Optimization Of Rotary Ultrasonic Assisted Milling For Graphite Material

Othman, Nur Ainina Izzati (2017) Optimization Of Rotary Ultrasonic Assisted Milling For Graphite Material. Project Report. UTeM, Melaka. (Submitted)

Text Optimization Of Rotary Ultrasonic Assisted Milling For Graphite Material - Nur Ainina Izzati Othman -24 pages.pdf - Submitted Version Download (433kB)

Abstract

Graphite has been widely used in a variety of applications of manufacturing processes. It is materials that have unique properties that allows it to be manipulated to form into various types to satisfy a research and industrial interest. However, graphite is an abrasive material that needs to be machined dry and thus, requires special machining techniques such as Rotary Ultrasonic Assisted Milling (RUAM) process. Smooth machined surface has been always the objective when machining this material. The present work aim to optimize the RUAM machining parameters (cutting speed, feed rate, depth of cut, amplitude and frequency) for effectively machining graphite material. A Box Behnken Design is chosen through Response Surface Methodology (RSM) has been used with the designof experiment with totals of 46 runs. Models are analyzed statically using analysis of variance (ANOVA) to determine significant parameters and possible interactions. Various diagnostic plots were analyzed to check the model effectiveness. Multi objectives optimization is performed through numerical optimization and predicted results are validated. The percentage error is less than 20% thus the solution is consider optimal run condition. The finding determine that surface roughness is sensitive toward cutting speed and feed rate while cutting force is sensitive toward cutting speed, feed rate and depth of cut. Frequency and amplitude give small but improving results towards this research. Therefore, the most optimum combination of parameters is when the cutting speed is high, low feed rate, low depth of cut, high frequency and high amplitude.

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