Optimization of Surface Roughness of AISI 1040 Stainless Steel in Milling Process Using Taguchi Method

Year 2019, Volume: 23 Issue: 1, 113 - 120, 01.02.2019

Neslihan Özsoy , Murat Özsoy

https://doi.org/10.16984/saufenbilder.466053

Cited By: 2

Abstract

Surface
roughness significantly affects the work efficiency and life of machine parts
interacting with each other. There are many parameters that affect surface
roughness such as processed material, cutting tool, cutting parameters, cooling
type. For this reason, optimization of the machining parameters and proper
processing conditions are very important. In this study, the optimum machining
conditions were determined by investigating the surface roughness of the milled
AISI 1040 steel alloy depending on the feed per tooth (0.08 mm/tooth, 0.12
mm/tooth, 0.16 mm/tooth, 0.20 mm/tooth), spindle speed (2000 rpm, 3000 rpm,
40000 rpm, 5000 rpm) and the cooling type (liquid, air) parameters. The Taguchi
experimental design method was used to help achieve results at acceptable
levels and to save time and cost in achieving optimal results. Experiments
designed with the Taguchi method were based on the L16 orthogonal array and
signal / noise (S/N) ratios were used in the evaluation of the experimental
results. The optimum levels of the control factors for minimizing the surface
roughness using S/N rates were determined. The optimal conditions for surface
roughness were observed at A1B1C2 (i.e.,feed per tooth=0.08 mm/tooth and 2000
rpm spindle speed, cooling type=liquid). Variance analysis was also conducted
in the study. According to the results of analyses, it was found that spindle
speed was the most significant parameter for surface roughness. Finally,
confirmation tests were conducted to check the success of the optimization.

Keywords

Taguchi method, optimization, surface roughness, ANOVA

References

• N. Tosun, C. Kuru, E. Altintas, O. E. Erdin, “Investigation of surface roughness in milling with air and conventional cooling method,” J. Fac. Eng. Arch. Gazi Univ. , vol. 25, pp.141-146, 2010.
• F. Kahraman, “Optimization of cutting parameters for surface roughness in turning of studs manufactured from AISI 5140 steel using the Taguchi method,” Materails Testing, vol. 59, no. 1, pp. 77-80, 2017, DOI: 10.3139/120.110968
• T. Kıvak, “Optimization of surface roughness and flank wear using the Taguchi method in milling of Hadfield steel with PVD and CVD coated inserts,” Measurement vol. 50, pp. 19–28, 2014, DOI: https://doi.org/10.1016/j.measurement.2013.12.017
• M. Günay, “Optimization with Taguchi method of cutting parameters and tool nose radius in machining of AISI 316L steel,” Journal of the Faculty of Engineering and Architecture of Gazi University, vol. 28, pp. 437-444, 2013.
• R. Çakıroğlu, A. Acır, “Taguchi optimization method of tool chip interface temperature depending on the cutting parameters in drilling operations,” Electronic Journal of Machine Technologies, vol.10, pp. 73-86, 2013.
• J. Z. Zhang, J. C. Chen, E. D. Kirby, “Surface roughness optimization in an end-milling operation using the Taguchi design method,” Journal of Materials Processing Technology vol. 184, pp. 233–239, 2007, DOI: 10.1016/j.jmatprotec.2006.11.029
• K. Palanikumar, “Experimental investigation and optimization in drilling GFRP composites,” Measurement, vol. 44, pp. 2138-2148, 2011.
• I. Asilturk, H. Akkus, “Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method,” Measurement, vol. 44, pp. 1697-1704, 2011.
• K. R. Ranjit, “A Primer on the Taguchi Method,” Competitive Manufacturing Series, New York, 1990.