A

Project Work PHASE-I Report

On

“EXPERIMENTAL INVESTIGATION AND OPTIMIZATION

OF MILLING PROCESS PARAMETERS ON CNC END
MILLING MACHINE FOR ALUMINIUM ALLOY (7085)
MATERIALS BY USING FUZZY AND TAGUCHI METHOD”

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By

B .RAMU 20705A0364
H.VAMSI 20705A0382
S.VISHNU VARDHAN REDDY 20705A0392
B.NAGA NARASIMHA REDDY 20705A0349
Under the guidance of
Mrs. N. GLORY UJWALA, M. Tech
Assistant professor
DEPARTMENT OF MECHANICAL ENGINEERING

Submitted to

DEPARTMENT OF MECHANICAL ENGINEERING

ANNAMACHARYA INSTITUTE OF TECHNOLOGY AND SCIENCES
(Autonomous)
(Approved by AICTE, JNTUA, Ananthapuramu, Accredited by NBA, NAAC & IEI)
New Boyanapalli, Rajampet, Kadapa Dist., A.P - 516 126.
 2022-2023
ANNAMACHARYA INSTITUTE OF TECHNOLOGY AND SCIENCES
DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE
(PROJECT WORK - PHASE-I)

This to certify that the project work entitled “EXPERIMENTAL INVESTIGATION

AND OPTIMIZATION OF MILLING PROCESS PARAMETERS ON CNC END
MILLING MACHINE FOR ALUMINIUM ALLOY (7085) MATERIALS BY USING
FUZZY AND TAGUCHI METHOD” is a bonafide PROJECT WORK PHASE-I
submitted by
B .RAMU 20705A0364

H.VAMSI 20705A0382

S.VISHNU VARDHAN REDDY 20705A0392

B.NAGA NARASIMHA REDDY 20705A0349

in the department of MECHANICAL ENGINEERING in partial fulfillment

of requirements for the Project Work Phase-I in “Mechanical Engineering” for the academic
year 2022-2023. This work has been carried out under my guidance and has not been submitted
the same for any university/institution for award of any Degree/Diploma.

PROJECT GUIDE HEAD OF DEPARTMENT

Mrs. N. GLORY UJWALA Dr. A. HEMANTH KUMAR

Assistant professor

Place:

Date:
 DECLARATION

We hear by declare that the project report “EXPERIMENTAL INVESTIGATION AND

OPTIMIZATION OF MILLING PROCESS PARAMETERS ON CNC END
MILLING MACHINE FOR ALUMINIUM ALLOY (7085) MATERIALS BY USING
FUZZY AND TAGUCHI METHOD”under the guidance of Mrs. N. GLORY UJWALA,
Assistant professor, Department of Mechanical Engineering is submitted in partial fulfillment
of the requirements for the award of the degree of Bachelor of Technology in Mechanical
Engineering.

PROJECT ASSOCIATES

B .RAMU 20705A0364
H.VAMSI 20705A0382
S.VISHNU VARDHAN REDDY 20705A0392
B.NAGA NARASIMHA REDDY 20705A0349
 ABSTRACT

This Project focus on the optimization of CNC Milling Parameters using the Fuzzy-
Taguchi technique to obtain minimum surface roughness (Ra) and maximize material removal
rate(MRR).A number of milling experiments will be conducted by using the L9 orthogonal
array on a CNC END Milling machining. The experiments will be conducted on Al-7085
material blocks. A Design of experiment employed to determine the most significant control
factor affecting the surface roughness and material removal rate . The spindle speed , feed and
depth of cut will select as the control factor. After the nine experimental trails it will find out
the most significant factor on the surface roughness and the material removal rate.

Keywords : CNC END milling , Aluminium Alloys (7085), Design of Experiments,

Fuzzy-Taguchi Method.
 TABLE OF CONTENTS

Chapte
Contents Page no.
No.

1 Introduction 1-4

2 Literature Review 5-7

3 Objective (Identification of work) 8

4 Reference 9
 CHAPTER – 1

INTRODUCTION

Advancements in nonconventional machining technologies are now widely employed

to address a variety of challenges in machining processes, such as machining high-strength
materials, improving surface integrity, achieving high levels of precision, reducing surplus
material, and shortening production time. CNC end milling is one of the most versatile
machining processes in which a desired output can be achieved with reliability and accuracy.
Many industries and researches are employing different techniques to understand the behavior
of alloy materials during machining by monitoring Ra, MRR, etc.

Many investigations and studies are performed using optimization techniques to determine
the effect of Ra, MRR, etc. on the machining performance of both brittle and ductile materials.
Such studies usually incorporate the application of numerical and statistical models combined
with the design of experiment (DoE). Generally, the surface roughness of the CNC end milling
parameters is predicted using a mathematical model followed by the application of regression
analysis for predicting the results. Such results are validated with the experimental values.
researcher used DoE to evaluate the Ra and MRR of the aluminum metal matrix composites.
quality achieved postmachining is compared with the projected values .

Nowadays metal matrix composites are being used in many applications in

different engineering fields, which are very significant in the recent progress in material science
and hence it is acting as a substitute for several engineering materials. Particularly aircraft,
automotive, and locomotive industries are replacing steel and cast iron in different mechanical
components with lighter high strength alloys and composites like aluminium (Al) matrix
composites. As an outcome of this trend, the machining of metal matrix composites becomes
very vital in the final stage of manufacturing, which needs further research. The first generation
of aluminium based composite materials having ceramic reinforcements are found to reveal
good quality strength to weight ratio and better corrosion resistance.

1
1.1.1 WHAT DOES ALUMINUM (7085) MEAN?
7085 aluminum alloy is the latest generation of advanced aluminum alloy
developed by Alcoa in the United States in 2002. Because of its high hardenability, high
strength, and high damage tolerance, it has a major application background in large aircraft
and other fields. However, its corrosion resistance is not ideal, which will inevitably affect
the safe application of Al-Zn-Mg-Cu aluminum alloys.
Aviation structural materials have a long contact time with corrosive media in
the atmosphere, and in long-distance flight, the environment is relatively harsh. Corrosion
resistance is an important indicator for investigating aluminum alloys for aviation. The
7085 aluminum alloy forgings are mainly used for load-bearing structural parts such as
wing spars, wing ribs and landing gears of the Airbus A380, which in turn requires high
strength.
Information on composition limits, fabrication characteristics, processing effects on
physical and mechanical properties, and application performance of thick plate and forging
alloy 7085. It presents the specified minimum strength and fracture properties for plate,
die, and hand forgings.
Al 7085 alloy is a new type of structural material, and therefore, better mechanical
properties are very important for its application. Although CR technology has been applied
to many materials, there are still relatively few reports on Al 7085 alloys. Therefore, this
work aims to investigate the effects of CR and subsequent ageing treatment on the
microstructure and mechanical properties of Al 7085 alloy.

1.1.2 PROPERTIES AND COMPOSITION OF Al7085

Density : 2.85 g/cc
Color and State : Solid, nonmagnetic, non-lustrous, silvery-white with slight bluish tint
Thermal ExpansionS: Aluminum has a thermal expansion coefficient of 23.2
COMPOSITION:
Aluminum - 87.62 - 90.42 %
Chromium - <= 0.04 %
Copper - 1.3 - 2.0 %
Iron - <= 0.08 %
Magnesium - 1.2 - 1.8 %
Silicon - <= 0.06 %
Titanium - <= 0.06 %
Zinc - 7.0 - 8.0 %
Zirconium - 0.08 - 0.15

2
1.2 OPTIMISATION TECHNIQUES

Optimization technique is a powerful tool to obtain the desired design parameters and best
set of operating conditions .This would guide the experimental work and reduce the risk and
cost of design and operating. Optimization refers to finding the values of decision variables,
which correspond to and provide the maximum or minimum of one or more desired
objectives. Reliability of optimum solutions depends on formulation of objective functions
and selected optimization technique. In this project we are using the fuzzy and taguchi
techniques for optimisation test.

1.2.1 TAGUCHI
Taguchi method allows for the analysis of many different parameters without a
prohibitively high amount of experimentation.
The usual steps to apply Taguchi experimental design are:
(a) to select the output variable(s) (response(s)) to be optimized.
(b) to identify the factors (input variables) affecting output variable(s) and to choose the
levels of these factors.
(c) to select the appropriate Orthogonal Array.

1.2.1 FUZZY
Fuzzy optimization is a well-known optimization problem in artificial intelligence,
manufacturing and management, so establishing general and operable fuzzy optimization
methods are important in both theory and application. fuzzy logic is used in a broad range
of applications including: aerospace engineering, automotive traffic control, business
decision-making, industrial processes, artificial intelligence, and machine learning. In
standard logic, every statement must have an absolute value: true or false.

3
 Flow chart of fuzzy technique

1.3 CNC END MILLING

Advancements in nonconventional machining technologies are now widely employed to

address a variety of challenges in machining processes, such as machining high-strength
materials, improving surface integrity, achieving high levels of precision, reducing surplus
material, and shortening production time. CNC end milling is one of the most versatile
machining processes in which a desired output can be achieved with reliability and accuracy.
End Mill is one kind of milling cutter to do the process of removing metal by CNC Milling
machines. There are various diameters, flutes, lengths, and shapes to choose from. Basically,
users choose them according to the material of the workpiece and the surface finish required
for the workpiece.
1.3.1 APPLICATIONS
• Aerospace
• Agriculture
• Automotive industry
• Medical industry

4
 CHAPTER -2
LITERATURE REVIEW
1.Biswait Das , S. Roy, R.N. Rai, S.C. Saha
In this journal the author use the gray relational analysis and fuzzy techniques for
optimisation cnc milling parameters on aluminium alloy .The input parameters are speed,
feed and depth of cut. Response parameters are surface roughness (Ra and Rz) and cutting
force(Fc) . Taguchi’s L25 orthogonal array design is used for performing CNC milling
operation on the composite plates.
• It was found that a cutting speed of 600 rpm, feed of 40 mm/ min and a depth of cut
of 0.30 mm is the optimal combination of input parameters
• ANOVA statistics exposed that cutting speed is the most influencing factor in
effecting the response parameters.
2. Aman Sharma , Anas Islam, Kamal Sharma, Pradeep Kumar Singh
In this journal the author use the Taguchi and ANOVA techniques for optimisation of
milling process parameters on CNC milling machine for AA-3105. He consisting of
different process parameters considered in this phase of milling, i.e. spindle speed, feed
rate, and cutting depth and response parameters are Material Removal rate and Surface
Roughness.
• After completing the project the optimum value of the surface finish can be
observed on the Spindle Speed level at 950 pm, the Feed Rate level at 0,570 mm /
rev, and the Cut Depth at 3 mm.
• On completion, the optimum removal value can be observed at the spindle speed
of 950 rpm, Feed Rate at 4 mm, and Cut Depth of 0.460 mm/rev
3. R. Suresh Kumar , S. Senthil Kumar , K. Murugan
In this project the authors Using Taguchi Method and Grey Relational Analysis for
optimisation of milling process parameters on CNC milling machine Green Machining
Characteristics Study of Al-6063. The input parameters are speed ,feed and depth of cut
and response parameters are Material Removal rate and Surface Roughness. The study is
performed as single response and multi-response optimization. For single response ,
Taguchi design is followed, and for multi response, GRA is applied.
• In case of multresponse optimization, GRA results align with the higher level of Ss
and the medium level of Dc, followed by Fr.

5
4. Tamal Ghosh, Yi Wang , Kristian Martinsen,Kesheng Wang
In this journal author is using a Bayesian regularized neural network (surrogate) and a
beetle antennae search algorithm (optimizer) to perform the process optimization of end
mill cutting of aluminum alloy on a desktop milling machine. He consisting of different
process parameters considered in this phase of milling, i.e. . spindle speed,tool
diameter,feed rate, and cutting depth for To facilitate that, material removal rate (MRR),
surface roughness (Ra), and cutting forces.
• AA3105 shows substantially good machining properties under the end milling on
the Proxxon FF 500 BL CNC with proper settings of the parameters. The ideal
settings for the parameters are found to be (TD = 10 mm, SS = 1646 rpm, FR =
4.66 mm/s, and DOC = 1.54 mm).
5. R. Suresh Kumar , S. Senthil Kumar ,K. Murugan,B.Guruprasad
In this journal author is used Taguchi and gray relation analysis for optimization of end
milling process parameters on CNC end milling for low carbon mold steel.He consisting
different process parameters considered in the phase of milling,i.e.Spindle speed,depth of
cut,feed rate and coolant flow and response parameters are Power consumption ,sureface
roughness and metal removal rate(MRR)..
• . Minimum surface roughness attained in the combination of 2500 rpm, 0.6 mm,
1500 mm/min, and 6 l/min. Minimum power consumption attained in the
combination of 1850 rpm, 0.2 mm, 1000 mm/min, and 6 l/min. Maximum material
removal attained in the combination of 1850 rpm, 0.6 mm, 1500 mm/min, and 8
l/min.

6. Tuhin Kar,Nirmal Kumar Mandal,Nirmal Kumar Singh.

In this journal author is used Fuzzy logic for optimization of milling process
parameters on CNC vertical milling machine for Iconal 718 Alloy .Input parameters are
Spindle speed ,feed rate,depth of cut and output parameters are Surface roughness,metal
removal rate,Axial cutting force.
• After completing the project the optimum value of the surface finish (0.739),MMR
(192.82) and Axial force (305.25) can be observed on the Spindle Speed level at
3500 pm, the Feed Rate level at 100 mm / rev, and the Cut Depth at 0.25mm.

6
7. Rajender Kumar , Puneet Katyal, Kamal Kumar , Vijender Singh .
In this journal author is used end milling parameters in CNC milling machine on
ZE41A Mg alloy by using method of Taguchi and TOPSIS approach . He used different
process parameters in this phase of milling i.e. spindle speed , depth of cut , and feed
rate.Response parameters are Metal removal rate and Thermal stresses.
• For single response optimization, maximum MRR is achieved at process variable
setting: CS 1200 rpm, FR: 100 mm/min, DoC: 1.25 mm; and for minimum thermal
stresses: CS: 1700 rpm, FR: 100 mm/min and DoC: 0.5 mm has been recommended
with the deviation range of 6%
• For multi-response optimization, optimized process parameter settings suggested
by TOPSIS: CS 1200 rpm, FR: 100 mm/min, DoC: 1.25 mm. ANOVA verified the
main influencing factors for multi-response optimization on preference value are
FR (71.85%), CS (18.93%), and DoC (5.27%).

8. Visnu Sasindran , Vignesh M , Arvind Krishna S , Madusudhanan

The experiment is designed using Taguchi Method and the model development is done
using Fuzzy Logic and Artificial Neural Network (ANN) approach. .Input parameters are
Spindle speed ,feed rate,depth of cut and output parameters are Surface roughness and
carbon emission.
• Comparing the two models proposed by fuzzy logic and artificial neural network, the
latter is found to give more accurate results. Hence artificial neural network model is
considered to be more effective for carrying out further analysis.

9. P. Hema, K.JayaPadmavathi , B. Narayana Reddy

In this journal author is used The Genetic Algorithm (GA) and Simulated Annealing (SA)
optimization techniques were used for optimizing the cutting conditions of Alloy Steel
4130. On end milling machining parameters. .Input parameters are Spindle speed ,feed
rate,depth of cut and output parameters are Surface roughness
• Moreover, the percentage of errors for SA method is less than the GA method. Hence,
it can be learnt that SA optimization techniques provide better results than GA
technique for predicting Surface Roughness for end-milling process. The evident for
achieving the confirmation test value 0.4173 µm of SA.

7
 CHAPTER – 3
OBJECCTIVE

• To increase the Metal removal rate.

• To increase productivity.
• To obtain Better Surface finish.
• To determine most significant factors for High MRR & Better Ra .

8
 CHAPTER – 4

REFERENCS
[1]. Biswajit Das , S. Roy, R.N. Rai, S.C. Saha “Application of grey fuzzy logic for the
optimization of CNC milling parameters for Al–4.5%Cu–TiC MMCs with multi-
performance characteristics” National Institute of Technology, Agartala, Barjala, Jirania,
Tripura, Pin-799046, India.
[2]. Aman Sharma ⇑ , Anas Islam, Kamal Sharma, Pradeep Kumar Singh” Optimization
techniques to optimize the milling operation with different parameters for composite of AA
3105” IET Department of Mechanical Engineering, GLA University, Mathura 281406,
India(01/01/2021)
[3]. R. Suresh Kumar , S. Senthil Kumar , K. Murugan, and Sintayehu Mekuria Hailegiorgis ”
Green Machining Characteristics Study of Al-6063 in CNC Milling Using Taguchi Method
and Grey Relational Analysis” 1Department of Mechanical Engineering, Sri Eshwar College
of Engineering, Coimbatore, Tamil Nadu, India(2021).
[4]. Tamal Ghosh1& Yi Wang & Kristian Martinsen1& Kesheng Wang” A surrogate-assisted
optimization approach for multi-response end milling of aluminum alloy AA3105” Department
of Manufacturing and Civil Engineering, Norwegian University of Science Technology, 2815
Gjøvik, Norway(27/09/2020)
[5]. R. Suresh Kumar , S. Senthil Kumar , K. Murugan, B. Guruprasad , 4Sreekanth Manavalla
, S. Madhu , M. Hariprabhu , S. Balamuralitharan , and S. Venkatesa Prabhu “Optimization
of CNC End Milling Process Parameters of Low-Carbon Mold Steel Using Response Surface
Methodology and Grey Relational Analysis” Department of Mechanical Engineering, Sri
Eshwar College of Engineering, Coimbatore, India(16/08/2021)
[6]. Tuhin Kar · Nirmal Kumar Mandal · Nirmal Kumar Singh” Multi-response Optimization
and Surface Texture Characterization for CNC Milling of Inconel 718 Alloy” Received: 26
September 2019 / Accepted: 26 December 2019 © King Fahd University of Petroleum &
Minerals 2020.
[7] Rajender Kumar a,b,⇑ , Puneet Katyal a , Kamal Kumar c , Vijender Singh a” Multiresponse
optimization of end milling process parameters on ZE41A Mg alloy using Taguchi and TOPSIS
approach” Department of Mechanical Engineering, Punjab Engineering College (Deemed to
be University), Chandigarh 160012, India
[8] Visnu Sasindran , Vignesh M , Arvind Krishna S1 , Madusudhanan A and Gokulachandran
J” Optimization of Milling Parameters of Gun Metal Using Fuzzy Logic and Artificial Neural
Network Approach” : Visnu Sasindran et al 2019 IOP Conf. Ser.: Mater. Sci. Eng. 577 01201.
[9]. Dr. P. Hema , K.JayaPadmavathi, B. Narayana Reddy” CNC MACHINING OF ALLOY
STEEL 4130 AND OPTIMIZATION OF PROCESS PARAMETER” Assistant Professor,
Dept. of Mechanical Engineering & SVUCE.