Optimisation of Machining Parameters for CNC Milling of Fibre Reinforced Polymers

Abstract

The objective of the presented work is to improve the machining parameters of fibre reinforced polymer (FRP) using Taguchi's robust design technique. A large number of variables impact the quality of the completed component throughout the machining process. The quality of machined FRP components is greatly influenced by the surface roughness. Manufacturers can make sure that the finished product fulfils the necessary quality requirements and is cost-effective by optimizing machining settings to achieve the specified surface roughness. Optimizing machining parameters for achieving the desired surface roughness can help reduce production costs by minimizing waste, improving tool life, and reducing the need for post-processing operations. To optimize the process, Three levels of each parameter were chosen for investigation for each such adjustable process parameter. Machining was performed on a CNC milling machine using a carbide end mill. Experiments were conducted utilising Taguchi's technique to generate an experiment design (L9 orthogonal array). Analysis of variance was used to determine the impact of each parameter (ANOVA). The recommended control factor values for the best possible surface finish of FRP are 1.64 m, 400 rpm spindle/cutting velocity, 1.5 mm depth of cut and 0.3 millimetre/revolution feed rate. Surface roughness was shown to be most impacted by cutting speed, followed by feed rate and depth of cut. To determine the relationship between process parameters and quality attributes, regression analysis and response surface methodology was used.