Abstract
Milling is the surface machining process by removing material from the raw stock using revolving cutters. This process accounts for a major stake in most of the Original Equipment Manufacturing (OEM) industries. This paper discusses optimizing process parameters for machining the AA 2014 T 651 using a vertical milling machine with coated cutting tools. The process parameters such as cutting speed, depth of cut, and type of the cutting tool with all its levels are identified from the previous literature study and several trial experiments. The Taguchi L9 Orthogonal Array (OA) is used for the experimental order with the chosen input parameters. The commonly used cutting tools in the machining industry, such as High-Speed Steel (HSS) and its coated tools, are considered in this study. These tools are coated with Titanium Nitride (TiN) and Titanium Aluminum Nitride (TiAlN) by Physical Vapor Deposition (PVD) technique. The output responses such as cutting forces along the three-axis are measured using a milling tool dynamometer for the corresponding input factors. The input process parameters are optimized by considering the output responses such as MRR, machining torque, and thrust force. Grey Taguchi-based Response Surface Methodology (GTRSM) is used for multiobjective multiresponse optimization problems to find the optimum input process parameter combination for the desired response. Polynomial regression equations are generated to understand the mathematical relation between the input factor and output responses as well as Grey Relational Grade (GRG) values. The optimum process parameter combination from the desirability analysis is the HSS tool coated with TiAlN at a cutting speed of 270 rpm and a depth of cut value of 0.2 mm.
Highlights
Modern-day cutting tools used in the machining industry can be coated with combination of alloying elements, which provides a wide range of advantages in improving the tool life. ese coated tools may reduce the manufacturing cost, and thereby the cost of the manufactured part is significantly reduced. e majority of modern machining is done using computer numerical control (CNC), which allows computers to control mills, lathes, and other cutting machines
Machining Torque is calculated with the help of cutting force and diameter of the tool, and Metal Removal Rate is calculated using the volume of material removed and HSS tool (HSST)-Titanium Nitride (TiN) HSST-Titanium Aluminum Nitride (TiAlN) HSST-TiN HSST-TiAlN
The results proved that the Material Removal Rate (MRR) is directly proportional to the cutting speed
Summary
Modern-day cutting tools used in the machining industry can be coated with combination of alloying elements, which provides a wide range of advantages in improving the tool life. ese coated tools may reduce the manufacturing cost, and thereby the cost of the manufactured part is significantly reduced. e majority of modern machining is done using computer numerical control (CNC), which allows computers to control mills, lathes, and other cutting machines. From small individual pieces to huge, heavy-duty group milling processes, it encompasses a Advances in Materials Science and Engineering wide range of procedures and machinery. It is one of the most widely utilized procedures for machining parts with sufficient precision and tolerance control in industry and machine shops today. Used milling cutters include end mill, ball nose cutter, slab mill, side and face cutter, hob, thread mill, face cutter, fly cutter, woodruff cutter, and hollow mill Materials used in those cutters include High-Speed Steel (HSS), cemented carbides, tool steels, cast-tool material, plain carbon tool steel, and stellite. High-Speed Steel (HSS) mill tool is utilized in this work, which is widely used by several manufacturing industries for affordable metal cutting operations
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