Title: A response surface methodology based approach to machining processes: modelling and quality of the models

Authors: A-R. Alao, M. Konneh

Addresses: Mechanical Engineering Department, King Fahd University of Petroleum and Minerals (KFUPM), P.O. Box 130, Dhahran 31261, Saudi Arabia. ' Department of Manufacturing and Materials, International Islamic University (IIUM), P.O. Box 10, 50728 Kuala Lumpur, Malaysia

Abstract: Various techniques for developing prediction models for various machining performance measures such as surface roughness/surface integrity, cutting force, tool life/tool wear etc in machining processes are available. These methods include, but are not limited to, analytical, numerical, empirical, and artificial intelligence (AI) based methods. While empirical modelling often employs the use of response surface methodology (RSM), however, proper understanding must be established regarding RSM-based models with respect to their development, validation and acceptability. Therefore, the general framework for developing RSM-based prediction models and testing their quality are discussed in this paper. This is followed by a practical surface roughness (Rt) model developed for precision grinding of silicon, a machining process that is very difficult to model. The result shows that the procedural modelling frameworks work well for the Rt developed model.

Keywords: empirical models; modelling procedures; response surface methodology; RSM; analysis of variance; ANOVA; residual plot analyses; precision grinding; surface roughness; silicon grinding; machining performance; performance measures.

DOI: 10.1504/IJEDPO.2009.030320

International Journal of Experimental Design and Process Optimisation, 2009 Vol.1 No.2/3, pp.240 - 261

Published online: 14 Dec 2009 *

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