Application of Taguchi Method for Surface Roughness and Roundness Error in Drilling of AISI 316 Stainless Steel
11
0
0
Tam metin
(2) 1 ; < 2,* 2 1 Y^ ?
(3)
(4) 1 7; Y= 78 7
(5) D
(6)
(7) Y^ ; 2 Y^ ?
(8)
(9) 6
(10)
(11) 7O
(12) D
(13) Y^ ; In this study, the effects of deep cryogenic treatment and drilling parameters on surface roughness and roundness error were investigated in drilling of AISI 316 austenitic stainless steel with M35 HSS twist drills. In addition, optimal control factors for the hole quality were determined by using Taguchi technique. Two cutting tools, cutting speeds and feed rates were considered as control factors, and L8(23) orthogonal array was determined for experimental trials. Multiple regression analysis was employed to derive the predictive equations of the surface roughness and roundness error achieved via experimental design. Minimum surface roughness and roundness error were obtained with treated drills at 14 m/min cutting speed and 0.08 mm/rev feed rate. Confirmation experiments showed that Taguchi method precisely optimized the drilling parameters in drilling of stainless steel. Keywords: cryogenic treatment, drilling, surface roughness, roundness error, Taguchi method. 0 INTRODUCTION ; =
(14) 77
(15)
(16) 7
(17) =
(18)
(19)
(20) =
(21)
(22)
(23) .
(24) C ;
(25)
(26) ==
(27)
(28) 7
(29)
(30)
(31) 7
(32) = 7 = 7
(33) C 7
(34) ==
(35)
(36) 7
(37)
(38) C= 7 .
(39)
(40)
(41)
(42) ==
(43)
(44) 7
(45) 3C 6
(46) 77
(47)
(48)
(49) =
(50)
(51) 77
(52) 77
(53) *
(54) =
(55) O
(56) +
(57)
(58)
(59) = C;
(60)
(61) =
(62)
(63) 7
(64)
(65)
(66)
(67) 7 7=
(68) *7_ 34_ »6+
(69)
(70) C = =
(71)
(72)
(73) 7 ! /!!À &C
(74)
(75)
(76) 7 7
(77)
(78)
(79) C 6
(80)
(81) =
(82) 7 =
(83)
(84)
(85) 7
(86) 7
(87) 7
(88)
(89)
(90)
(91) /C ; 7
(92)
(93)
(94) = = =
(95)
(96) 7
(97)
(98) = C O
(99)
(100)
(101) 7
(102)
(103) 7
(104) = 7 7
(105)
(106) 7
(107) = 4C 7 7
(108)
(109)
(110)
(111) 7
(112) =
(113)
(114)
(115) ==
(116) 7
(117)
(118)
(119)
(120) == 7= CD2
(121) 7 7
(122)
(123)
(124) 7 7
(125) C ; 7 . 77 7
(126)
(127)
(128)
(129) = 7
(130) 7 =
(131)
(132)
(133)
(134) 7
(135) 0C ; = 77
(136) 7
(137)
(138)
(139) *
(140)
(141)
(142)
(143) + =
(144)
(145) ^
(146)
(147) ;
(148)
(149) =
(150) C ;7 7 7 ===
(151) =
(152)
(153) 77 ' C ; ;
(154)
(155)
(156)
(157)
(158)
(159)
(160) =7
(161)
(162)
(163) C 8 ;
(164) = =
(165)
(166) 7
(167)
(168) 77 7
(169)
(170)
(171) = 7 2=
(172) C X ;
(173)
(174) =
(175)
(176)
(177) 7
(178) . ! C 9 ==
(179) ;
(180)
(181)
(182)
(183) 72=
(184)
(185)
(186)
(187)
(188)
(189) 7
(190)
(191)
(192) 77
(193)
(194)
(195)
(196)
(197) 7 77 7
(198) = 7 =7
(199) 7 7
(200)
(201)
(202) 7
(203)
(204) 7
(205) 7
(206) 3 &C 6 /;
(207) =
(208)
(209)
(210)
(211) 7 =
(212) 7 =7
(213)
(214)
(215)
(216)
(217) = 7 = 7
(218) = 7 .
(219) C 7
(220)
(221) .
(222)
(223) 7
(224)
(225) 7 77
(226) 7 C 9
(227) ^
(228) 4 ;
(229) 2=77 7
(230)
(231) =
(232)
(233)
(234) = 7
(235) =
(236)
(237) ^
(238) . *Corr. Author’s Address: Düzce University, Cumayeri Vocational School of Higher Education, 81700, Cumayeri, Düzce, Turkey, turgaykivak@duzce.edu.tr. 165.
(239) Strojniški vestnik - Journal of Mechanical Engineering 58(2012)3, 165-174. 7
(240) = C ;
(241) ;
(242) =7 ==
(243)
(244) 72=
(245) CY
(246) X
(247) = . ==
(248) ;
(249) Z
(250)
(251)
(252) = 7
(253)
(254)
(255)
(256) =
(257)
(258) C
(259)
(260)
(261) 7
(262) =7 1 C ; 7 7
(263) =
(264) 77
(265) 7 C
(266) 2=
(267) 7
(268)
(269) =
(270)
(271)
(272) 7
(273) 77
(274)
(275)
(276) 0C ; O ' =7 =
(277)
(278) .
(279) 7 7 7
(280)
(281)
(282) 7 =
(283)
(284) C; == ;
(285)
(286) 7
(287)
(288) C; 2=
(289) 7
(290)
(291)
(292)
(293) 7
(294) 7 77
(295) 7
(296) 7 =
(297) =
(298) 7 C I C =7 7 ;
(299)
(300) ==
(301)
(302) =
(303)
(304) ^7
(305)
(306) 6Z67
(307)
(308) =
(309) C ;
(310)
(311) 7
(312) =
(313)
(314) ^
(315)
(316)
(317) = 77 C Z C 3!
(318)
(319) ^ ;
(320)
(321)
(322) =
(323)
(324) = 7 7
(325)
(326) 7 !&!
(327) ;
(328) Z
(329) C;
(330) =
(331)
(332) 7 = 7 =
(333)
(334) ^ 7
(335)
(336) 7 C < C 3 = ;
(337)
(338) =
(339)
(340) ^
(341) 7
(342) = 77 7
(343)
(344)
(345)
(346)
(347)
(348) = C;
(349)
(350) 7 ;
(351) == = =
(352)
(353) ^
(354)
(355) C ; #
(356) 7
(357)
(358)
(359)
(360) 77 7
(361) 77 ==
(362) 8&4 O
(363)
(364)
(365) = 7
(366)
(367) =
(368)
(369)
(370) =
(371) ;
(372)
(373)
(374) =
(375)
(376)
(377)
(378)
(379) 7 &
(380) C 1 EXPERIMENTAL METHODS.
(381)
(382)
(383) 77 7 7 7 =
(384) C ;
(385) = 7 *Ra+ *Re+
(386)
(387)
(388)
(389)
(390) C ; 7 7
(391) C ; =
(392)
(393)
(394)
(395)
(396)
(397) 7 2=
(398)
(399) C ;
(400)
(401) =7
(402) Q 786'4! 2 6Z6
(403)
(404)
(405) ==
(406) 2
(407) =
(408) = 7 C!!! = 0C4
(409) C ; =7
(410) 77
(411) =* 3 /
(412) + 7 *!C!'. !C +
(413) = = &C Table 1. Chemical composition of AISI 316 austenitic stainless steel C 0.05. Si. Mn. P. S. Cr. 0.380 0.971 0.039 0.006 16.58. Ni 9.94. Mo. Cu. 2.156 0.321. Y
(414)
(415)
(416) = 7
(417) &! 7
(418)
(419)
(420) 7
(421)
(422) 77 C ; 7 7
(423)
(424) 8
(425) 7 Q &! = 7 *Ra+ C 7
(426)
(427)
(428)
(429)
(430)
(431) DY8 = 2C ; =7
(432) 8
(433) 6X; 64//
(434)
(435)
(436)
(437)
(438) *688+
(439) C8
(440)
(441) !=
(442)
(443)
(444)
(445) =7C 1.2 Cryogenic Treatment 7 8&4O
(446)
(447) *
(448) +
(449)
(450) 7
(451)
(452) 77 7 =
(453) 7 C 6
(454) =
(455)
(456) ==
(457) 7 8&4 O
(458)
(459)
(460) 2=
(461)
(462)
(463) ; 3 &=
(464) C Table 2. Chemical composition of M35 drills. 1.1 Drilling Experiments = &
(465)
(466)
(467) =
(468)
(469) C ;
(470)
(471) 7 =
(472) !!Á 0!Á 4 C 6
(473) =
(474)
(475) 7 &
(476)
(477)
(478) ; C 9
(479)
(480)
(481) C97
(482)
(483) 2=
(484) 166. C 0.9. Cr 4.2. Co 4.8. Mo 5.0. W 6.5. V 2.0. ;
(485) 7 8&4 O
(486) =7
(487) = 7= »6
(488) 7 C4 »6
(489)
(490)
(491)
(492) .
(493) .
(494) Strojniški vestnik - Journal of Mechanical Engineering 58(2012)3, 165-174. = 7 3/
(495)
(496) = =
(497) 7 C4»6
(498)
(499) C Table 3. Properties of M35 drills Tool material Tool reference Coating Diameter Point angle Helix angle. M35 DIN 1897 Uncoated 6 mm 118° 35°. 2 EVALUATIONS OF EXPERIMENTAL RESULTS Y
(500)
(501)
(502) =
(503) =
(504)
(505)
(506)
(507) 2 = 7
(508) 7
(509)
(510)
(511) .
(512) 7 33C
(513)
(514)
(515)
(516) =
(517)
(518)
(519)
(520)
(521) 3&C;
(522) 77
(523)
(524) *7 +
(525)
(526)
(527) =
(528) 7 C
(529)
(530)
(531)
(532) 7 =
(533)
(534)
(535) 77 C
(536)
(537)
(538)
(539) 7
(540)
(541) =
(542) 7 7
(543) C 7
(544)
(545)
(546)
(547) = 3/ 34C ;
(548) 2=
(549)
(550)
(551) = *9?D+ 7
(552)
(553) =
(554)
(555) ^ =
(556)
(557)
(558)
(559) = 3C 9?D
(560)
(561)
(562) 7
(563)
(564) 7 7 C 9?D
(565) . 7
(566) 7
(567) 7 =
(568)
(569)
(570) C
(571)
(572)
(573)
(574)
(575)
(576) = 7
(577)
(578) =
(579)
(580) = 30C
(581)
(582)
(583)
(584)
(585)
(586) =
(587) 9?D.
(588) = C
(589)
(590)
(591)
(592)
(593) 7
(594)
(595)
(596) 7
(597)
(598)
(599) 7 3'C 3 TAGUCHI EXPERIMENTAL DESIGN APPROACH ; ;
(600) =
(601) ;
(602)
(603)
(604)
(605)
(606) = =
(607) C
(608)
(609)
(610) =
(611)
(612)
(613) =
(614) = 3 &!C
(615) ;
(616)
(617)
(618) =
(619)
(620)
(621) 7
(622) 7 2=
(623) C ;. ;
(624)
(625) 2=
(626)
(627)
(628) 7
(629)
(630)
(631) 7
(632)
(633)
(634) & &3C ; ;
(635)
(636)
(637) 7
(638) =% Â
(639) 7 Â
(640)
(641) 7 ===
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(643) 7
(644) 2 2=
(645) Â ^
(646) =
(647) 7 7 Â =7 7
(648)
(649) 2=
(650)
(651) 7
(652)
(653) Â
(654) =
(655)
(656)
(657) C ; ;
(658) 7
(659)
(660)
(661)
(662)
(663) C " 7
(664)
(665)
(666) *SN+
(667) *?+C
(668) 77
(669)
(670)
(671) *D C * + *&++
(672) SN
(673)
(674) . ÃZ
(675)
(676) Ä Ã"
(677) Ä. Ã
(678) ÄC1 7= =
(679)
(680)
(681)
(682) S/N
(683) C Z
(684)
(685) | ⎛ y η = S / NT = 10 log ⎜ 2 ⎜ sy ⎝. ⎞ ⎟ , ⎟ ⎠. * +.
(686) | ⎛1 n 1 ⎞ η = S / N L = −10 log ⎜ ∑ 2 ⎟ , ⎝ n i =1 y ⎠. *3+.
(687) | ⎛1 n ⎞ η = S / N S = −10 log ⎜ ∑ yi 2 ⎟ , n ⎝ i =1 ⎠. *&+. y
(688) 7 s 2y
(689)
(690) 7y, n
(691) 7
(692) y
(693) 3!C 3.1 Selection of Control Factors and Orthogonal Array
(694)
(695) *6O; _ 6
(696) O ; 6; _ 6
(697) ; +
(698) = *V+ 7 *f+ 7
(699)
(700)
(701) ; /C ;7
(702) =7;
(703)
(704) . ===
(705) C; ===
(706) *"'2&+
(707) &&. Application of Taguchi Method for Surface Roughness and Roundness Error in Drilling of AISI 316 Stainless Steel. 167.
(708) Strojniški vestnik - Journal of Mechanical Engineering 58(2012)3, 165-174. =
(709)
(710)
(711) = ^ 77 7 = C ;
(712)
(713) =
(714)
(715)
(716)
(717) 7
(718)
(719) = 7
(720) ; 4C Table 4. Cutting parameters and their levels Symbol. Levels. Cutting Parameter. A B C. 1 CHT 12 0.08. Cutting Tools (Ct) Cutting Speed (V) [m/min] Feed Rate (f) [mm/rev]. 2 CT 14 0.1. Table 5. Orthogonal array of Taguchi L8(23) Trial no. L8 1. A 1. B 1. C 1. 2 3 4 5 6 7 8. 1 1 1 2 2 2 2. 1 2 2 1 1 2 2. 2 1 2 1 2 1 2. ;
(721) =
(722) 77
(723) 2=
(724) =7
(725)
(726)
(727) 7 2=
(728)
(729) C ;. 7
(730)
(731) 7
(732)
(733)
(734) = 7 7 7 7
(735) C; 7 7 * 7 7 '_ Å0+7"'
(736) = = C; 7
(737) 2=
(738)
(739) 7
(740)
(741) 7 7 C;
(742)
(743) 7
(744)
(745)
(746) 7 7 =
(747)
(748)
(749) *SN+
(750) C 3.2 Analysis of the Signal-to-Noise (S/N) Ratio ; ;
(751) SN
(752)
(753)
(754) 7 2=
(755)
(756) C ;
(757) 7 Ã
(758) Ä *D C *&++ 7
(759) 7 SN
(760)
(761) 7 7
(762)
(763) 7 =
(764) C SN
(765) 7 7
(766) ; C
(767) ;
(768)
(769) =
(770)
(771)
(772)
(773)
(774)
(775) 77 =
(776) 77
(777) C 7
(778) 2=
(779)
(780) 7 7 3C!' Æ SN
(781) 77 _C39C;. Table 6. S/N ratios of experimental results for surface roughness and roundness error Cutting parameter level Trial no.. A Cutting tool B Cutting speed C Feed rate (Ct) (V) (f) 1 CHT 12 0.08 2 CHT 12 0.1 3 CHT 14 0.08 4 CHT 14 0.1 5 CT 12 0.08 6 CT 12 0.1 7 CT 14 0.08 8 CT 14 0.1 TRa (Surface roughness total mean value)= 2.08 μm TRa–S/N (Surface roughness S/N ratio total mean value)= _6.29 dB TRe (Roundness error total mean value)= 6.36 μm TRe-S/N (Roundness error S/N ratio total mean value)= _16.03. Measured surface roughness. S/N (?i i. Measured roundness error. S/N (?i i. Ra [μm]. [dB]. Re [μm]. [dB]. 2.35 2.47 1.9 1.95 2.1 2.22 1.82 1.81. -7.42 -7.85 -5.57 -5.80 -6.44 -6.92 -5.20 -5.15. 6.3 7.5 6.1 6.4 6.1 7.1 5.4 6. -15.99 -17.50 -15.71 -16.12 -15.71 -17.03 -14.65 -15.56. Table 7. Mean S/N ratios [dB] of control factors Control Factors A B C. 168. Surface Roughness (Ra) Level 1 -6.66 -7.16 -6.16. Level 2 -5.93 -5.43 -6.43. Roundness Error (Re) Max_Min 0.73 1.73 0.27
(782) . Level 1 -16.33 -16.55 -15.51. Level 2 -15.74 -15.51 -16.55. Max_Min 0.59 1.04 1.04.
(783) Strojniški vestnik - Journal of Mechanical Engineering 58(2012)3, 165-174. Fig. 1. Effects of control factors on surface roughness and roundness error; A: Cutting tool, B: Cutting speed [m/min], C: Feed rate [mm/rev], TRa-S/N: Surface roughness S/N ratio total mean value line, TRe-S/N : Roundness error S/N ratio total mean value line. 7 SN
(784) 7 C&Æ. C!&9=
(785) C8 SN
(786) 7 7
(787)
(788) =
(789) 77 7 =
(790) ; 0C ; 77 7 7 7
(791)
(792)
(793) ^
(794) SN
(795) C ; 77 7
(796)
(797) 7 2=
(798)
(799) SN
(800) C;=
(801) 7 . 7 7 2=
(802)
(803) C
(804)
(805)
(806) 7 =
(807)
(808)
(809) =
(810) C ;=
(811)
(812)
(813)
(814) 77 7 7
(815) 7
(816)
(817) C ; 7 7
(818) 77 =
(819) ; 0 SN =
(820) 7 7
(821) *1
(822) C +C Y
(823)
(824)
(825) 7 7 SN
(826) 7 7
(827) 1
(828) C C
(829) Ã
(830) Ä 7 7 7
(831)
(832)
(833)
(834) =
(835)
(836)
(837) 7
(838)
(839) = 7 C ;7 =
(840)
(841)
(842) 77
(843) A2B2C1*A2ÅCT, B2Å /
(844) C1Å!C!'+ A2B2C1*A2ÅCT, B2Å /
(845) C1 Å!C!'+=
(846) C; =
(847) ==7
(848)
(849)
(850)
(851) =
(852)
(853)
(854) *'73&Å'+C. 3.3 ANOVA and the Equations of Surface Roughness and Roundness Error
(855) Z ^77 7
(856)
(857) = 7 7 C
(858)
(859)
(860) =
(861)
(862)
(863)
(864) 7 7
(865)
(866)
(867) C Z
(868)
(869)
(870) 7
(871)
(872)
(873)
(874)
(875)
(876)
(877) 7 7 C
(878) =
(879)
(880)
(881) 7 7 =
(882) 77
(883)
(884)
(885) C ; =7 2=
(886) = 7
(887) 7 4ÀC Z
(888) 2=
(889) 77 Z
(890)
(891) ; '. =
(892) C;
(893)
(894) 7
(895) 7 7
(896) Z
(897)
(898) =
(899) F 7 7 F!C!4 7 C 7 7 C *7 + 7 7 7 ; 'C ; *e+
(900) *et+
(901)
(902)
(903)
(904) =
(905) C ; 7
(906)
(907) ÃÈÄC
(908) =
(909) 7 B *
(910) =+
(911). 77 *0'C À+ 7 C;
(912) 7 7 7 A *
(913) +
(914)
(915) 7 &C4/ÀC 6
(916)
(917) *'C3À+ 7
(918)
(919) C; 7
(920)
(921) ÃÈÄ
(922)
(923) 7 Z =7 7 SN
(924)
(925) ; C
(926)
(927) 7
(928) . Application of Taguchi Method for Surface Roughness and Roundness Error in Drilling of AISI 316 Stainless Steel. 169.
(929) Strojniški vestnik - Journal of Mechanical Engineering 58(2012)3, 165-174. =
(930)
(931) 7 B 7 # 7 *'!C!'À+C ;
(932) 7
(933) 7 7
(934)
(935) 7 &C40&ÀC;
(936)
(937) *C&/ À+
(938)
(939) SN
(940)
(941)
(942) C Z. 72=
(943)
(944) SN
(945) 77 = C 7
(946) 7 A *
(947) + 7 7; 'C 7 7 B C
(948)
(949) 7
(950) 77 *&4C&43À+
(951)
(952) 7
(953) =
(954) C 6
(955) *= + 3C3ÀC 7 SN
(956) 7
(957) ; 7 B
(958)
(959) 7
(960) 77 *&4C/'À+C 1 C
(961) = 77 *&4C3&4À+ 7 . BC 6
(962)
(963) 3C30ÀC Z. 72=
(964)
(965) S/N
(966) 7 = C 8
(967) =
(968)
(969) =
(970) =
(971)
(972)
(973) 7 7 C ;
(974) 7 7 7
(975)
(976)
(977) C; =
(978)
(979)
(980) 7 7 *Ra1+ *Re1+
(981)
(982) D C*/+. *4+=
(983) C Ra1Å/C0&_!C 'CtÉ!C3!04VÉ&C4f. */+. Re1Å'C44_/34CtÉ!C&'04VÉ&'C04f. *4+. R2* 77
(984)
(985) 7
(986)
(987) + 7 7 !C& !C!=
(988) C . Table 8. Results of ANOVA for surface roughness and roundness error Variance Source Surface roughness (Ra) A B C Error (e) Pooled Error (et) Total Roundness error (Re) A B C Error (e) Pooled Error (et) Total. Sum of squares (SS). Degree of freedom (DF). Mean square (MS). F ratio. Contribution [%]. 0.064 0.344 0.01* 0.016* (0.026) 0.434. 1 1 1 4 (5) 7. 0.064 0.344 (0.005) -. 16.51 87.76 -. 13.594 78.11 8.296 100. 0.361* 1.201 1.201 0.275* (0.636) 3.038. 1 1 1 4 (5) 7. 1.201 1.201 (0.127) -. 17.47 17.47 -. 35.352 35.352 29.296 100. Sum of squares (SS). Degree of freedom (DF). Mean square (MS). F ratio. Contribution [%]. 1.069 5.979 0.149* 0.185* (0.334) 7.382. 1 1 1 4 (5) 7. 1.069 5.979 (0.067). 23.14 129.42 -. 13.573 80.086 6.341 100. 0.705* 2.183 2.169 0.446* (1.151) 5.503. 1 1 1 4 (5) 7. 2.183 2.169 (0.23) -. 19.56 19.44 -. 35.489 35.235 29.276 100. Table 9. Results of ANOVA for S/N ratio Variance Source Surface roughness (Ra) A B C Error (e) Pooled error (et) Total Roundness error (Re) A B C Error (e) Pooled error (et) Total. 170.
(989) .
(990) Strojniški vestnik - Journal of Mechanical Engineering 58(2012)3, 165-174. =
(991)
(992)
(993)
(994)
(995) 7 .
(996)
(997)
(998) 77 *Ra2+ *Re2+
(999) D C *+ *0+ =
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