Optimisation of cutting parameters on high-speed CNC milling for precision parts of non-ferrous castings using RSM
by N. Parameshwari; M. Ramesh; V.S. Thangarasu
International Journal of Computational Materials Science and Surface Engineering (IJCMSSE), Vol. 7, No. 2, 2018

Abstract: This research paper analyses the cutting parameter optimisation suitable for precision parts manufacturing units, which mainly uses non-ferrous cast blocks for their job orders using Box-Behnken's response surface method. This solution method developed based on case studies conducted from industrial units involved in precision components manufacturing in 100% export oriented units around Coimbatore. The problem is converted into a simultaneous optimisation model for getting better material removal rate (MRR) on high-speed CNC milling process while maintaining the surface roughness requirements less than 20 microns. The experiments were carried out for different alloy materials of non-ferrous group frequently used for manufacturing precision components aluminium 6,061, brass, gunmetal, phosper bronze. The group of materials is of heterogeneous but they share similar mechanical properties required for a precision component, it is generally difficult to machine these material due to either soft ductile/hard brittle characters. However this research is to give an adaptable solution to the small and medium type job order companies, which struggle to maintain the precision at a minimised cost of manufacturing. The results show that MRR could be maximised by optimisation of input parameters while keeping R_a in the range less than 0.25 microns.

Online publication date: Sun, 24-Jun-2018

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