Abstract
Burr formation and surface roughness are crucial surface quality attributes that vary widely according to machining conditions used. Inappropriate selection of cutting parameters may lead to tremendous non-desirable expenses and poor product quality. This becomes more apparent in slot milling operation that has a complex burr formation mechanism, and it is associated with multiple burrs with non-uniform dimensions appearing in the machined part edges. Therefore, as the first objective of this study, experimental characterization of governing cutting parameters on surface quality attributes, including exit burr size as well average surface roughness (R a ), is presented. Based on experimental observations, each aforementioned surface quality attribute is affected by different cutting parameters, and in fact, no systematic relationship can be formulated between them and the cutting parameters used. Therefore, advanced strategies are demanded for adequate selection of cutting parameters and reduction in the needs of deburring and surface treatment operations. Except the works reported by the authors, very limited studies are available on advanced optimization approaches for simultaneous minimization of surface quality attributes in slot milling operations. This can be considered as the second objective of this work. To that end, desirability function, D i (x), was used as the proposed approach to evaluate the possibility of simultaneous minimization of aforementioned surface quality attributes, despite the low control ability of each response. Using this approach, the optimum and near to optimum setting levels of cutting parameters were defined by means of surface quality improvement and the adequacy of the proposed optimum cutting conditions was reconfirmed through verification tests. The presented results in principle can be very useful in practice by local and international automotive industries dealing with similar family of materials.
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Niknam, S.A., Balazinski, M. & Songmene, V. To characterize and optimize the surface quality attributes in slot milling operation. Int J Adv Manuf Technol 93, 727–746 (2017). https://doi.org/10.1007/s00170-017-0460-5
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DOI: https://doi.org/10.1007/s00170-017-0460-5