Basha 2

MINI PROJECT WORK
Surface Roughness Optimization Techniques of CNC Milling
Project Guidance under Dr. C LABESH KUMAR sir
Team details:
22955A0302, K.
Anjaneyulu
22955A0314, Shaik Basha
21951A0331, Uday
ABSTRACT
 The main aspect of machining today is producing and achieving a better surface quality quickly and with lower energy
consumption.
 Surface roughness is a common criterion of the quality characteristics for machining processes.
 To increase the consistency of the surface finish, suitable cutting parameters should be implemented.
 This thesis aimed to optimize the surface roughness in 3D cutting using a CNC end milling machine.
 The depth of cut, the cutting speed, and the feed rate are the parameters used in optimizing the surface roughness.
 The best range of the cutting parameters was obtained by using the design of Experiment (DOE) which is the Response Surface
Methodology (RSM) method.
 The RSM method is used because it is one of the most efficient and effective techniques to determine the best combination of
parameters.
 The experiments were run by using the data simulation from Mastercam X7 and all the data commands were used in Nexus
410A-II 3-Axis Computer Numerical Method (CNC) machine with the MAZATROL controller.
 The surface roughness of the workpiece is measured using a surface roughness tester, Mitutoyo SJ-410. The analyzing data are
made by employing RSM and ANOVA using Minitab 19 software.
 The direct effects and interaction effects were graphically plotted which helps to study the significance of these parameters on
surface roughness.
Objectives:
Improved Part Functionality: Ensuring that the surface roughness of machined parts meets the required
specifications is crucial for their intended functionality. Optimization techniques aim to minimize surface
roughness to enhance the performance of components, such as reducing friction or improving sealing
properties.
Enhanced Aesthetics: In applications where appearance matters, such as consumer products or automotive
components, optimizing surface roughness helps achieve a desirable aesthetic finish. This involves
minimizing imperfections on the surface of the part, such as tool marks or irregularities, to enhance visual
appeal.
Dimensional Accuracy: Surface roughness optimization techniques also contribute to maintaining
dimensional accuracy. By minimizing surface irregularities, the dimensions of machined parts can be better
controlled, ensuring they meet design specifications and tolerances.
Reduced Friction and Wear: Smoother surfaces resulting from surface roughness optimization
techniques can reduce friction and wear between moving parts. This is particularly important in
applications such as bearings, gears, and sliding components, where friction and wear can impact
performance and longevity.
Objectives:
Improved Surface Integrity: Optimizing surface roughness can help improve the overall integrity of
machined parts. By reducing surface roughness, the likelihood of defects such as cracks or surface fatigue
is minimized, leading to parts with better mechanical properties and longer service lifeOptimized
Manufacturing Costs: Surface roughness optimization techniques can also contribute to cost savings in
manufacturing. By minimizing the need for post-processing operations such as polishing or grinding,
overall production costs can be reduced. Additionally, improved surface quality may lead to fewer rejected
parts, further reducing manufacturing expenses.
Process Efficiency: Optimizing surface roughness in CNC milling processes can enhance overall process
efficiency. By implementing techniques such as optimal tool selection, cutting parameters, and machining
strategies, manufacturers can achieve smoother surfaces more effectively, reducing cycle times and
improving productivity.
Consistency and Reproducibility: Surface roughness optimization techniques aim to ensure consistency
and reproducibility in the manufacturing process. By controlling variables such as cutting parameters, tool
wear, and machine condition, manufacturers can achieve consistent surface finishes across multiple parts,
maintaining quality standards and meeting customer requirements.
Conclusion
 The effect of cutting speed, depth of cut and feed rate on the surface roughness have been studied
and analysed by using response surface methodology technique. The parameters were measured
using the experimental design. According to the ANOVA analysis, feed rate affects the most on
the surface roughness. Besides, from the 3D graphs that were plotted, the surface roughness
changes drastically with the increasing of feed rate regardless of the change of depth of cut.
 Feed rate, cutting speed and depth of cut are very crucial factors that need to be controlled and
chosen carefully. The optimization plot has been developed by using Response Surface
Methodology, RSM for prediction of surface roughness in milling. Finally, an attempt has been
made to estimate the optimum machining conditions to produce the best possible surface quality
within the experimental constraints
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MINI PROJECT WORK

Surface Roughness Optimization Techniques of CNC Milling

Project Guidance under Dr. C LABESH KUMAR sir

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