AL-6061 دراسة عملية لخصائص عملية الخرائط لأجزاء من الالمنيوم
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Date
2022-06-21
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Abstract
The present research aims to study the significance of the influence of the
process parameters on response variables such as hardness, roughness of
surface and the rate of metal removal.
Traditionally, the selection of cutting parameters for turning is left to
machine operators, but in this case, even for a skilled operator, it is very
difficult to obtain the optimum values of the parameters. To determine a good
quality characteristic, it is necessary to set the optimum value of the parameters
for that the optimization technique is used.
Experiments designed using the taguchi method with three parameters and
five levels which are spindle speed (500, 750, 1000, 1250, and 1500 rpm),
cutting depth of (0.100,0.575, 1.050, 1.525and 2.000 mm) and feeding rate of
(0.050, 0.075, 0.100, 0.125 and 0.150 mm/rev).
Twenty five tests were conducted on FANUS (series oi Mate-TC) CNC
machine by choosing aluminum 6061 to be specimen material. For obtaining the
optimal turning factors, mathematical models were prepared by statistical
method (linear and quadratic regression) for each of hardness, roughness, and
MRR.
For finding out the accuracy of these equations, the expected values of the
outputs were extracted, and then tested the agreement between expected and
reality values of responses. The effect of process parameters on roughness of
surface, hardness, and MRR were analyzed statistically by analysis of variance
(ANOVA) and analysis of S/N ratio. From this analysis, the results indicate that
the depth, speed, and feeding rate have dominant effect on the responses
hardness, roughness of surface, and MRR in both dry and wet environments.
It can be concluded that the wet condition turning process is better than that
of the dry condition in terms of surface roughness, hardness, and MRR.
From the S/N optimization process, it can be seen that the optimum sets of
input parameters for hardness in the dry state were (speed= 500 rpm, feed=
0.050 mm/rev, and depth= 0.100mm), while in the wet condition the optimum
sets were (speed= 1500 rpm, feed= 0.050 mm/rev, and depth= 1.525). The
optimum sets of turning parameters for roughness in dry conditions were
(speed= 1500 rpm, feed= 0.050 mm/rev, and depth= 0.100 mm), while in wet
conditions the optimum sets were (spindle speed= 1250 rpm, feed= mm/rev, and
depth = 1.525 mm). The optimum sets of control variables to maximize material
removal rate in dry condition were (spindle speed= 1500 rpm, feed rate= 0.075
mm/rev, and depth of cut= 2.000 mm), while the optimum sets of turning
parameters in wet condition were (spindle speed= 1250 rpm , feed= 0.125
mm/rev, depth of cut= 2.000 mm).