Parametric Optimization of Dry Turning of Al6061-T6 Alloy Using CNC Machine with Cemented Carbide Tool

Abstract

In any machining process, it is most important to determine the optimal machining parameters to achieve the desired product quality. Therefore, it is essential to investigate the effect of cutting parameters on surface roughness in a machining operation to accomplish the desired quality of an item. In this research, optimization of effect of cutting parameter (cutting speed, feed rate and depth of cut) on output response variables such as surface roughness, tool wear, MRR and cutting temperature during dry turning of Al6061-T6 alloy by using CNC machine. The tool insert used in this experiment was cemented carbide. The specimen used was an Al6061-T6 alloy specimen that was 340mm long and 38mm in diameter. The Taguchi L9 orthogonal array was selected for the experiment design, and optimization based on signal-to noise ratio has been applied. The analysis of variance (ANOVA) was found which parameters significantly affect the quality characteristic Surface roughness, cutting temperature and tool wear was measured by Vogel surface roughness tester, infrared thermometer and optical microscope respectively. Optimization of the turning parameters for lower tool wear, cutting temperature, surface roughness and higher material removal rate simultaneously using grey relational analysis (GRA). Analysis of variance shows that cutting speed was the most significant parameter followed by feed rate and depth of cut, affecting surface roughness by 61.23%, 18.89% and 15.4% respectively at the confidence level of 95%. Feed rate had a significant effect on the material removal rate (63.75%), followed by depth of cut and cutting speed at percentages of contribution of 30.1% and 3.12% respectively. The lower tool wear 0.051mm was obtained at high value of cutting speeds of 191 m/min, medium feed of 0.15mm/rev, and low depth of cut of 0.2 mm. The highest temperature (45.30°C) was observed for higher cutting parameter. The highest value of GRG was obtained with input parameters of feed 0.25 mm/rev, speed 191 m/min, and depth of cut 0.2 mm.In Any Machining Process, It Is Most Important To Determine The Optimal Machining Parameters To Achieve The Desired Product Quality. Therefore, It Is Essential To Investigate The Effect Of Cutting Parameters On Surface Roughness In A Machining Operation To Accomplish The Desired Quality Of An Item. In This Research, Optimization Of Effect Of Cutting Parameter (Cutting Speed, Feed Rate And Depth Of Cut) On Output Response Variables Such As Surface Roughness, Tool Wear, Mrr And Cutting Temperature During Dry Turning Of Al6061-T6 Alloy By Using Cnc Machine. The Tool Insert Used In This Experiment Was Cemented Carbide. The Specimen Used Was An Al6061-T6 Alloy Specimen That Was 340mm Long And 38mm In Diameter. The Taguchi L9 Orthogonal Array Was Selected For The Experiment Design, And Optimization Based On Signal-To Noise Ratio Has Been Applied. The Analysis Of Variance (Anova) Was Found Which Parameters Significantly Affect The Quality Characteristic Surface Roughness, Cutting Temperature And Tool Wear Was Measured By Vogel Surface Roughness Tester, Infrared Thermometer And Optical Microscope Respectively. Optimization Of The Turning Parameters For Lower Tool Wear, Cutting Temperature, Surface Roughness And Higher Material Removal Rate Simultaneously Using Grey Relational Analysis (Gra). Analysis Of Variance Shows That Cutting Speed Was The Most Significant Parameter Followed By Feed Rate And Depth Of Cut, Affecting Surface Roughness By 61.23%, 18.89% And 15.4% Respectively At The Confidence Level Of 95%. Feed Rate Had A Significant Effect On The Material Removal Rate (63.75%), Followed By Depth Of Cut And Cutting Speed At Percentages Of Contribution Of 30.1% And 3.12% Respectively. The Lower Tool Wear 0.051mm Was Obtained At High Value Of Cutting Speeds Of 191 M/Min, Medium Feed Of 0.15mm/Rev, And Low Depth Of Cut Of 0.2 Mm. The Highest Temperature (45.30??C) Was Observed For Higher Cutting Parameter. The Highest Value Of Grg Was Obtained With Input Parameters Of Feed 0.25 Mm/Rev, Speed 191 M/Min, And Depth Of Cut 0.2 Mm.