston which will be X- direction. In present work Taguchi analysis using ANOVA for 3 parameter, 3 level experimentation - full factorial (l27 array) were done with output response variables like resultant cutting forces, mean surface roughness (Ra), maximum surface roughness (Rt). Main effects of factors and their interactions were studied and multiple optimizations of the responses were analyzed by grey relational analysis using Taguchi methods to find the best optimal setting of parameter levels. The confirmation tests were carried out to reveal the accuracy of the best setting of parameter levels. Through analysis of variance (ANOVA), it was found that selection of depth of cut tool has greater influence on cutting surface roughness, selection of feed and cutting speed has greater influence on resultant cutting forces. Whereas selection of cutting speed, feed rate and depth of cut has greater influence on the cutting forces. Grey relational analysis using Taguchi techniques gives the best optimal results by setting cutting parameters at lower level of 300 m/min, feed at lower level of 0.04 mm/rev and depth of cut 6 mm at higher level for better output. It was also found that the cutting speed and feed rate tool has the strongest effect on the multi-performance characteristics among the other machining parameters.This paper describes Grey relational analysis. Taguchi techniques gives the best optimal results by setting cutting parameters at lower level of 300 m/min, feed at lower level of 0.04 mm/rev and depth of cut 6 mm at higher level for better output. It was also found that the cutting speed and feed rate tool has the strongest effect on the multi-performance characteristics among the other machining parameters.