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405704

Surface Roughness, Flatness Error and Material Removal Rate Optimization in End Milling Operation Using Taguchi Method

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Last updated: 20 Jan 2025

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Abstract

Taguchi design of experiments and analysis of variance (ANOVA) are introduced to investigate the effect of the end milling parameters on surface quality. Spindle speed, feed rate, number of flutes of end mill are selected as the control parameters. An aluminum silicon (Al-Si) alloy reinforced with different volume fraction of MWCNTs was used as a workpiece material. The machining responses were surface roughness, flatness error and material removal rate of the machined workpieces. An orthogonal array L27 of the Taguchi technique and S/N ration were selected to investigate and analyze the effect of the different control parameters on the process responses. The results of the study indicated that feed rate is the most significant factor on MRR, followed by number of flutes. Feed rate is the most significant factor on surface roughness followed by spindle speed. Number of flutes is the most significant factor on flatness error followed by spindle speed. The optimal levels of control parameters are determined from main effects plot for SN ratios for different responses, for maximum MRR (277.1363 mm3/min) at the optimal levels are A3 B2C1D3, for minimum surface roughness (0.492um) at level A2B2C3D1and minimum flatness error (0.064 um) at A3B3C2D1.

DOI

10.21608/erjsh.2020.405704

Keywords

End milling, Nanocomposites, Surface roughness, Flatness error- Design of experiments

Authors

First Name

M.

Last Name

Hamad

MiddleName

H.

Affiliation

Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, Cairo, Egypt.

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First Name

E.

Last Name

Mansour

MiddleName

H.

Affiliation

Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, Cairo, Egypt.

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Orcid

-

First Name

S.

Last Name

Zaian

MiddleName

A.

Affiliation

Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, Cairo, Egypt.

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-

City

-

Orcid

-

First Name

A.

Last Name

Gaafer

MiddleName

M.

Affiliation

Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, Cairo, Egypt.

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Volume

44

Article Issue

1

Related Issue

34764

Issue Date

2020-04-01

Receive Date

2025-01-17

Publish Date

2020-04-01

Page Start

65

Page End

70

Print ISSN

3009-6049

Online ISSN

3009-6022

Link

https://erjsh.journals.ekb.eg/article_405704.html

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http://journals.ekb.eg?_action=service&article_code=405704

Order

405,704

Type

Research articles

Type Code

2,276

Publication Type

Journal

Publication Title

Engineering Research Journal (Shoubra)

Publication Link

https://erjsh.journals.ekb.eg/

MainTitle

Surface Roughness, Flatness Error and Material Removal Rate Optimization in End Milling Operation Using Taguchi Method

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Article

Created At

20 Jan 2025