OPTIMIZATION OF REAMING

PARAMETERS TO IMPROVE
SURFACE FINISH OF EN1A PRESS
TOOL

11ME001
ARIVAZHAGAN .S
Guided by
Dr. P. ASHOK VARDHANAN., ME., Ph.D

INTRODUCTION
Surface roughness is one of the most important parameters to
determine the quality of a product.
Surface roughness consists of the fine irregularities of the
surface texture, including feed marks generated by the
machining process.
Several factors will influence the final surface roughness in a
CNC reaming operation controllable factors such as (spindle
speed, feed rate and depth of cut) and uncontrollable factors
(tool geometry and material properties of both tool and work
piece).
MACHINING PARAMETERS
1. Depth of Cut
2. Cutting Speed
3. Feed Rate
4. Number of flutes
5. Helix angle
6. Number of passes
7. Rake angel

PROPERTIES
Work piece properties:
1. Hardness
2. thickness
3. Diameter
Cutting Tool properties:
1. Tool Material
2. Tool Shape
3. Run out Errors
OUTPUT PARAMETERS
1.Surface roughness
(Other output parameters)
2. Material removal rate
3. Tool life
4. Productivity
5. Quality
6.Machining time
7. Machining cost
OPTIMIZATION TECHINIQUES
Experimental method
SA (Simulated annealing)
RSM (Response Surface Methodology)
PSO (Particle Swarm optimization)
GA (Genetic Algorithm)
TS (Tabu Search)
ACO (Ant Colony Optimization)
EXPERIMENTAL DESIGN
Experimental method is very old technique used for
optimization of output results.
In this method required number of experiments are done to
know the optimum results.
It is like a trial and error method.
It doesnt give the best optimum results compare to other
modern optimization techniques like RSM, PSO, GA, etc.,


RSM
Response surface methodology (RSM) is a collection of
mathematical and statistical techniques for empirical model
building.
By careful design of experiments, the objective is to optimize a
response (output variable) which is influenced by several
independent variables (input variables).
An experiment is a series of tests, called runs, in which
changes are made in the input variables in order to identify
then reasons for changes in the output response.
REGRESSION MODELING
The measurement of surface roughness in reaming in relation
to the independent variables commonly investigated is
expressed mathematically as follows
R
a
= c v
k
f
l
d
m


Output Result in the form of first order model or second order
model = y - = b
0
x
0
+ b
1
x
1
+ b
2
x
2
+ b
3
x
3
, x0=1 is a dummy
variable. x
1
, x
2
and x
3
are the cutting condition values.
PARTICLE SWARM OPTIMIZATION
Each particle keeps track of its coordinates in the solution
space which are associated with the best solution (fitness) that
has achieved so far by that particle. This value is called
personal best , pbest.
Another best value that is tracked by the PSO is the best value
obtained so far by any particle in the neighborhood of that
particle. This value is called gbest.
The basic concept of PSO lies in accelerating each particle
toward its pbest and the gbest locations.


LITERATURE SURVEY
1. APPLICATION OF GA TO OPTIMIZE CUTTING CONDITIONS FOR
MINIMIZING SURFACE ROUGHNESS IN END MILLING
MACHINING PROCESS

Work Piece : Annealed alpha-beta titanium alloy
Tool : Uncoated , TIAlN , SNTR
Machining parameters : Cutting Speed, Feed rate, Rake angle
Output result : Surface Roughness




















REGRESSION MODEL
R uncoated = 0. 451- 0.00267x1+5.671x2+0.0046x3
R TIAIN =0.292-0.000855x1+5.383x2-0.00553x3
R SNTR = 0.237-0.00175x1+8.693x2-0.00159x3
x1= cutting speed, x2= feed rate, x3= Rake angle

In this Journal they done
24 experimental trials
Develop regression model for 3 different tools from the
experimental data.

From the 3 regression model the best regression model is
determined

Then using GA predicted surface roughness value, it is expected to
be lower than the minimum R
a
vale of the experimental and
regression model.
The GA results are compared with the RSM of (Mohruni ,2008)

They conclude that GA technique estimates the lower value of the
best surface roughness value compared to the RSM technique.
2. OPTIMIZATION OF CUTTING CONDITIONS IN END
MILLING PROCESS WITH THE APPROACH OF
PARTICLE SWARM OPTIMIZATION

Work Piece : Annealed alpha-beta titanium alloy
Tool : Uncoated , TIAlN , SNTR
Machining parameters : Cutting Speed, Feed rate, Rake angle,
Depth of cut
Output result : Surface Roughness






REGRESSION MODEL
R uncoated = 0. 451- 0.00267x1+5.671x2+0.0046x3+0.469x4
R TIAIN =0.292-0.000855x1+5.383x2-0.00553x3+0.469x4
R SNTR = 0.237-0.00175x1+8.693x2-0.00159x3+0.469x4

x1= cutting speed, x2= feed rate, x3= Rake angle, x4= depth of cut



In this journal
They used regression equation to establish a relationship
between four selected input variables, such as speed, feed,
depth of cut and rake angle and the output variable, surface
roughness.
PSO is used to optimize the predicted models given above.
PSO is one of the soft computing which is extensively used in
research work.
The program code is write in MATLAB 10 version. The
computational time is less than one minute.
It is really very easy to apply and time saving technique.
The results obtained by PSO are superior to the results
obtained by GA used by Zain et al., and it indicates that PSO is
more suitable for this category.
3. EFFECTS OF MACHINING PARAMETERS WHEN
REAMING ALUMINIUM-SILICON (SAE 322) ALLOY
This paper evaluates the dimensional stability (diameter,
roundness and cylindricity) and surface roughness of reamed
cylindrical holes using K10 cemented carbide welded blade
reamers on aluminium-silicon cast alloy at various cutting
conditions in order to optimize the cutting process.

Eleven experiments are conducted by 11 different reamers.

The 11 reamers are vary by diameter, Margin, Rake face
finishing, Helix angle, Number of blades.
RESULTS
Reaming at lower depths of cut gave the results in overall
terms of accuracy, surface finish, roundness and
cylindricity of the holes produced.

The best dimensional stability, surface finish as well as
the lowest power consumption can be achieved when
reaming the aluminium-silicon alloy at a lower cutting
speed.

Reamers with more blades produced better hole diameter
accuracy, surface finish and roundness at the expense of
holes with a poorer cylindiricity and power consumption.


MODELLING AND OPTIMIZATION OF PROCESS
PARAMETERS DURING END MILLING OF HARDENED
STEEL
In this study, the average surface roughness values obtained
when milling EN24 grade steel with a harness of 260 BHN
using solid coated carbide tools.
Cutting parameters such as cutting speed (v), feed rate (f) and
depth of cut(d) are optimized by using RSM technique.
Sufficient numbers of experiments were run and second order
quadratic model is designed.
RSM has been proven to be an efficient method to predict the
surface finish during end-milling of EN24 alloy steel. It is
also reduces the number of experiments.
Increment of cutting speed and decrement of feed will result in
better surface quality.



METHODOLOGY



1. Study the real machining experimental set data to examine the cutting
conditions used (Cutting speed, feed and depth of cut) that contribute to
the surface roughness results. For this purpose, the machining experiment
in conducting this work involves reaming EN1A leaded material using
experiment set data for uncoated tool under flood conditions.
2. A response surface model was designed and analyzed using JMP software
the analysis of Variance ANOVA was carried out to determine the effect
of cutting parameters on the surface roughness. The optimum cutting
parameters to minimize surface roughness were obtained by maximizing
the overall desirability function.



3. Develop the machining model to describe the relationship between
independent machining variables (cutting conditions) and dependent
machining variables (surface roughness) by using the regression
technique. By the t-test, the best regression model is determined as
the choice for the fitness function (objective function) in the PSO
optimization technique.
4. Find the optimal set value off independent variables to present the
minimum objective function using the PSO technique. The objective
function or fitness function of PSO leads to the minimum (lower)
value of surface roughness.
5. Evaluate the PSO solution. The optimal cutting conditions that give
minimum surface roughness values generated from PSO are
compared to the experimental sample data, RSM model and
regression model. From the compared result the optimum parameter
to minimize surface roughness is taken.




OBJECTIVES
The objective of the present work is to optimize the cutting parameters
to minimize the surface roughness of EN1A leaded material.
A new set of research is carrying out by reaming EN1A leaded material
with two different types of cutting tools and optimization of cutting
parameter is done by PSO technique.
The various cutting parameters which mainly affect surface roughness
are to be optimized:
Cutting speed (m/min)
Feed rate (mm/tooth)
Depth of cut (mm)
Determine the surface roughness of the work piece by surface
roughness testing instrument.
Comparing the results of Experimental sample data, RSM, Regression
model and PSO results



EXPERIMENTAL METHOD
MACHINE MODEL

In this research the cutting experiments are conducted on a
Vertical Machining Center.

AMS MODEL MCV-450
Capacity 800 x 450 x 500
Max Spindle Speed 8000 RPM

With 4
th
axis Nikken CNC Rotary Table Model 180FA and
Hydraulic power pack.

TOOL
Two different types of coated tools will be used in this experiment
TiA1N and SNTR. Generally Coated tools improve the tool life,
dimensional accuracy and surface roughness.

Cutter diameter = 12.025 mm
Fluted length = 50 mm
Helix angle = 0
0
(straight flute)
Number of flutes = 5

MACHINING PARAMETERS
LEVEL Cutting speed
(m/min)
Feed Rate
(mm/rev)
Depth of Cut (mm)
1 28 0.1 0.215
2 32 0.15 0.315
3 36 0.2 0.415
CONCLUSION

In this phase, a brief literature survey had been done and
maximum and minimum value of cutting parameters such as
Cutting speed, Feed rate and depth of cut are noted by
machining the EN1A leaded material.
TiA1N coating is done on uncoated straight flute reamer with
5 number of blades.
Using JMP software DOE is done and RSM, Regression
model also created.
Best regression model is selected by t-test and the best model
is taken for PSO technique.
FUTURE WORK
SNTR coating will be done on uncoated tool.
Using DOE number of experiments will select.
By the help of JMP software optimum parameter will obtain
by RSM technique.
Regression model is also develop by using JMP software.
Best model is selected and PSO will apply to obtain the best
optimum parameters fro reaming.
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Azalan ohd Zain, Habibollah Haron, Safian Sharif, Application of Ga to
optimize cutting conditions for minimizing surface roughness in end
milling machining process, Expert Systems with Application 37 (2010)
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Vikas Pare, Geeta Agnihotri & C.M. Krishna, Optimization of Cutting
Conditions in End Milling Process with the Approach of Particle Swarm
Optimization , International Journal of Mechanical and Industrial
Engineering (IJMIE), ISSN No. 2331-6477, Volume-1, Issue-2 2011.

Anayt Ullah Patwari, A.K.M. Nurul Amin, Muammer D.Arif, Optimization of
Surface Roughness in End Milling of Medium Carbon Steel by coupled
Statistical Approach with Genetic Algorithm, The First International
Conference on Interdisciplinary Research and Development, 31 May - 1
June 2011.
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December. 2008 ISSN 1995-6665 Pages 209- 214.

Turnad L. Ginta , A.K.M. Nurul Amin, H.C.D. Mohd Radzi, Mohd Amri
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