Prediction of optimal process parameters for precision parts of phosphor bronze in high speed milling

Abstract

In any machining process, two essential but contradictory criteria are quality and productivity. Optimizing quality and productivity at the same time is therefore important. In the machining process, quality refers an acceptable yield in terms of product characteristics as required by customers and productivity can be understood m terms of the rate of matenal removal. One of the important customer requirement is surface quality and Surface roughness (Ra) is the key measure of surface quality in machined components. Increase m productivity is possible by compromising in quality loss as a result of reduced machmmg time. An improvement in quality, on the contrary, leads to an mcrease m machimng time, thus decreasing productivity. It is very interesting and difficult to comprehend the correlation between quality and productivity. In this work, surface roughness (Ra) and matenal removal rate (MRR) of the product which were prepared by the computenzed numerical control end milling operation are experimentally evaluated and the results are analytically interpreted. The experimental work was carried out by taking Phosphor Bronze as work matenal. Depth of cut, feed and speed were taken as mput parameters m three levels and these parameters were optimized for surface firnsh and MRR. The use of a signal-to-noise (S/N) ratio and analysis of variance (ANOVA) is employed to examme the influence of end milling parameters on these responses. Further, this study is used to correlate and suggest the best set of rnput parameters for the output variables m High speed computerized numerical control machmmg process usmg the DOE method.