RSM: A Key to Optimize Machining: Multi-Response Optimization of CNC Turning with Al-7020 Alloy

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Parametric optimization, especially in machining of non-ferrous alloys seems to be quite rare and needs an immediate attention because of its associated downstream financial and non-financial losses. This book tries to fill the gap and presents an optimization problem of commonly used Al-7020 Alloy. Principles of Response Surface Methodology (RSM) have been implemented through Minitab software to bring necessary multi-response optimization, while turning on a CNC turner. The present study focuses on to enhance Material Removal Rate (MRR) while simultaneously reducing the Surface Roughness (Ra), during turning of Al-alloy. Such opposite natured response optimization is much difficult to achieve, particularly when uncoated carbide tip has been used as a cutting tool. Intensive literature survey helps to pin point parameters like; Cutting Speed, Feed Rate and Depth of Cut as a most critical to machining parameters, as far as effective and efficient optimization of selected responses are concerned. All these control-parameters are directly or inversely related to each other. If the depth of cut is increased MRR increases at the same time we get poor surface finish. Increase in the cutting speed has positive impact on both material removal rate and surface finish. Shortlisted parameters are conflicting, so we have to optimize these for further enhancement of the overall turning performance. At last, the optimized results are verified by using ANOVA as a statistical tool. This book provides quite rare Case-study of multi-response optimization (while non-ferrous CNC turning) to practioners, machinists and SME owners appropriately.

Dr. BIKRAM JIT SINGH is working as a Professor in Mechanical Engineering Department of Maharishi Markandeshwar University, Sadopur, Ambala (Haryana). He is PhD. from National Institute of Technology, Kurukshetra on Six Sigma and has done Masters of Engineering with distinction in Industrial Engineering from Thapar University, Patiala. He has a three year Professional Experience as a Manager in Light Alloy Foundry at FEDRAL MOGUL, INDIA (A US based Multi-National at Bahadurgarh, India.). He was undergone on the job training on SAP (PP-Module), QS-9000, ISO-TS 16949, SQC Tools and TPM for 2 years. He had worked as Lecturer in Mechanical Engineering Department for Two Years at RIMT-Institute of Engineering & Technology, Mandi Gobindgarh, India. He was also posted as HOD-Mechanical at BBSBPC, Fatehgarh Sahib, India for One Year. He has around 15 International Journal publications along with paper presented in number of International and National Conferences. He is a main and corresponding Author and can be contacted at [email protected]. Dr. DINESH KHANDUJA is a regular Professor from last 15 years at National Institute of Technology, Kurukshetra, India. Earlier he was posted as Assistant Professor in Regional Engineering College Kurukshetra. His fields of specializations are Industrial Engineering, Production Engineering and TQM. He had participated in more than 25 International and National Conferences and publishes around 38 Papers in various International and National Journals. He had also guided number of Master¿s and Doctorate students in the field of Six Sigma, Productivity Management, Waste Management and Entrepreneurship. He is also working as Head of Entrepreneurial Cell at NIT Kurukshetra India. He can be contacted at [email protected].