Optimization of Machining Parameters Using RSM Analysis in the Face Milling of STAVAX Material

Chua, Jing Xuan (2024) Optimization of Machining Parameters Using RSM Analysis in the Face Milling of STAVAX Material. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

Text CHUA JING XUAN_Full Text.pdf Restricted to Registered users only Download (13MB)

Abstract

While trial and error can be a component of CNC (Computer Numerical Control) machining processes[1], it is not the primary strategy employed by skilled technicians or machinists. The lack of a systematic methodology to identify the optimal combination of parameters leads to inefficient material removal rates, poor surface finish quality, increased tool wear, and longer machining time. Optimization in CNC machining refers to the process of finding the best combination of machining parameters, such as cutting speed, depth of cut, feed rate, and spindle speed to achieve desired surface finishing. The surface finishing of CNC machined parts plays a critical role in their final quality and performance, making optimization of machining parameters crucial. By optimizing these parameters, manufacturers can minimize surface roughness, reduce power consumption, and improve overall production efficiency. This study aims to find the optimized machining parameters to obtain the best surface quality for STAVAX material. This study implemented the use of Taguchi orthogonal L9 array for 4 machining parameters in 3 levels into the experiment consisting of Depth of Cut (0.04mm, 0.06mm, 0.08mm), Width of Cut (0.07mm, 0.10mm, 0.13mm), Cutting Speed (9000rpm, 11000rpm, 13000rpm), and Feed Rate (2000mm/min, 2500mm/min, 3000mm/min). It involves orthogonal arrays and signal-to-noise ratios to identify optimal parameter settings. Subsequently, to model and analyses the relationship between input variables (machining parameters) and output variables (quality characteristics), Response Surface Methodology (RSM) were also used to aid determining the optimal parameter settings to achieve desired performance. For the conclusion, it can be observed that Feed Rate ranked the highest, Cutting Speed ranked second, followed by Width of Cut, and finally, Depth of Cut. This shows that the Feed Rate has the most significant effect against the average surface roughness (Ra) for STAVAX material while the Depth of Cut has the least effect. After the optimization of the machining parameters for the minimum surface roughness, the generated solution suggests that to achieve the lowest surface roughness (in this case, 0.28μm) for STAVAX material, the depth of cut must be 0.04mm, width of cut to be 0.098mm, cutting speed to be 10333.3rpm, and Feed Rate to be 2000mm/min.