Surface Roughness Optimization in End Milling Operation with Damper Inserted End Milling Cutters
This paper presents a study of the Taguchi design
application to optimize surface quality in damper inserted end milling
operation. Maintaining good surface quality usually involves
additional manufacturing cost or loss of productivity. The Taguchi
design is an efficient and effective experimental method in which a
response variable can be optimized, given various factors, using
fewer resources than a factorial design. This Study included spindle
speed, feed rate, and depth of cut as control factors, usage of different
tools in the same specification, which introduced tool condition and
dimensional variability. An orthogonal array of L9(3^4)was used;
ANOVA analyses were carried out to identify the significant factors
affecting surface roughness, and the optimal cutting combination was
determined by seeking the best surface roughness (response) and
signal-to-noise ratio. Finally, confirmation tests verified that the
Taguchi design was successful in optimizing milling parameters for
surface roughness.
[1] Cobb, W. T., "Design of Dampers for Boring Bars and Spindle
Extensions," Master-s Thesis, Mechanical Engineering, University of
Florida, Gainesville, FL, 1989.
[2] Keyvanmanesh, Amir, "Evaluation of Chatter Detection and Control
System," Master-s Thesis, Mechanical Engineering, University of
Florida, Gainesville, FL, 1990.
[3] Smith, Kevin Scott, "Chatter, Forced Vibrations, And Accuracy In High-
Speed Milling," Master-s Thesis, Mechanical Engineering, University of
Florida, Gainesville, 1985.
[4] Cook, R. A., Bloomquist, D., Richard, D. S., and Kalajian, M.A.,
"Damping Of Cantilevered Traffic Signal Structures," Journal of
Structural Engineering, 2001,Vol. 25, pp 1476-1483.
[5] Slocum, H. Alexander, "Precision Machine Design", Society Of
Manufacturing Engineers, Dearborn, MI, 1992.
[6] J. Tlusty, K.S. Smith, W. Winfough, "Techniques for the use of long
slender end mills in high-speed machining", Annals of the CIRP 25 (1)
(1996) 393-396
[7] E. Soliman, F. Ismail, "Chatter suppression by adaptive speed
modulation", International Journal of Machine Tools & Manufacture 37
(3) (1997) 355-369.
[8] E.G. Kubica, F. Ismail, "Active suppression of chatter in peripheral
milling", International Journal of Advanced Manufacturing Technology
12 (4) (1996)236-245.
[9] Delio T., Tlusty J., Smith S. "Use of audio signals for chatter detection
and control". Journal of Engineering for Industry , 1992, 114: 146-157
[10] Weck, M., Altintas.Y. Beer.C, "CAD assisted chatter free NC tool path
generation in milling" ,International journal of machine tools and
manufacture,1994 ,34,879-891.
[11] M. Liang, T. Yeap, A. Hermansyah, "A fuzzy system for chatter
suppression in end milling", Proceedings of the Institution of
Mechanical Engineers Part B: Journal of Engineering Manufacture
(2004) 403-417.
[12] S.smith and J.Tlusty, "Stabilizing chatter by automatic spindle speed
regulation", Annals of CIRP, 41(1):433-436, 1992.
[13] Englehardt, R., Lin, S. C., Devor, R. E., and Kapoor, S. G "A
Verification of the Use of Variable Spindle Speed for Vibration
Reduction inFace Milling", Proc. of the 17th NAMRI/SME Conference,
1989,Vol. 17, pp. 115-122,
[14] Ralston, P.A. & Ward, T.L. "Adaptive Control of Machine Tools: the
past and projected role of Numerical Control Computers". Computers
and Industrial Engineering. Vol. 14, No. 2, 1988, pp. 85-94.
[15] J.Y. Zhu, A.A. Shumsheruddin and J.G. Bollinger, "Control of Machine
Tools Using the Fuzzy Control Technique", CIRP Annals -
Manufacturing Technology ,Volume 31, Issue 1, 1982, Pages 347-352
[16] K. Nagaya, J. Kobayasi, K. Imai, "Vibration control of milling machine
by using auto-tuning magnetic damper and auto-tuning vibration
absorber", International Journal of Applied Electromagnetics and
Mechanics 16 (1-2) (2002) 111-123.
[17] J.C. Ziegert, C. Stanislaus, T. Schmitz, R. Sterling, "Enhanced Damping
in Long Slender End" Transactions of the North American
,Manufacturing Research Institute of SME, vol. 32 2004 pp. 1-8.
[18] N.H. Kim, K.K. Choi, J.S. Chen, Y.H. Park, "Meshless shape design
sensitivity analysis and optimization for contact problem with friction",
Computational Mechanics 25 (2/3) (2000) 157-168.
[19] T. Schmitz, J.C. Ziegert, C. Stanislaus, "A Method for Predicting
Chatter Stability for Systems with Speed-Dependent Spindle Dynamics"
SME Technical Paper TP04PUB182, Transactions of the 2004 North
American Manufacturing Research Institute of SME, vol.32 2004 pp.
17-24.
[20] Sridhar, R., Hohn, R. E., and Long, G. W., 1968, ÔÇÿÔÇÿA General
Formulation of the Milling Process EquationÔÇöContribution to Machine
Tool Chatter ResearchÔÇö5,-- ASME J. Eng. Ind., pp. 317-324.
[21] E. Budak, Y. Altintas, "Analytical prediction of chatter stability in
milling-part I: general formulation; part II: application to common
milling systems", Transactions of the ASME, Journal of Dynamic
Systems, Measurement, and Control 120 (1998) 22-36
[22] M.Alauddin, M.A.EL Baradie, M.S.J.Hashmi,"Prediction of tool life in
end milling by response surface methodology", Vol 71,1997, 456-465.
[23] M. Hasegawa, A. Seireg, R.A. Lindberg, "Surface roughness model for
turning", Tribology International, December Vol,1976, 285-289.
[24] M.A. EI-Baradie, "Surface roughness model for turning grey cast iron
1154 BHN)", Proc. IMechE, 207 ,1993, pp 43-54.
[25] B.P. Bandyopadhyay and E.H. Teo, "Application of lactorial design of
experiment in high speed turning", Proc. Mam~ll htt. Part 4, Adrances
in Materials & Automation, Atlanta. GA, USA, ASME, NY, 1990, 3-8.
[26] O.A. Gorlenko, "Assessment of starface roughness parameters and their
interdependence", Precis. Eng., 3 (1981)2.
[27] T.R. Thomas, "Characterisation of surface roughness", Precis. Eng.,
Vol. 3, 1981.
[28] Krishna Mohana Rao,P.Ravi Kumar , "Surface roughness analysis in
milling" World Academy of Science, Engineering and Technology, Issue
59,November 2011
[1] Cobb, W. T., "Design of Dampers for Boring Bars and Spindle
Extensions," Master-s Thesis, Mechanical Engineering, University of
Florida, Gainesville, FL, 1989.
[2] Keyvanmanesh, Amir, "Evaluation of Chatter Detection and Control
System," Master-s Thesis, Mechanical Engineering, University of
Florida, Gainesville, FL, 1990.
[3] Smith, Kevin Scott, "Chatter, Forced Vibrations, And Accuracy In High-
Speed Milling," Master-s Thesis, Mechanical Engineering, University of
Florida, Gainesville, 1985.
[4] Cook, R. A., Bloomquist, D., Richard, D. S., and Kalajian, M.A.,
"Damping Of Cantilevered Traffic Signal Structures," Journal of
Structural Engineering, 2001,Vol. 25, pp 1476-1483.
[5] Slocum, H. Alexander, "Precision Machine Design", Society Of
Manufacturing Engineers, Dearborn, MI, 1992.
[6] J. Tlusty, K.S. Smith, W. Winfough, "Techniques for the use of long
slender end mills in high-speed machining", Annals of the CIRP 25 (1)
(1996) 393-396
[7] E. Soliman, F. Ismail, "Chatter suppression by adaptive speed
modulation", International Journal of Machine Tools & Manufacture 37
(3) (1997) 355-369.
[8] E.G. Kubica, F. Ismail, "Active suppression of chatter in peripheral
milling", International Journal of Advanced Manufacturing Technology
12 (4) (1996)236-245.
[9] Delio T., Tlusty J., Smith S. "Use of audio signals for chatter detection
and control". Journal of Engineering for Industry , 1992, 114: 146-157
[10] Weck, M., Altintas.Y. Beer.C, "CAD assisted chatter free NC tool path
generation in milling" ,International journal of machine tools and
manufacture,1994 ,34,879-891.
[11] M. Liang, T. Yeap, A. Hermansyah, "A fuzzy system for chatter
suppression in end milling", Proceedings of the Institution of
Mechanical Engineers Part B: Journal of Engineering Manufacture
(2004) 403-417.
[12] S.smith and J.Tlusty, "Stabilizing chatter by automatic spindle speed
regulation", Annals of CIRP, 41(1):433-436, 1992.
[13] Englehardt, R., Lin, S. C., Devor, R. E., and Kapoor, S. G "A
Verification of the Use of Variable Spindle Speed for Vibration
Reduction inFace Milling", Proc. of the 17th NAMRI/SME Conference,
1989,Vol. 17, pp. 115-122,
[14] Ralston, P.A. & Ward, T.L. "Adaptive Control of Machine Tools: the
past and projected role of Numerical Control Computers". Computers
and Industrial Engineering. Vol. 14, No. 2, 1988, pp. 85-94.
[15] J.Y. Zhu, A.A. Shumsheruddin and J.G. Bollinger, "Control of Machine
Tools Using the Fuzzy Control Technique", CIRP Annals -
Manufacturing Technology ,Volume 31, Issue 1, 1982, Pages 347-352
[16] K. Nagaya, J. Kobayasi, K. Imai, "Vibration control of milling machine
by using auto-tuning magnetic damper and auto-tuning vibration
absorber", International Journal of Applied Electromagnetics and
Mechanics 16 (1-2) (2002) 111-123.
[17] J.C. Ziegert, C. Stanislaus, T. Schmitz, R. Sterling, "Enhanced Damping
in Long Slender End" Transactions of the North American
,Manufacturing Research Institute of SME, vol. 32 2004 pp. 1-8.
[18] N.H. Kim, K.K. Choi, J.S. Chen, Y.H. Park, "Meshless shape design
sensitivity analysis and optimization for contact problem with friction",
Computational Mechanics 25 (2/3) (2000) 157-168.
[19] T. Schmitz, J.C. Ziegert, C. Stanislaus, "A Method for Predicting
Chatter Stability for Systems with Speed-Dependent Spindle Dynamics"
SME Technical Paper TP04PUB182, Transactions of the 2004 North
American Manufacturing Research Institute of SME, vol.32 2004 pp.
17-24.
[20] Sridhar, R., Hohn, R. E., and Long, G. W., 1968, ÔÇÿÔÇÿA General
Formulation of the Milling Process EquationÔÇöContribution to Machine
Tool Chatter ResearchÔÇö5,-- ASME J. Eng. Ind., pp. 317-324.
[21] E. Budak, Y. Altintas, "Analytical prediction of chatter stability in
milling-part I: general formulation; part II: application to common
milling systems", Transactions of the ASME, Journal of Dynamic
Systems, Measurement, and Control 120 (1998) 22-36
[22] M.Alauddin, M.A.EL Baradie, M.S.J.Hashmi,"Prediction of tool life in
end milling by response surface methodology", Vol 71,1997, 456-465.
[23] M. Hasegawa, A. Seireg, R.A. Lindberg, "Surface roughness model for
turning", Tribology International, December Vol,1976, 285-289.
[24] M.A. EI-Baradie, "Surface roughness model for turning grey cast iron
1154 BHN)", Proc. IMechE, 207 ,1993, pp 43-54.
[25] B.P. Bandyopadhyay and E.H. Teo, "Application of lactorial design of
experiment in high speed turning", Proc. Mam~ll htt. Part 4, Adrances
in Materials & Automation, Atlanta. GA, USA, ASME, NY, 1990, 3-8.
[26] O.A. Gorlenko, "Assessment of starface roughness parameters and their
interdependence", Precis. Eng., 3 (1981)2.
[27] T.R. Thomas, "Characterisation of surface roughness", Precis. Eng.,
Vol. 3, 1981.
[28] Krishna Mohana Rao,P.Ravi Kumar , "Surface roughness analysis in
milling" World Academy of Science, Engineering and Technology, Issue
59,November 2011
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:59130", author = "Krishna Mohana Rao and G. Ravi Kumar and P. Sowmya", title = "Surface Roughness Optimization in End Milling Operation with Damper Inserted End Milling Cutters", abstract = "This paper presents a study of the Taguchi design
application to optimize surface quality in damper inserted end milling
operation. Maintaining good surface quality usually involves
additional manufacturing cost or loss of productivity. The Taguchi
design is an efficient and effective experimental method in which a
response variable can be optimized, given various factors, using
fewer resources than a factorial design. This Study included spindle
speed, feed rate, and depth of cut as control factors, usage of different
tools in the same specification, which introduced tool condition and
dimensional variability. An orthogonal array of L9(3^4)was used;
ANOVA analyses were carried out to identify the significant factors
affecting surface roughness, and the optimal cutting combination was
determined by seeking the best surface roughness (response) and
signal-to-noise ratio. Finally, confirmation tests verified that the
Taguchi design was successful in optimizing milling parameters for
surface roughness.", keywords = "ANOVA, Damper, End Milling, Optimization,
Surface roughness, Taguchi design.", volume = "6", number = "10", pages = "2216-5", }
