Date of Publication :8th August 2017

Abstract: This study aims to develop a mathematical model for analyzing the surface roughness and delamination factor and to infer the influence of the individual input machining parameters (cutting speed, depth of cut and feed rate) on the responses in milling of Sheet Metal Composite (SMC) with solid carbide end mill cutter coated with PCD using Taguchi methodology. In Taguchi methodology, three factors and two responses were employed to carry out the experimental investigation. Multiple Regression Analysis from “Minitab” software was used for regression and graphical analysis of the data were collected. The optimum values of the selected variables were obtained by solving the regression equation. Analysis of variance (ANOVA) was applied to check the validity of the model and for finding the significant parameters. It is seen that Feed rate is the most influencing factor in affecting the surface roughness and delamination. In SMC composite as the speed and feed increases the surface roughness value decreases. Moderate feed and speed gives ideal finish. But the parameter depth of cut shows a wavy nature. Only for a very high depth, the roughness increases. The optimized values of the machining parameters were used to calculate the surface roughness and delamination factor of the machined surfaces, with the chosen range resulting with 93 per cent.

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