Pak. J. Biotechnol. Vol.

14 special issue I (International Conference on Futuristic Innovations in

Mechanical Engineering and Manufacturing Management) Pp. 106- 108 (2017)

OPTIMIZATION OF MACHINING PARAMETERS IN CNC DRILLING OF ALUMINIUM 6351

ALLOY
S.Sakthivelu1*, M.Meignanamoorthy2, M.Ravichandran3
1
Department of Mechanical Engineering, M. Kumarasamy College of Engineering, Karur-639 113, 2Department of
Mechanical Engineering, Mother Terasa College of Engineering and Technology, Pudukkottai- 622 102,
3
Department of Mechanical Engineering, Chendhuran College of Engineering and Technology, Pudukkottai- 622
506, India. Email: *sakthis1691@gmail.com
ABSTRACT
In this research, an experimental investigation of the machining parameters of Aluminium Alloy 6351 in CNC lathe machine
for drilling operation using HSS drill bit had been carried out. In machining operation, the minimum surface roughness was
considered as important factor for the better quality of the product. Subsequently, the decision of upgraded cutting parameters is
imperative for controlling the required quality. The motivation behind this exploration is centered on the investigation of ideal
cutting conditions for least surface harshness in CNC drilling of Aluminum Alloy 6351 by Taguchi strategy. The experiment has
been carried out based on L16 standard orthogonal array design with three process parameters namely Spindle Speed, Feed rate,
Depth of Cut. The experiment results were used to characterize the main factors affecting surface finishing by Signal to Noise ratio
and Analysis of Variance method. The investigations infer that the surface roughness was influenced by the feed rate. It was
identified that the Surface roughness decreases with increase in feed rate.

I. INTRODUCTION
Aluminum amalgams contain the normal alloying II.MATERIALS AND METHOD
components, for example, copper, magnesium, manga- The materials used in this experimentation
nese, silicon and zinc and in which Aluminum (Al) is were discussed below and the method adopted for
the prevalent metal. Here Aluminum 6351 composite is experimentation is illustrated clearly.
taken as work piece material and HSS as cutting device A. Work Piece Material
[1-2]. The fundamental properties of Aluminum are In this research work, AA6351 is used as a material.
light weight, quality, recyclability, consumption resis- The properties of AA60663 is clearly shown in the
tance, toughness, pliability, formability and conducti- below Table 1 & 2.
vity, which make them significant material [3]. Design Table 1: Composition of AA6351
of Experiment (DOE) is an influential method to
improve manufactured goods design presentation where
Elements Weight (%)
it can be used to decrease cycle time needed to improve
new process [4-5]. The Analysis of Variance is a Si 0.8
powerful statistical tool for test of significance. Fe 0.12
ANOVA is a separation of variance ascribable to one Cu 0.051
prove of process of the variance ascribable to the other Mn 0.52
groove. Taguchi’s Method Taguchi defines as the Mg 0.75
product quality should not deviate from its target value Pb 0.01
[6]. These losses were due to the deviance of the Ti 0.02
products functional characteristic from its desired target Sn 0.004
value, and these were called losses due to functional Sb 0.02
variation. The noise factors which were not controlled, Zr 0.003
which cause the functional characteristics of a product
Al Bal
to deviate from their defined values. The goal of quality
engineering was to make products that are roust with
respect to all noise factors [7-9]. Table 2: Mechanical Properties of AA6351
S/N ratios has been calculated in three ways lower Density 2.6-2.8kg/cm3
is best, higher is best and nominal is best. Depends upon Elastic Modulus (GPa) 70-80GPa
the machining parameters suitable S/N ratio has been Tensile Strength (MPa) 250MPa
selected [10]. Strength (MPa) 150MPa

For Surface Roughness (Smaller is Better), B. Experimental Setup

S/N Ratio = The experimental work was carried out on CNC
drilling center JOBBER XL using high speed steel drill
Where,
bit. Figure 1 clearly shows the experimental set up of
“y” is the experimental data at ‘i’ th trial and “n” is
CNC turning center. The specifications of the machine
the number of trials.
are given in Table 3.

106
 Pak. J. Biotechnol. Vol. 14 special issue I (International Conference on Futuristic Innovations in
Mechanical Engineering and Manufacturing Management) Pp. 106- 108 (2017)

Table 3: CNC Turning Center Specification In this work, each factor has three levels. L16 ortho-
Machine Type JOBBER XL gonal array is followed. The process parameters and their
Year 2012 levels are given in the Table 4.
Supply Voltage 380V/415V
Control Voltage 24V D.C Table 4: Process Parameters and their Levels
Back Up Fuse 63 AMPS Levels
S.No Parameters
1 2 3 4
Spindle Speed 1900
1 1300 1500 1700
(rpm)
2 Feed rate (mm/min) 0.05 0.10 0.15 0.20
3 Depth of Cut (mm) 0.2 0.4 0.6 0.8

Figure 1: CNC Turning Center – JOBBER XL

C. Drilling Tool
The tool used for this research is 16mm HSS drill bit.

Figure 4: Machined Workpiece

Figure 2: HSS drill bit.

Table 5: Experiment Results
Trial SPINDLE DEPTH FEED SURFACE S/R RATIO
No. SPEED OF CUT RATE ROUGHNESS (µm) FOR SR
1 1300 0.2 0.05 1.56 -3.862491967
2 1300 0.4 0.1 1.24 -1.868433703
3 1300 0.6 0.15 1.36 -2.670778167
4 1300 0.8 0.2 2.1 -6.444385895
5 1500 0.2 0.1 1.75 -4.860760974
6 1500 0.4 0.05 1.64 -4.296876961
7 1500 0.6 0.2 1.45 -3.227360045
8 1500 0.8 0.15 0.96 0.354575339
9 1700 0.2 0.15 0.91 0.819172154
10 1700 0.4 0.2 2.17 -6.729194677
11 1700 0.6 0.05 1.38 -2.797581728
12 1700 0.8 0.1 1.47 -3.346346695
13 1900 0.2 0.2 0.78 2.158107946
14 1900 0.4 0.15 1.87 -5.436832131
15 1900 0.6 0.1 0.85 1.411621486
16 1900 0.8 0.05 1.05 -0.423785981

107
 Pak. J. Biotechnol. Vol. 14 special issue I (International Conference on Futuristic Innovations in
Mechanical Engineering and Manufacturing Management) Pp. 106- 108 (2017)

III.RESULTS AND DISCUSSION Table 5, superlative parameters found for minimum

A. Signal to Noise Ratio for Surface Roughness. surface finish machining are feed rate= 0.2mm/min,
The purpose of this work is to optimize the drilling spindle speed = 1900rpm and depth of cut= 0.2mm.
parameters (spindle speed, feed rate and depth of cut) to Results got from Taguchi method precisely matches
achieve low value of the surface roughness. Taguchi with ANOVA and confirmation test results are also
method used for analyzing data offers two advantages; matched with the predicted results.
it offers guidance for choosing the optimum level REFERENCES
parameter and the other one is comparison of two sets of [1] Sahoo, A.K., A.N. Baral, Multi-objective optimi-
experimental results. Table 6 shows the response table zation and predictive modelling of surface rough-
values. Depth of cut is influencing towards the ness and material removal rate in turning using grey
machining performance for lower surface roughness relational and regression analysis. Elsevier Procedia
which is followed by spindle speed and feed rate Engineering 38: 1606-1627 (2012).
[2] Gulhane, U.D., S.P.Ayare, V.S.Chandorkar, Inves-
Table 6: Response Table for SR
Level Spindle Speed Depth of Cut Feed rate tigation of Turning Process To Improve Produc-
1 -3.7115 -1.4365 -2.8452 tivity (MRR) For Better Surface Finish Of AL7075-
2 -3.0076 -4.5828 -2.1660 T6 Using DOE. International Journal of Design and
3 -3.0135 -1.8210 -1.7335 Manufacturing Technology 4(1): 59-67 (2013).
-0.5727 -2.4650 -3.5607 [3] Warhade, P., S.K.Bhilare, S.R.Gaikwad, Modeling
Delta 3.1388 3.1463 1.8272 and analysis of machining process using response
Rank 2 1 3 surface methodology. International Journal of
Engineering and Development 2: (2013).
[4] Ramudu, C., M.N.P. Sastry, Analysis and optimi-
zation of turning process parameters using design of
experiments. International Journal of Enginee-ring
Research and Application 2(6): 20-27 (2012).
[5] Dave, H.K., L.S.Patel, H.K.Raval, Effect of mach-
ining conditions on mrr and surface roughness
during cnc turning of different materials using tin
coated cutting tools-a taguchi approach. Inter-
national Journal of Industrial Engineering Compu-
tations 3: 925-930 (2012).
[6] Kaladhar, M., K.V.Subbaiah, Ch.Srinivasa Rao,
Review, application of taguchi approach and utility
Figure 3: Main effect plots for Ra concept in solving the multi-objective problem
when turning aisi 202 austenitic stainless steel.
B. Analysis of Variance (ANOVA) for Surface Journal of Engineering Science and Technology
Roughness: Taguchi method will not deliver any details 4(1): 55-61 (2011).
about the influencing parameters. So, the contribution of [7] Chandrasekar, M., S. Rajkumar, D. Valavan, A
each parameter can be determined by ANOVA. Minitab review on the thermal regulation techniques for non
17 software is one of the statistical software used for the integrated flat PV modules mounted on building
analysis of influence of parameters. top. Energy Build 86: 692–697 (2015).
Table 7: ANOVA for Surface Roughness [8] Gulhane, U.D., B.D. Sawant, P.M.Pawar, Analysis
Source DF SS MS F-Value of influence of shaping process parameters on mrr
Spindle Speed 3 0.4205 0.14017 0.57 and surface roughness of al6061 using taguchi
Depth of cut 3 0.6029 0.20096 0.82 method. International Journal of Applied Research
Feed Rate 3 0.2850 0.09501 0.39 and Studies 4(2): 134-140 (2013).
Error 6 1.4779 0.24632 [9] Johnson, R.D.J.,K.L.D.Wins, A.Raj, B.A.Beatrice,
Total 15 2.7864 Optimization of cutting parameters and fluid
application parameters during turning of ohns steel.
IV. CONCLUSION Procedia Engineering 97: 172-177 (2013).
Taguchi method had been implemented for [10] Alagarsamy, S.V., Raveendran, P., A.ockia, V.S.
optimizing process parameters for CNC Drilling Al S., Tamil, V.S., Optimization of machining
6351 Alloy with L16 orthogonal array. From Table 6, parameters for turning of aluminium alloy 7075
Table 7, and Figure 4, depth of cut is the most using taguchi method. International Research
influencing parameter for minimum surface finish Journal of Engineering and Technology 3(1): 316-
which is followed by spindle speed and feed rate. From 322 (2016).
108