Article: Experimental investigation and multi-response optimisation of end milling in aluminium-5083 alloy using desirability analysis Journal: International Journal of Manufacturing Research (IJMR) 2023 Vol.18 No.3 pp.284 - 310 Abstract: The present study deals with end milling of aluminium alloy (Al 5083-H112) with carbide tools in dry condition. Process parameters, such as cutting speed, feed rate, depth of cut, and tool parameters such as nose shape and number of flutes are varied to investigate their effect on material removal rate (MRR), resultant cutting force (CF) and surface roughness (R<SUB align="right"><SMALL>a</SMALL></SUB>). Analysis of variance is employed to find the significance of the individual process parameters on the responses. The concept of desirability function analysis is employed to optimise the process parameters for machining. The composite desirability value determines the optimum combination of parameters obtained from all the responses' simultaneous optimisation. A confirmation test is conducted based on the optimal parameter setting to exemplify the potency of the approach. The confirmation test results are convincingly close to the predicted ones as the errors are less than 5%, which signifies the robustness of the model. [Submitted 9 August 2021; Accepted 14 December 2021] Inderscience Publishers - linking academia, business and industry through research

Title: Experimental investigation and multi-response optimisation of end milling in aluminium-5083 alloy using desirability analysis

Authors: Abhiman Debnath; Siddhartha Kar; Uttam Kumar Mandal; Vidyut Dey

Addresses: Department of Production Engineering, National Institute of Technology Agartala, Agartala, 799046, Tripura, India ' Department of Industrial Engineering and Management, Ramaiah Institute of Technology, Bangalore, 560054, Karnataka, India ' Department of Production Engineering, National Institute of Technology Agartala, Agartala, 799046, Tripura, India ' Department of Production Engineering, National Institute of Technology Agartala, Agartala, 799046, Tripura, India

Abstract: The present study deals with end milling of aluminium alloy (Al 5083-H112) with carbide tools in dry condition. Process parameters, such as cutting speed, feed rate, depth of cut, and tool parameters such as nose shape and number of flutes are varied to investigate their effect on material removal rate (MRR), resultant cutting force (CF) and surface roughness (R_a). Analysis of variance is employed to find the significance of the individual process parameters on the responses. The concept of desirability function analysis is employed to optimise the process parameters for machining. The composite desirability value determines the optimum combination of parameters obtained from all the responses' simultaneous optimisation. A confirmation test is conducted based on the optimal parameter setting to exemplify the potency of the approach. The confirmation test results are convincingly close to the predicted ones as the errors are less than 5%, which signifies the robustness of the model. [Submitted 9 August 2021; Accepted 14 December 2021]

Keywords: aluminium alloy; end milling; carbide tool; material removal rate; MRR; cutting force; surface roughness; desirability.

DOI: 10.1504/IJMR.2023.132834

International Journal of Manufacturing Research, 2023 Vol.18 No.3, pp.284 - 310

Received: 09 Aug 2021
Accepted: 14 Dec 2021
Published online: 11 Aug 2023 *

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Title: Experimental investigation and multi-response optimisation of end milling in aluminium-5083 alloy using desirability analysis

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