Optimization of Milling Parameters to Control Chatter Reduction
RAMAVARAPU RAMA LAKSHMI
, N Chaitanya
milling, vibration, surface roughness, chatter
The application of micro-milling slotting on Ti6Al4V is crucial in developing microchannels for biomedical implants, lab-on-a-chip systems, and microscale components in aerospace and electronics manufacturing. This research focuses on the optimization of milling parameters for Ti6Al4V through a Genetic Algorithm (GA) to improve surface roughness and evaluate tool dynamics. The experiments involved end milling on Ti6Al4V plates using varying parameters: feed rates of 0.2, 0.4, 0.6 mm/rev/flute, a constant depth of cut at 0.1 mm, and spindle speeds of 2000, 4000, and 6000 rpm on a 3-axis CNC milling machine. Vibration analysis was conducted using a triaxial accelerometer combined with FFT analysis, and further modal analysis was carried out using an impact hammer and a Laser Doppler Vibrometer. Results indicated that surface roughness exceeded acceptable levels at feed rates over 0.4 mm/flute, particularly at the lower spindle speed of 2000 rpm, where surface roughness reached 3.8 µm. This increase in roughness correlated with significant tool wear and instances of tool breakage. The genetic algorithm was utilized to refine the milling parameters, effectively minimizing chatter. The optimized parameters suggested by the GA achieved a predicted surface roughness of 0.64 µm, which was experimentally verified as 0.62 µm. This study underscores the significant effects of feed rate and spindle speed on tool wear, surface integrity, and overall stability of the milling process.
"Optimization of Milling Parameters to Control Chatter Reduction", IJSDR - International Journal of Scientific Development and Research (www.IJSDR.org), ISSN:2455-2631, Vol.9, Issue 11, page no.403 - 412, November-2024, Available :https://ijsdr.org/papers/IJSDR2411052.pdf
Volume 9
Issue 11,
November-2024
Pages : 403 - 412
Paper Reg. ID: IJSDR_212735
Published Paper Id: IJSDR2411052
Downloads: 000346998
Research Area: Engineering
Country: akp, andharapradesh, India
ISSN: 2455-2631 | IMPACT FACTOR: 9.15 Calculated By Google Scholar | ESTD YEAR: 2016
An International Scholarly Open Access Journal, Peer-Reviewed, Refereed Journal Impact Factor 9.15 Calculate by Google Scholar and Semantic Scholar | AI-Powered Research Tool, Multidisciplinary, Monthly, Multilanguage Journal Indexing in All Major Database & Metadata, Citation Generator
Publisher: IJSDR(IJ Publication) Janvi Wave
