Investigation of surface roughness in face milling processes
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ORIGINAL ARTICLE
Investigation of surface roughness in face milling processes Muhammad Huzaifa Raza 1 & Faisal Hafeez 2 & Ray Y. Zhong 1 & Asif Imran 2 Received: 19 August 2020 / Accepted: 28 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This study aims to investigate the effects of dry, minimum quantity lubrication (MQL), and nanofluid cutting conditions on surface roughness (Ra) and material removal rate (MRR) for Al6082-T6. Three controllable factors, namely, feed rate (Fr), spindle speed (Vs), and depth of cut (Dc) are studied at three levels using Taguchi method. Single-response optimization is conducted using S/N ratio and contour plots. Empirical models of Ra and MRR for all cutting conditions are developed, and analysis of variance (ANOVA) is used to measure the adequacy of these models. Experimental results reveal that 26~30% improvement in Ra could be observed when experimental setup shifted from dry to MQL, and 13~16% improvement is recorded when further shifted to nanofluid cutting condition. No remarkable effect of cutting conditions (dry, MQL, and nanofluid) is observed on MRR. Additionally, Vs is observed insignificant for MRR in all cutting conditions. The appropriate cutting conditions and optimum values of input variables are proposed to the practitioners for industrial machining and production when contemplating face milling processes. Keywords Minimum quantity lubrication (MQL) . Nanofluid . Surface roughness . Face milling . Material removal rate (MRR)
Nomenclature ANOVA Analysis of variance MQL Minimum quantity lubrication MRR Material removal rate Ra Surface roughness S/N ratio Signal-to-noise ratio Fr Feed rate Vs Spindle speed Dc Depth of cut
1 Introduction Face milling is the secondary process used for the cutting and finishing of parts. The process is employed for the fabrication of tooling for other processes with high accuracy in a suitable processing time [1] and also used in the parts of aerospace and * Muhammad Huzaifa Raza [email protected] 1
Department of Industrial and Manufacturing System Engineering, The University of Hong Kong, Pok Fu Lam, Hong Kong
2
Department of Industrial Engineering, University of Engineering and Technology Taxila, Taxila, Pakistan
automotive industries, where quality is the prime factor [2]. Surface roughness is the measure of quality in machined parts, highly depends upon controlling parameters: Fr, cutting speed, and Dc [3]. There is a need to optimize these controlling parameters to enhance the quality of parts as Ra is sensitive to Fr [4, 5]. It was observed that the parameters other than feed (axial and radial Dc and cutting speed) are also significant factors that affect the Ra [6]. Material removal rate is the second major measure, which need to be maximized without compromising the surface quality of the part [7]. The factors that contribute in achieving maximum MRR are Fr and Dc [8]. High Fr results in higher MRR but it also increase the cutting temperature which reduces the tool life [9] and sur
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