Optimization of process parameters on mrr during face milling of rolled steel (aisi1040) using taguchi method

Abstract

Mass production at low cost in industry can be obtained by reducing the manufacturing time. In this study, a systematic approach based on Taguchi�s philosophy is proposed to optimize the metal removal rate (MRR) during face milling of rolled steel (AISI1040). Experiments are performed on vertical milling center (HURCO-VM10) using face milling cutter of 80 mm diameter. Cutting velocity, feed per teeth, and depth of cut are considered as quantitative parameters. Whereas rolling direction, cutter offset, and soaking time are considered as qualitative parameters under cutting strategy. Experiments are conducted on the basis of Taguchi�s L27 orthogonal array and MRR is calculated. Signal to noise (S/N) ratio is calculated to evaluate the optimum levels of process parameters. Analysis of variance (ANOVA) is conducted to identify the significant parameters, optimum settings, and percent contribution of each process parameter. The outcomes of ANOVA reveal that feed per teeth and cutting velocity are the main process parameters contributing to MRR. A confirmation test is performed to compare the predicted and experimental results of MRR. Results show that there is a significant improvement in the MRR by adopting the proposed optimization technique.