Modeling and optimization of surface roughness and tool vibration in CNC turning of Aluminum alloy using hybrid RSM-WPCA methodology

• Main Authors: Priyabrata Sahoo, Ashwani Pratap, Asish Bandyopadhyay
• Format: Article
• Language: English
• Published: Growing Science 2017-06-01
• Series: International Journal of Industrial Engineering Computations
• Subjects: CNC turning; Surface roughness; Tool vibration; RSM; WPCA; ANOVA
• Online Access: http://www.growingscience.com/ijiec/Vol8/IJIEC_2016_33.pdf

This paper suggests an advanced hybrid multi output optimization technique by applying weighted principal component analysis (WPCA) incorporated with response surface methodology (RSM). This investigation has been carried out through a case study in CNC turning of Aluminum alloy 63400 for surface roughness (Ra) and tool vibration (db) optimization. Primarily, input parameters such as spindle speed (N), feed rate (S) and depth of cut (t) are designed for experiment by using RSM Box-Behnken methodology. The aluminum alloy workpieces are machined by using coated carbide tool (inserts) in dry environment. Secondly, the empirical model for the responses as the functions of cutting parameters are obtained through RSM technique and the adequacy of the models have been checked using analysis of variance (ANOVA). Finally, the process parameters are optimized using WPCA technique. The confirmatory experiment has been performed using optimized result and it reveals that multiple response performance index (MPI) value was increased by 0.2908 from initial setting. The increases in MPI value indicates that the aforesaid optimization methodology is suitably acceptable for multi response optimization for turning process.