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Development Of Predictive Model For Surface Roughness In End Milling Of Al-Sicp Metal Matrix Composites Using Fuzzy Logic

Authors: M. Chandrasekaran; D. Devarasiddappa;

Development Of Predictive Model For Surface Roughness In End Milling Of Al-Sicp Metal Matrix Composites Using Fuzzy Logic

Abstract

{"references": ["U. Zuperl, F. Cus, M. Milfelner, \"Fuzzy control strategy for an adaptive\nforce control in end-milling\", Journal of Materials Processing\nTechnology Vol. 164, 2005, pp. 1472-1478.", "J. T Lin, D Bhattacharyya, V Kecman, \"Multiple regression and neural\nnetworks analyses in composites machining\", Composites Science and\nTechnology, Vol. 63, 2003, pp. 539-548", "D. R Cramer and D. F. Taggart, \"Design and manufacture of an\naffordable advanced composite automotive body structure\", Proc. 19th\nInternational Battery, Hybrid and Fuel Cell Electric Vehicle Symposium\nand Exhibition, October 19-23, 2002, pp. 1-12.", "M. Chandrasekaran, M. Muralidhar, C. M. Krishna and U.S. Dixit,\n\"Application of soft computing techniques in machining performance\nprediction and optimization: a literature review\", Int J Adv Manuf\nTechnol, Vol. 46, 2010, pp. 445-464", "L. A. Zadeh., \"Fuzzy sets\", Information and Control, Vol. 8, 1965, pp.\n338-353", "N. R. Abburi and U. S. Dixit, \"A knowledge based system for the\nprediction of surface roughness in turning process\", Robotics and\nComputer Integrated Manufacturing, Vol. 22, 2006, pp. 363-372", "T. Rajasekaran, K. Palanikumar and B.K Vinayagam, \"Application of\nfuzzy logic for modeling surface roughness in turning CFRP composites\nusing CBN tool\", Prod. Eng. Res. Devel, Vol. 5, 2011, pp. 191-199", "Harun Akkus and Ilhan Asilturk, \"Predicting surface roughness of AISI\n4140 steel in hard turning process through artificial neural network,\nfuzzy logic and regression models\", Scientific Research and Essays,\nVol. 6 (13), 2011, pp. 2729-2736", "M. K. Pradhan and C. K. Biswas, \"Nero -fuzzy and neural network-\nbased prediction of various responses in electrical discharge machining\nof AISI D2 steel\", Int J Adv Manuf Technol, Vol. 50, 2010, pp. 591-\n610.doi: 10.1007/s00170-010-2531-8]\n[10] J. P. Davim and C. A. Conceicao Antonio, \"Optimal drilling of\nparticulate metal matrix composites based on experimental and\nnumerical procedures\", International Journal of Machine Tools and\nManufacture, Vol. 41, 2001, pp. 21-31.\n[11] S. Basavarajappa, G. Chandramohan, M. Prabhu, K. Mukund and M.\nAshwin, \"Drilling of hydrid metal matrix composites - workpiece\nsurface integrity\", International Journal of Machine tools and\nManufacture, Vol. 47, 2007, pp. 92-96\n[12] R. Arokiadass, K. Palanirajda and N. Alagumoorthi, \"Predictive\nmodeling of surface roughness in end milling of Al/SiCp metal matrix\ncomposite\", Archives of Applied Science Research, Vol. 3(2), 2011, pp.\n228-236.\n[13] C. C. Tsao and H. Hocheng, \"Evaluation of thrust force and surface\nroughness in drilling composite material using Taguchi analysis and\nneural network\", Journal of material processing technology, Vol. 203,\n2008, pp. 342-348\n[14] N. Muthukrishan and P.J Davim, \"Optimization of machining\nparameters of Al/SiC -MMC with ANOVA and ANN analysis\", Journal\nof Materials Processing Technology, Vol. 209, 2009 pp. 225-232\n[15] P. J. Davim, \"Design of optimization of cutting parameters for turning of\nmetal matrix composites based on the orthogonal arrays\", Journal of\nMaterials Processing Technology, Vol. 132, 2003 pp. 340-344\n[16] K. A. Risbood, U. S. Dixit and A. D. Sahasrabudhe, \"Prediction of\nsurface roughness and dimensional deviation by measuring cutting\nforces and vibrations in turning process\", J Matter Process Technol, Vol.\n132, 2003 pp. 203-214. doi: 10.1016/s0924-0136(02)00920-2\n[17] D. K. Sonar, U. S. Dixit and D. K. Ojha, \"The application of radial basis\nfunction for predicting the surface roughness in a turning process\", Int J\nAdv Manuf Technol, Vol. 27, 2006, pp. 661-666. doi: 10.1007/s00170-\n004-2258-5\n[18] Y. M. Ali and L. C. Zhang, \"Surface roughness prediction of ground\ncomponents using a fuzzy logic approach\", Journal of Materials\nProcessing Technology, Vol. 89(90), 1999 pp. 561-568.\n[19] D. Devarasiddappa, M. Chandrasekaran and A. Mandal, \"Artificial\nneural network modeling for predicting surface roughness in end milling\nof Al-SiCp metal matrix composite and its evaluation\", Proc\n.International Conference on Intelligent Manufacturing Systems (ICIMS\n2012) SASTRA University, Thanjavur, Taminnadu (India), pp 119-125\n[20] J. C. Chen, J. T. Black, \"A fuzzy-nets in-process (FNIP) systems for too\nl breakage monitoring in end-milling operations\", Int J Mach Tools\nManuf, Vol. 37(6), 1997, pp.783-800."]}

Metal matrix composites have been increasingly used as materials for components in automotive and aerospace industries because of their improved properties compared with non-reinforced alloys. During machining the selection of appropriate machining parameters to produce job for desired surface roughness is of great concern considering the economy of manufacturing process. In this study, a surface roughness prediction model using fuzzy logic is developed for end milling of Al-SiCp metal matrix composite component using carbide end mill cutter. The surface roughness is modeled as a function of spindle speed (N), feed rate (f), depth of cut (d) and the SiCp percentage (S). The predicted values surface roughness is compared with experimental result. The model predicts average percentage error as 4.56% and mean square error as 0.0729. It is observed that surface roughness is most influenced by feed rate, spindle speed and SiC percentage. Depth of cut has least influence.

Keywords

surface roughness, End milling, fuzzy logic, metal matrix composites

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