Process Variables Optimization in Lapping of EN8 Material Using Taguchi Method

Rajesh Ramadass

doi:10.11648/j.engmath.20180201.15

Abstract

The main aim of this work is to minimize the surface roughness in the flat lapping of EN8 material. The process variables considered for the study were lapping time, abrasive size and abrasive carrier oil proportion. The mathematical model related to the lapping such as surface finish model, stress model and its significance was understood. The (L<sub>9</sub>) orthogonal array in Taguchi method was utilized to conduct the experiments and surface roughness values were measured. The significance of each process variable on the surface roughness was studied using S/N ratio results. From the results, it was inferred that most influence factor among process variables is abrasive carrier oil proposition in slurry. Response table showed a delta value of 0.1967 for the abrasive carrier oil proposition in slurry. The optimum combination of process variables was determined based on S/N ratio and it was understood that minimum aluminum oxide abrasive proportion in slurry provides better surface quality in lapping of EN8 material. The optimum combination for minimum surface roughness were 15 minutes lapping time, 80 µm abrasive size and 1:3 abrasive carrier oil proportion in slurry.

Highlights

In lapping process, chips were removed with loose grains distributed in lapping slurry which are guided through a shape transferring counterpart along undirected cutting paths
The theoretical and experimental values were compared the present study showed that newly developed lapping tool is capable to produce finer surface roughness
The Taguchi method is an experimental design technique that reduces the number of experiments dramatically through the application of orthogonal arrays and minimizes the effect of the factors that are out of control

Summary

Introduction

Chips were removed with loose grains distributed in lapping slurry which are guided through a shape transferring counterpart along undirected cutting paths. Good surface finish has become an essential part of product quality. One sided surface lapping process provides surface finish to a single surface of the component. I) Most work pieces can be processed without being clamped or fixed. Iii) Changeover times are very short d) Components of less than 0.1 mm thickness can be machined iv) The minimal heating effect prevents undesired thermal distortions and structural changes in the work piece. Vii) It is possible to machine multiple work pieces in one operational step. Jeoung-Du-Kim et al [1] determined the optimal combination of process variables for minimizing the surface roughness (Ra) in the cylindrical fine ceramics (Al2o3) S. N. Farris [2] conducted experiments on ceramic materials by lapping and polishing with the abrasives suspended in between them in the form of slurry

Objectives

Methods

Conclusion