Design Of Experiment (DOE) based approach in optimizing finishing parameters of CNC machining toward surface roughness

Che Hassim, Muhammad Dzulhelmy Che Hassim (2019) Design Of Experiment (DOE) based approach in optimizing finishing parameters of CNC machining toward surface roughness. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Taguchi Method is an effective tool introduced for the optimization of the product or process quality. Aluminum 3003 is a commercially pure, manganese-added aluminum. Because of its excellent characteristics, 3003 is the most widely used aluminum alloy and its surface roughness varies with the changes of the process parameters of the machine such as layer spindle speed, feed rate, depth of cut and others. The combinations of different sets of the parameters will definitely produce parts with different specifications, thus the study of the suitable combination of parameters is necessary for optimum output is carried out. In order to achieve the optimum performance of the machined sample, the Taguchi method was employed because it is a simplified yet powerful method for experimental design using the orthogonal array method. In this study, an orthogonal array of L₉ (33) was used and nine pieces of samples were determined for 3 parameters that namely are spindle speed, feed rate and finishing tolerance with three levels each. The samples for machining was designed using SolidWorks, coded using Siemens Sinumerik and machined by DMU eVo 6 milling machine for the nine samples. The results were obtained and data was analyzed. The data of confirmation test shows that the samples with optimum parameters was a combination of spindle speed (14000 rpm), feed rate (900m/min) and finishing tolerance of 0.635 with a percentage difference of 7% from the prediction data. From the analyzed data from the Signal to noise, ranked 1 is feed rate than followed by spindle speed, and finishing tolerance respectively. Thus, this result shows that the surface roughness of a sample produced using DMU eVo 6 machine with different combination of process parameters and the Taguchi Method provides the solution of determining the optimum surface roughness of combination parameter with minimum number of experiment.

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