Article: Optimisation of cutting parameters on high-speed CNC milling for precision parts of non-ferrous castings using RSM Journal: International Journal of Computational Materials Science and Surface Engineering (IJCMSSE) 2018 Vol.7 No.2 pp.89 - 103 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<SUB align="right"><SMALL>a</SMALL></SUB> in the range less than 0.25 microns. Inderscience Publishers - linking academia, business and industry through research

Title: Optimisation of cutting parameters on high-speed CNC milling for precision parts of non-ferrous castings using RSM

Authors: N. Parameshwari; M. Ramesh; V.S. Thangarasu

Addresses: Department of Mechanical Engineering, Latha Mathavan Engineering College, Madurai 625301, Tamil Nadu, India ' Department of Mechanical Engineering, SACS MAVMM Engineering College, Madurai 625301, Tamil Nadu, India ' Department of Mechanical Engineering, Nehru Institute of Engineering and Technology, Coimbatore 641105, Tamil Nadu, India

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.

Keywords: non ferrous metals; optimisation; surface roughness; high-speed machining.

DOI: 10.1504/IJCMSSE.2018.092535

International Journal of Computational Materials Science and Surface Engineering, 2018 Vol.7 No.2, pp.89 - 103

Accepted: 07 Sep 2017
Published online: 24 Jun 2018 *

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Title: Optimisation of cutting parameters on high-speed CNC milling for precision parts of non-ferrous castings using RSM

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