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Jeppiaar SRR Engineering college Padur, Chennai 603103
With the advent of the industrial revolution 4.0, the goal of the manufacturing industry is to produce a large number of products in relatively less time. This study applies the Taguchi L27 orthogonal array methodological paradigm along with response surface design. This work optimizes the process parameters in the turning of Aluminum Alloy 7075 using a Computer Numerical Control (CNC) machine. The optimal parameters influenced the rate of metal removal, the roughness of the machined surface, and the force of cutting. This experimental investigation deals with the optimization of speed (800 rpm, 1200 rpm, and 1600 rpm) and feed (0.15, 0.20, and 0.25 mm/rev) in addition to cutting depth (1.0, 1.5, and 2.0 mm) on the turning of Aluminum 7075 alloy in a CNC machine. The outcome in terms of results such as the removal rate of material (maximum), roughness on the machined surface (minimum), along with cutting force (least amount) were improved by the L27 array Taguchi method. There were 27 specimens of Al7075 alloy produced as per the array, and the corresponding responses were measured with the help of various direct contact and indirect contact sensors. Results were concluded all the way through diagrams of main effects in favor of signal-to-noise ratios and diagrams of surfaces with contour diagrams for various combinations of responses.
Mohammad Akhtar; T. Sathish; V. Mohanavel; Asif Afzal; K. Arul; M. Ravichandran; Inzarulfaisham Rahim; S. Alhady; Elmi Bakar; B. Saleh. Optimization of Process Parameters in CNC Turning of Aluminum 7075 Alloy Using L27 Array-Based Taguchi Method. Materials 2021, 14, 4470 .
AMA StyleMohammad Akhtar, T. Sathish, V. Mohanavel, Asif Afzal, K. Arul, M. Ravichandran, Inzarulfaisham Rahim, S. Alhady, Elmi Bakar, B. Saleh. Optimization of Process Parameters in CNC Turning of Aluminum 7075 Alloy Using L27 Array-Based Taguchi Method. Materials. 2021; 14 (16):4470.
Chicago/Turabian StyleMohammad Akhtar; T. Sathish; V. Mohanavel; Asif Afzal; K. Arul; M. Ravichandran; Inzarulfaisham Rahim; S. Alhady; Elmi Bakar; B. Saleh. 2021. "Optimization of Process Parameters in CNC Turning of Aluminum 7075 Alloy Using L27 Array-Based Taguchi Method." Materials 14, no. 16: 4470.
A lightweight, highly corrosive resistant, and high-strength wrought alloy in the aluminum family is the Aluminium 8006 alloy. The AA8006 alloy can be formed, welded, and adhesively bonded. However, the recommended welding methods such as laser, TIG (Tungsten Inert Gas welding), and ultrasonic are more costly. This investigation aims to reduce the cost of welding without compromising joint quality by means of friction stir welding. The aluminum alloy-friendly reinforcement agent zirconia is utilized as particles during the weld to improve the performance of the newly identified material AA8006 alloy in friction stir welding (FSW). The objectives of this research are to identify the level of process parameters for the friction stir welding of AA8006 to reduce the variability by the trial-and-error experimental method, thereby reducing the number of samples needing to be characterized to optimize the process parameters. To enhance the quality of the weld, the friction stir processing concept will be adapted with zirconia reinforcement during welding. The friction stir-processed samples were investigated regarding their mechanical properties such as tensile strength and Vickers microhardness. The welded samples were included in the corrosion testing to ensure that no foreign corrosive elements were included during the welding. The quality of the weld was investigated in terms of its surface morphology, including aspects such as the dispersion of reinforced particles on the welded area, the incorporation of foreign elements during the weld, micro defects or damage, and other notable changes through scanning electron microscopy analysis. The process of 3D profilometry was employed to perform optical microscopy investigation on the specimens inspected to ensure their surface quality and finish. Based on the outcomes, the optimal process parameters are suggested. Future directions for further investigation are highlighted.
Thanikodi Sathish; Abdul Kaladgi; V. Mohanavel; K. Arul; Asif Afzal; Abdul Aabid; Muneer Baig; Bahaa Saleh. Experimental Investigation of the Friction Stir Weldability of AA8006 with Zirconia Particle Reinforcement and Optimized Process Parameters. Materials 2021, 14, 2782 .
AMA StyleThanikodi Sathish, Abdul Kaladgi, V. Mohanavel, K. Arul, Asif Afzal, Abdul Aabid, Muneer Baig, Bahaa Saleh. Experimental Investigation of the Friction Stir Weldability of AA8006 with Zirconia Particle Reinforcement and Optimized Process Parameters. Materials. 2021; 14 (11):2782.
Chicago/Turabian StyleThanikodi Sathish; Abdul Kaladgi; V. Mohanavel; K. Arul; Asif Afzal; Abdul Aabid; Muneer Baig; Bahaa Saleh. 2021. "Experimental Investigation of the Friction Stir Weldability of AA8006 with Zirconia Particle Reinforcement and Optimized Process Parameters." Materials 14, no. 11: 2782.
Arul Kulandaivel; Senthil Kumar. Effect of magneto rheological minimum quantity lubrication on machinability, wettability and tribological behavior in turning of Monel K500 alloy. Machining Science and Technology 2020, 24, 810 -836.
AMA StyleArul Kulandaivel, Senthil Kumar. Effect of magneto rheological minimum quantity lubrication on machinability, wettability and tribological behavior in turning of Monel K500 alloy. Machining Science and Technology. 2020; 24 (5):810-836.
Chicago/Turabian StyleArul Kulandaivel; Senthil Kumar. 2020. "Effect of magneto rheological minimum quantity lubrication on machinability, wettability and tribological behavior in turning of Monel K500 alloy." Machining Science and Technology 24, no. 5: 810-836.
This work is intended to focus on the development and investigation of a novel designed magnetorheological based minimum quantity lubrication (MR-MQL) on turning operation of Monel K500 alloy. Nanosized CuO is used as a binder in magnetorheological fluids to promote lubricity on the tool chip interference. Experiments were conducted with operating conditions suich as cutting speed (95–125 m/min), feed rate (0.050–0.1 mm/rev), and depth of cut (0.25–0.75 mm) and variable rheological conditions such as working current (0–27 A) of the electromagnetic tool insert and flow rate (0–10 ml/min). Results obtained from the MR-MQL process prove that the cutting tool temperature was reduced by 9.36% when compared with the MQL process and surface roughness was reduced by 26.58% when compared with the MQL process. Microstructural analysis clarifies the wear scar zone reduction due to Cu2C3 intermetallic compound formation near the tool tip interference.
Arul K; Senthil Kumar V.S.. Magnetorheological based minimum quantity lubrication (MR-MQL) with additive n-CuO. Materials and Manufacturing Processes 2020, 35, 405 -414.
AMA StyleArul K, Senthil Kumar V.S.. Magnetorheological based minimum quantity lubrication (MR-MQL) with additive n-CuO. Materials and Manufacturing Processes. 2020; 35 (4):405-414.
Chicago/Turabian StyleArul K; Senthil Kumar V.S.. 2020. "Magnetorheological based minimum quantity lubrication (MR-MQL) with additive n-CuO." Materials and Manufacturing Processes 35, no. 4: 405-414.
Turning operation is one of the most commonly used machining processes. However, turning of high strength materials involves high heat generation which, in turn, results in undesirable characteristics such as increased tool wear, irregular chip formation, minor variations in physical properties etc. In order to overcome these, synthetic coolants are used and supplied in excess quantities (flood type). The handling and disposal of excess coolants are tedious and relatively expensive. In this proposed work, Water Soluble Cutting Oil suspended with nanoparticles (Graphene) is used in comparatively less quantities using Minimum quantity lubrication (MQL) method to improve the quality of machining. The testing was done on Turning operation of Monel K500 considering the various parameters such as the cutting speed, feed and depth of cut for obtaining a surface roughness of 0.462μm and cutting tool temperature of 55°C for MQL-GO (Graphene oxide) process.
Arul Kulandaivel; Senthil Kumar Santhanam. Experimental Investigation on Turning of Monel K500 Alloy Using Nano Graphene Cutting Fluid Under Minimum Quantity Lubrication. Volume 2A: Advanced Manufacturing 2019, 1 .
AMA StyleArul Kulandaivel, Senthil Kumar Santhanam. Experimental Investigation on Turning of Monel K500 Alloy Using Nano Graphene Cutting Fluid Under Minimum Quantity Lubrication. Volume 2A: Advanced Manufacturing. 2019; ():1.
Chicago/Turabian StyleArul Kulandaivel; Senthil Kumar Santhanam. 2019. "Experimental Investigation on Turning of Monel K500 Alloy Using Nano Graphene Cutting Fluid Under Minimum Quantity Lubrication." Volume 2A: Advanced Manufacturing , no. : 1.