Analysis of Cutting Forces and Optimization of Cutting Parameters in High Speed Ball-end Milling Using Response Surface Methodology and Genetic Algorithm

Dikshit, Mithilesh K.; Puri, Asit Baran; Maity, Atanu; Banerjee, Amit

doi:10.1016/j.mspro.2014.07.350

Cited by 28 publications

(11 citation statements)

References 12 publications

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“…The statistical analysis of the results obtained produced a mathematical model, which correlates the cutting force as a function of the independent process parameters. The choice of the low cutting speed stems from the fact that the cutting of titanium often causes vibration, deflection and chatter when subjected to high-speed cutting pressure and the spring-back induces cutting edge failure and vibration [Ezugwu and Wang, 1997]. Furthermore, the growth of flank wear grows linearly between 20 to 200 m/min of cutting speed for Ti6Al4V and for 250 m/min the flank wear growth found to have an exponential increase [Nurul, 2007].…”

Section: The Design Of the Numerical Experimentsmentioning

confidence: 99%

“…Many researchers have reported on the modelling and optimization of cutting forces and other process parameters during the machining operations, using different approaches. For instance, the use of analytical approach [López de Lacalle et al, 2006;Urbikan et al 2017;González et al 2018] and numerical models such as the Response Surface Methodology, Taguchi and Generic Algorithm [Dikshit et al, 2014;Ribeiro et al, 2017], Artificial Neural Network [Karabulut, 2015], Fuzzy rules based models [Nandi 2012], analytical models [Jing et al, 2014;Perez et al, 2013;Altintas and Lee, 1996], adaptive linear control systems [Leal-Muñoza et al, 2018;Orra and Choudhury, 2015], have been reported. [Urbikan et al 2017] carried out the numerical simulation of milling forces with barrel-shaped tools considering runout and tool inclination angles.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Modelling and Optimization of the Cutting Forces During Ti6al4v Milling Process Using the Response Surface Methodology and Dynamometer

Daniyan¹,

Tlhabadira²,

Phokobye³

et al. 2019

MM SJ

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The measurement of cutting forces using highly sensitive piezoelectric force sensors is significant in the optimization of the machining process. In this study, the modelling and optimization of the cutting forces during the milling process of Ti6Al4V was carried out using the Response Surface Methodology (RSM) and the dynamometer. The ranges of the process parameters are: cutting speed (250-280 mm/min), feed per tooth (0.06-0.24 mm) and axial depth of cut (0.30-3.0 mm) are varied over four levels while cutting force serves as the response of the designed experiment. The physical experiments were carried out using a DMU80monoBLOCK Deckel Maho 5-axis CNC milling. Three sets of 2-flute, 10 mm corner radius mills was used for the machining operation. A solid rectangular work piece of Ti6Al4V was screwed to the stationary dynamometer (KISTLER 9257A 8-Channel Summation of Type 5001A Multichannel Amplifier) mounted directly to the machine table. Milling operations were performed using different cutting parameters of cutting speed, feed per tooth and depth of cut and data were collected through Data Acquisition (DAQ) connected to the computer. The numerical experiment produced a mathematical model for predicting the values of the cutting forces as a function of the independent process parameters while the physical experiment revealed that the piezoelectric sensor is highly sensitive to variations in the values of the cutting force.

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Section: The Design Of the Numerical Experimentsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modelling and Optimization of the Cutting Forces During Ti6al4v Milling Process Using the Response Surface Methodology and Dynamometer

Daniyan¹,

Tlhabadira²,

Phokobye³

et al. 2019

MM SJ

View full text Add to dashboard Cite

show abstract

“…Computer Numerical Controlled (CNC) milling is an essential metal cutting technique among various machining processes in the modern era of manufacturing. CNC milling not only makes the milling process fully automated, but also enhances the machining time, reduces milling process variations, improves the quality of the machined parts, and enriches the overall productivity of the manufacturing companies [8]. For CNC milling, end mill is one of the most vital tools amongst various milling cutters due to its ability of high-speed cutting of metal with minimum surface roughness in a single pass [12].…”

Section: Introductionmentioning

confidence: 99%

NSGA III for CNC End Milling Process Optimization

Ghosh

Martinsen

2020

Communications in Computer and Information Science

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Computer Numerical Controlled (CNC) end milling processes require very complex and expensive experimentations or simulations to measure the overall performance due to the involvement of many process parameters. Such problems are computationally expensive, which could be efficiently solved using surrogate driven evolutionary optimization algorithms. An attempt is made in this paper to use such technique for the end milling process optimization of aluminium block and solved using Non-dominated Sorting Genetic Algorithm (NSGA III). The material removal rate, and surface roughness are considered as the crucial performance criteria. It is shown that the regression driven NSGA III is efficient and effective while obtaining improved process responses for the end milling.

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“…Korkut and Donertas [3] found that the cutting forces are getting bigger by increasing the feed rate and depth of cut. Dikshit, et al [4] found that the axial depth of cut is a dominant parameter that affects the tangential and radial forces and radial depth of cut has more influence on radial and axial cutting forces in comparing to feed per tooth.…”

Section: Introductionmentioning

confidence: 99%

Simulating the effect of depth of cut and feed rate on the force components in face milling

Akkad

Felhő

2019

MDT

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This paper presents a study about the workpiece force components (Fx, Fy, Fz) changes in face milling, which results from changing the depth of cut and the feed rate values. The values of the three force components in the face milling operation were found through the FEA-software AdvantEdge by Third Wave Systems. This program is uniquely intended for modelling of cutting processes. Simulations were carried out within five different cutting depth of cut and feed rate, to compare the obtained values and find out the results of the impact of changes on the three force components.

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Analysis of Cutting Forces and Optimization of Cutting Parameters in High Speed Ball-end Milling Using Response Surface Methodology and Genetic Algorithm

Cited by 28 publications

References 12 publications

Modelling and Optimization of the Cutting Forces During Ti6al4v Milling Process Using the Response Surface Methodology and Dynamometer

Modelling and Optimization of the Cutting Forces During Ti6al4v Milling Process Using the Response Surface Methodology and Dynamometer

NSGA III for CNC End Milling Process Optimization

Simulating the effect of depth of cut and feed rate on the force components in face milling

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