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Surface roughness analysis and optimization for the CNC milling process by the desirability function combined with the response surface methodology

  • Ugur Esme
Published/Copyright: May 16, 2018
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Materials Testing
From the journal Materials Testing Volume 57 Issue 1

Abstract

The present study is aimed for an optimization strategy for the CNC pocket millingprocess based on the desirability function approach (DFA) combined with the response surface methodology (RSM). Firstly, the milling parameters such as cutting speed, feed rate and depth of cut are designed using the rotatable central composite design (CCD). The AISI 1050 medium carbon steel is machined by a flat end 8 mm high speed steel (HSS) tool on a zigzag cutting path under air flow condition. The influence of milling parameters is examined. Secondly, the model for the surface roughness, as a function of milling parameters, is obtained using the RSM. Finally, the power and adequacy of the quadratic mathematical model has been proven by the analysis of variance (ANOVA) method. The results indicate that the feed rate is the dominant factor affecting the surface roughness, which is minimized when the feed rate and depth of cut are set to the experimental range. A high correlation coefficient of R2 = 0.99 has been obtained between the predicted and the experimental surface roughness. This reveals that the prediction system established in this study produces satisfactory results with an improved performance compared to other models in the literature. The enhanced method proposed in this study can be readily applied to different metal cutting processes with greater confidence.

Kurzfassung

Die diesem Beitrag zugrunde liegende Studie zielt darauf ab, eine Optimierungsstrategie im CNC-Taschenfräsprozess basierend auf dem Erwünschtheitsfunktionsansatz (Desireability Function Approach – DFA) kombiniert mit der Antwortoberflächen-Methode (Response Surface Methodology – RSM) zu entwickeln. Zunächst wurden hierzu die Fräsparameter, wie die Schnittgeschwindigkeit, die Vorschubrate und die Schnitttiefe mittels rotierendem zentralen Kompositdesign (Central Composite Design – CCD) bestimmt. Der AISI 1050 Stahl mit mittlerem Kohlenstoffgehalt wurde hierzu mit einem 8 mm dicken HSS-Werkzeug im Zick-Zack-Vorschub unter Luftkühlung bearbeitet. Dabei wurde der Einfluss der Fräsparameter untersucht. Danach wurde ein Modell für die Oberflächenrauheit als Funktion der Fräsparameter mittels RSM bestimmt. Schließlich wurde die Leistungsfähigkeit und die Adäquanz des quadaratischen mathematischen Modells mittels Varianzanalyse (ANOVA) geprüft. Die Ergebnisse zeigen, dass die Vorschubrate der dominierende Faktor hinsichtlich des Einflusses auf die Oberflächenrauheit ist, die minimiert wird, wenn die Vorschubrate und die Schnitttiefe auf Werte des experimentellen Rahmens gesetzt werden. Ein hoher Korrelationskoeffizient von R2 = 0.99 zwischen der vorhergesagten und der experimentell bestimmten Oberflächenrauheit wurde ermittelt. Daraus ergibt sich, dass das in dieser Studie hergeleitete Vorhersagesystem befriedigende Ergebnisse liefert und eine verbesserte Performanz gegenüber anderen Modellen in der Literatur aufweist. Das verbesserte und in dieser Studie vorgeschlagene Verfahren kann sofort auf verschiedene Metallfräsprozesse mit größerer Konfidenz angewendet werden.

*Correspondence Address, Associate Prof. Dr. Ugur Esme, Department of Manufacturing Engineering, Technology Faculty, Mersin University Institute of Natural and Applied Sciences, 33400, Tarsus-Mersin, Turkey, E-mail:

Assoc. Prof. Dr. Ugur Esme is a lecturer at Mersin University, Turkey, Tarsus Technology Faculty Department of Automotive Engineering. He obtained his PhD degree from Cukurova University, Turkey, Department of Mechanical Engineering in 2006. His research areas include CAD/CAM technology, welding, modeling, designing and water jet cutting applications.

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Published Online: 2018-05-16
Published in Print: 2015-01-05

© 2015, Carl Hanser Verlag, München

Articles in the same Issue

  1. Inhalt/Contents
  2. Inhalt
  3. Fachbeiträge/Technical Contributions
  4. A simple procedure for estimating SN-lines for crack initiation from SN-lines for total failure*
  5. Modellbasierte Korrelation zwischen dem elektrischen Widerstand und der Versetzungsstruktur des ermüdungsbeanspruchten ICE-Radstahls R7
  6. Effect of cobalt on the aging kinetics and the properties of a CuCoNiBe alloy
  7. Effect of heat treatment on microstructure and mechanical properties of Fe-5Cr-1.4B alloy
  8. Interface characterization of friction welded low carbon steel and copper alloys
  9. Field test methods for aluminum gas cylinders
  10. Application of the Taguchi method for parameter optimization of the surface grinding process
  11. A discrete dislocation technique for fatigue microcracks (Part I)
  12. A discrete dislocation technique for fatigue microcracks (Part II)
  13. Synchrotron X-ray CT of rose peduncles – evaluation of tissue damage by radiation*
  14. Surface roughness analysis and optimization for the CNC milling process by the desirability function combined with the response surface methodology
  15. Design, manufacture and analysis of composite epoxy material with embedded silicon carbide (SiC) and alumina (Al2O3) nanoparticles/fibers
  16. Performance of organic and inorganic substances as inhibitors for chloride-induced corrosion in concrete
  17. Fillet welding of austenitic stainless steel using the double channel shielding gas method with cored wire
  18. Applying quadraphonic transmission ultrasonic defectoscopy on standard aluminum materials
  19. Kalender/Calendar
  20. Kalender
https://doi.org/10.3139/120.110679

Articles in the same Issue

  1. Inhalt/Contents
  2. Inhalt
  3. Fachbeiträge/Technical Contributions
  4. A simple procedure for estimating SN-lines for crack initiation from SN-lines for total failure*
  5. Modellbasierte Korrelation zwischen dem elektrischen Widerstand und der Versetzungsstruktur des ermüdungsbeanspruchten ICE-Radstahls R7
  6. Effect of cobalt on the aging kinetics and the properties of a CuCoNiBe alloy
  7. Effect of heat treatment on microstructure and mechanical properties of Fe-5Cr-1.4B alloy
  8. Interface characterization of friction welded low carbon steel and copper alloys
  9. Field test methods for aluminum gas cylinders
  10. Application of the Taguchi method for parameter optimization of the surface grinding process
  11. A discrete dislocation technique for fatigue microcracks (Part I)
  12. A discrete dislocation technique for fatigue microcracks (Part II)
  13. Synchrotron X-ray CT of rose peduncles – evaluation of tissue damage by radiation*
  14. Surface roughness analysis and optimization for the CNC milling process by the desirability function combined with the response surface methodology
  15. Design, manufacture and analysis of composite epoxy material with embedded silicon carbide (SiC) and alumina (Al2O3) nanoparticles/fibers
  16. Performance of organic and inorganic substances as inhibitors for chloride-induced corrosion in concrete
  17. Fillet welding of austenitic stainless steel using the double channel shielding gas method with cored wire
  18. Applying quadraphonic transmission ultrasonic defectoscopy on standard aluminum materials
  19. Kalender/Calendar
  20. Kalender
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