A Study On The Effect Of Machining Parameters On The Surface Roughness Of Aluminum Alloy Castings Obtained By Evaporative Pattern Casting (Epc) Process
Keywords:
Machining, parameters, aluminum, casting, mouldingAbstract
In this study, the effect of machining parameters on the integrity of aluminum alloy obtained by evaporative casting pattern (EPC) process was considered. The pattern, gating system and mould were designed for the casting process. Three process parameters used in generating the Taguchi’s code for the analysis of the surface roughness are the pouring temperature, grain finest number of the moulding material and the gating ratio. The analysis revealed that the best surface finish of aluminium alloy was obtained at 650°C. At temperature higher than this, casting obtained have very rough surfaces with more defects. The Taguchi codes generated lead to nine numbers of runs, and the results of surface roughness gotten under the examination of computer numeric control (CNC) machine were analysed by statistical analysis software (Minitab). The effect of speed decreases with the increase in speed, the effect of feed rate gives a better finish at 90mm/min while the parameter depth of cut gives a reasonable result between 0.5 to 1.0 mm. In the analysis, it was discovered that machining parameters also have significant effect on the surface roughness of cast aluminium alloy.
References
ASME. Pouring temperature ranges for metal and alloys. Chicago USA: American society of mechanical engineering. 1996.
Astakhov, V. P. Metal Cutting Mechanics. Boca Raton: CRC. 1999
Behm, S.U., Gunter, K.L., & Sutherland, J.W. (2003). An Investigation into the Effect of Process Parameter Settings on Air Characteristics in the Lost Foam Casting Process: Michigan Technological University, Houghton, Michigan. Unpublished
Black, J. T. Flow stress model in metal cutting. Journal of engineering for industry, 403-419. 1979.
Cai, M., Siak, J., Powell, B.R., Nouaime, G. & Swarin, S.J. (2002). Physical and Chemical Analysis of the Degradation Products of Expanded Polystyrene Patters with Short Thermal Exposure. Transactions of the American Foundrymen’s Society, 110(2), 1463-1481
Clegg, A.J. (1991). Precision Casting Processes: England: Pergamon Press Plc
Clegg, A.J. (2000). A review of recent developments and progress. 10-15. Retrieved on August 10, 2010 from http://www.allbusiness.com/primarymetal
Konig, W. A. ‘Machining and machinability of aluminum cast alloy’. Annals of the CIRP, 32, 2. 1983.
Maltais, A. D. Improvement in the metallography of as-cast AZ91 alloy. Material characterization, 52, 103-119. 2004
Omidiji, B. V. Application of Taguchi's approach in the optimization of evaporative pattern casting (EPC) process parameters. AU Journal of Technology, 17, 47-54. 2015.
Omidiji, B.V., Owolabi, H.A. and Khan, R.H. ‘Application of Taguchi’s approach for obtaining mechanical properties and microstructures of evaporative pattern castings’. The International Journal of Advanced Manufacturing Technology.79: 461-468, 2015
Omidiji, B.V.,R.H. Khan and M.S. Abolariin (2015): Silica –Kaolin Mix Effect on Evaporative Pattern Castings Surface Roughness. Archives of Foundry Engineering. 16 (3), 83-88, 2016.
Raji, A. A. ‘Effects of pouring temperature and squeeze pressure on Al and sSi alloy squeeze cast parts’. AU Journal of Technology, 9, 229-237. 2006.
Rao, P.N. (2001). Manufacturing Technology: Foundry, Forming and Welding: New Delhi: Tata McGraw-Hill Publishing Company Limited.
