MULTI VARIABLE OPTIMISATION OF MILLING ON

NIMONIC 75 USING
GREY RELATIONAL ANALYSIS
A PRELIMINARY PROJECT REPORT
Submitted by

KNR15ME014 ARJUN SURENDRAN

KNR15ME027 JISHNAV MELUR
KNR15ME028 JITHIN P
KNR15ME050 ROHITH N
to
the APJ Abdul Kalam Technological University
in partial fulfillment of the requirements for the award of the Degree
of
Bachelor of Technology
in
Mechanical Engineering

Department of Mechanical Engineering

Government College of Engineering Kannur- 670563

NOVEMBER 2018
Project report 2018

MULTI VARIABLE OPTIMISATION OF MILLING ON

NIMONIC 75 USING
GREY RELATIONAL ANALYSIS
A PRELIMINARY PROJECT REPORT
Submitted by
KNR15ME014 ARJUN SURENDRAN
KNR15ME027 JISHNAV MELUR
KNR15ME028 JITHIN P
KNR15ME050 ROHITH N

under the Supervision of

Prof. Ajayakumar N
(Asst. professor, ME Dept., GCEK)

to
the APJ Abdul Kalam Technological University
in partial fulfillment of the requirements for the award of the Degree
of
Bachelor of Technology
in
Mechanical Engineering

Department of Mechanical Engineering

Government College of Engineering Kannur- 670563

NOVEMBER 2018

i
Project report 2018 DECLARATION

DECLARATION

We undersigned hereby declare that the project report “MULTI VARIABLE

OPTIMISATION OF MILLING ON NIMONIC 75 USING GREY RELATIONAL
ANALYSIS”, submitted for partial fulfillment of the requirements for the award of degree of
Bachelor of Technology of the APJ Abdul Kalam Technological University, Kerala is a
bonafide work done by me under supervision of Prof. Ajayakumar N. This submission
represents my ideas in my own words and where ideas or words of others have been included,
We have adequately and accurately cited and referenced the original sources. We also declare
that we have adhered to ethics of academic honesty and integrity and have not misrepresented
or fabricated any data or idea or fact or source in my submission. We understand that any
violation of the above will be a cause for disciplinary action by the institute and/or the
University and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been obtained. This report has not
been previously formed the basis for the award of any degree, diploma or similar title of any
other University.

GCE Kannur
29 Nov. 18
Arjun Surendran
Jishnav Melur
Jithin P
Rohith N

ii
Project report 2018 ACKNOWLEDGMENT

DEPARTMENT OF MECHANICAL ENGG.

GOVERNMENT COLLEGE OF ENGINEERING KANNUR- 670563

CERTIFICATE

29/11/2018

This is to certify that the Project Report entitled “MULTI VARIABLE OPTIMISATION
OF MILLING ON NIMONIC 75 USING GREY RELATIONAL ANALYSIS.”
submitted by ‘ARJUN SURENDRAN, JISHNAV MELUR, JITHIN P, ROHITH N –of
7th semester Mechanical Engineering, submitted to the APJ Abdul Kalam Technological
University in partial fulfillment of the requirements for the award of the degree of Bachelor
of Technology in Mechanical Engineering is a bonafide record of the project work carried out
by their project group under my guidance and supervision. This report in any form has not
been submitted to any other University or Institute for any purpose.

Signature:
(Supervisor)

Signature Signature
(Seminar Coordinator) (Head of the Department)

iii
Project report 2018 ACKNOWLEDGMENT

ACKNOWLEDGEMENT

I am very glad to express my deep sense of gratitude all those concerned and especially to our
principal Dr. N VIJAYAKUMAR and to all the staff of Govt. College of Engineering Kannur
for their encouragement and support in presenting the seminar and this report.

I sincerely thank Dr. P SOORAJ, Head of the department of mechanical engineering

department, Govt. college of Engineering Kannur who gave opportunity for fulfilling my
seminar in Govt. College of engineering Kannur. With great pleasure I acknowledge the help
received from all other faculty members of the Department of Mechanical Engineering, Govt.
College of engineering Kannur.

I would like to extend my sincere thanks to Prof. Ajayakumar N, for his valuable guidance,
keen interest, timely suggestions and help for this work. Also I extend my thanks to all
professors in the seminar evaluation panel.

Finally I extend my thanks to my parents and my friend for their moral support to do this
work.

Arjun Surendran
Jishnav Melur
Jithin P
Rohith N

iv
Project report 2018 ABSTRACT

ABSTRACT

NIMONIC 75 is one of the important materials in the group of nickel based super alloys. It
has wide applications in marine, aircraft, aerospace and chemical industries as they can
withstand at very high temperatures. But NIMONIC 75 is very hard material to machining, so
it is essential to estimate the optimum cutting parameters to machine it for desired output
responses. CNC milling is widely used in machining operations due to it offers flexibility in
producing complex shapes.

The effect of cutting parameters in NIMONIC75 milling using Titanium Aluminium Nitride
(TiAlN) coated solid Tungsten Carbide tool is analysed .The selected cutting parameters are
speed, feed rate and depth of cut. Orthogonal arrays are developed using Taguchi method in
Minitab software. The experiment is done with different combination of parameters under
flooded condition.The lubricant choosen is water soluble oil.The optimal machining
parameters such as feed, depth of cut and spindle speed in CNC milling of NIMONIC 75 are
estimated for the minimum Surface Roughness(Ra) and for maximum Material Removal Rate
(MRR) by using Grey relational analysis and mathematical modelling is done using Surface
roughness methodology.

v
Project report 2018 CONTENTS

CONTENTS

Title page i
Certificate iii
Acknowledgement iv
Abstract v
Contents vi
CHAPTER 1: INTRODUCTION 1

CHAPTER 2: METHODOLOGY 2
2.1 Process variable 2
2.2 Experiment Used 2
2.3 Analysis 2

CHAPTER 3: CONCLUSION 3

REFERENCE 4

vi
Project report 2018 INTRODUCTION

CHAPTER 1
INTRODUCTION

Computer numeric control (CNC) machine used for controlling the motion in one or more
axes with the help of computers. It is first originated in 1950s able to manufacture complex
jet air craft parts. Now a day’s CNC machines utilizes software programmes for generating
instructions to control the axis motions, tool changers, spindle speeds etc.

Milling is the most common machining operation and can be performed using a wide range
of different tools. The milling machine removes metal with a revolving cutting tool called a
milling cutter. With various attachments, milling machines can be used for boring, slotting,
circular milling dividing, and drilling. This machine can also be used for cutting keyways,
racks and gears and for fluting taps and reamers. Face milling and end milling is the process
of machining surfaces perpendicular to the axis of the cutter. Face milling cutter and end
milling cutter are used for respective milling operations. The size and nature of the workpiece
determines the type and size of the cutter required.
For machining of hard materials like nickel alloys (NIMONIC), CNC milling is suitable. But
it is required to analyse the cutting parameters to overcome machining problems and to
forecast the machinability conditions. Machinability is estimated by the analysis of outputs
like surface roughness, material removal rate (MRR). Machining should provide accurate
individual desired outputs such as MRR, surface roughness etc. The index which determines
the quality of machined products is surface roughness and it depends on cutting parameters.
It has wide applications in marine, aircraft, aerospace and chemical industries as they can
withstand at very high temperatures. But NIMONIC 75 is very hard material to machining, so
it is essential to estimate the optimum cutting parameters to machine it for desired output
responses.
This project is an investigation on determining the optimum parameters on NIMONIC75
alloy milling using water soluble oil lubricant by carrying out the experiment under varying
conditions of feed rate, depth of cut, and cutting speed. Finally we aim at developing a
mathematical model of surface roughness and material removal rate for end milling of TiAIN
coated solid tungsten carbide using lubricant and we determine which the most influencing
parameter is .

ME Department 1 GCE Kannur

Project report 2018 METHODOLOGY

CHAPTER 2

METHODOLOGY
DoE is the most common technique for conducting systematic experiments that enable
meaningful data to be collected and through the use of analytical techniques, allow
appropriate conclusions to be drawn.

PROCESS VARIABLE

The four parameters – cutting speed (Vc), feed rate (fz), depth of cut (d) , and machining
environment are selected as input for DoE. A combination of cutting speed , feed rate ,depth
of cut each at three levels are generated using an L9 orthogonal array . Experiments are
conducted on CNC milling machine in flooded condition.

EXPERIMENT USED

TiAlN coated solid carbide cutting tool will be used for each machining experiment. A block
of 186 mm × 41mm × 12mm annealed NIMONIC 75 alloy was prepared for each machining
experiment and all the blocks were sourced in one batch. Taylor Hobson Talysurf surface
roughness testing machine will be used to measure the surface roughness. Material removal
rate can be measured using electro weighing machine and the most influencing parameter is
determined by Taguchi method.

ANALYSIS

Optimum machining parameters are determined by Grey relational analysis. Mathematical

model of machining are obtained using Response Surface Methodology and the most
influencing parameter is analysed.

ME Department 2 GCE Kannur

Project report 2018 CONCLUSION

CHAPTER 3

CONCLUSION

• NIMONIC 75 is a hard to machine material so,a best combination of input parameters

need to be identified.
• Water soluble oil is choosen as the lubricant as it is easily available at cheap rate and
it improves machinability.
• Detailed study about Grey relational analysis method helps in analyzing the optimum
parameters easily.
• Surface roughness methodology focuses on the mathematical modeling of surface
roughness(Ra) and Material Removal Rate (MRR) which makes further analysis
simpler and also focuses on determining the most influencing parameter on the
milling operation.
• Reduce the machining cost without compromising the surface quality of finished
product.

ME Department 3 GCE Kannur

Project report 2018 REFERENCE

REFERENCE

1. Experimental investigation on the machining characteristics of Nimonic 75 using

uncoated and TiAlN coated tungsten carbide micro end mills. Niharika Swain, Harash C
Barshilia .

2. Optimisation of machining parameters for dry turning of Incoloy 800 H using Taguchi
based Grey Relational Analysis. A Palanisamy , T Selvaraj.

3. Performance and surface integrity of Nimonic 75 alloy machined by Electrical discharge

machining. Rajesh Choudhary, Vivek Kumar Gupta, Yogesh Batra, Akashdeep Singh.

4. Optimisation of process parameters for micro milling Ti6Al4V Alloy using Taguchi
based Grey relational analysis. K. Aslantas, E. Ekici, A. Çiçe.

ME Department 4 GCE Kannur