FEA Analysis Of The Lathe Machining On Machining Characteristics Towards Aluminium Alloy Using RSM Method

• Main Author: Liew, Yoong Ler
• Format: Thesis
• Language: English; English
• Published: 2020
• Online Access: http://eprints.utem.edu.my/id/eprint/25361/1/FEA%20analysis%20of%20the%20lathe%20machining%20on%20machining%20characteristics%20towards%20aluminium%20alloy%20using%20RSM%20method.pdf; http://eprints.utem.edu.my/id/eprint/25361/2/FEA%20analysis%20of%20the%20lathe%20machining%20on%20machining%20characteristics%20towards%20aluminium%20alloy%20using%20RSM%20method.pdf; http://eprints.utem.edu.my/id/eprint/25361/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=119163

This project focuses on the simulation of the turning process by using the finite element analysis (FEA) machining Deform 3D software based on the Box-Behnken of response surface method (RSM) experimental matrix. Based on the Box-Behnken design matrix, there were 13 simulation runs with one centre point in order to analyze the influence of the cutting parameters on the output responses of the turning process such as cutting temperature, effective stress and material removal rate. The selected cutting parameters in this turning simulation of the aluminium alloy 7075 were cutting speed (200 m/min – 250 m/min), feed rate (0.1 mm/rev – 0.25 mm/rev) and depth of cut (0.5 mm – 0.6 mm). The analysis of variance (ANOVA) was used to determine the most influential cutting parameters on the output responses. The Box-Behnken of response surface method was employed to investigate the interactions between the cutting parameters on the output responses and to optimize the cutting parameters setting of the turning process. From the results, it is found that the depth of cut is the most influential cutting parameter for the cutting temperature. Meanwhile, the feed rate is the most significant cutting parameter for effective stress. For the material removal rate, the most influential cutting parameter is the feed rate. Furthermore, the interaction between cutting speed and depth of cut is the predominant interaction that gives a significant effect on the cutting temperature, which shows that the cutting temperature increases with the increase in depth of cut and decrease in cutting speed. In the meantime, the interaction between cutting speed and feed rate is the major interaction that gives the most influential impact on the effective stress, which shows that the effective stress increases with the increase in both of the cutting speed and feed rate. The most influential interaction that gives a significant effect on the material removal rate is the interaction between feed rate and depth of cut, which shows that the material removal rate increases with the increase in both of the feed rate and depth of cut. Moreover, after the optimization process, the cutting temperature gives the minimum value of 401.89 ℃. Further, the effective stress gives the minimum value of 792.14 MPa. While the material removal rate gives the maximum value of 5126375 mm^3/s. Overall, all the objectives of this project are achieved. Thus, a decrease in both of the cutting temperature and effective stress with the increase of material removal rate, therefore the defect of the wear on the cutting tool can be reduced.