Skip to main content
Log in

Investigation on surface finish and metallic particle emission during machining of aluminum alloys using response surface methodology and desirability functions

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The surface finish of a mechanical part plays an important role as it determines the part’s field performance. The machining parameters and conditions governing the part surface finish also impact on the other machining process performance indicators such as tool wear, tool life, cycle time, machining cost, and undesirable emissions of aerosols and metallic particles. In today’s metal cutting industry, a major concern is the occupational safety and health hazard associated with cutting fluids usage and metallic particle emission. It is therefore necessary to determine machining conditions that could improve the part surface finish while maintaining low the aerosol emission. In this research study, statistical methods are used to study the surface finish parameters and the metallic particle emissions during milling of aluminum alloys (6061-T6, 7075-T6, and 2024-T351) with two coated carbide tools (TiCN and a multilayer TiCN + Al2O3 + TiN). Following an implementation of multilevel design of experiment, machining trials and determination of mains most influential factors, surface responses and desirability functions are used to determine the best process operational conditions and windows. The results of this research demonstrate that TiCN-coated tool generates fewer respirable airborne particles during machining than multilayers TiCN + Al2O3 + TiN-coated tool. Overall, it is shown that the use of TiCN coating tool provides a better opportunity for an environmentally benign dry machining along with improvement on surface quality.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Djebara A, Songmene V, Khettabi R, Kouam J (2012) An experimental investigation on ultrafine particles emission during milling process using statistical analysis. Int J Adv Mach Form Oper 4(1):15–37

    Google Scholar 

  2. Sutherland JW, Kulur VN, King NC (2000) An experimental investigation of air quality in wet and dry turning. CIRP Ann Manufactur Technol 49(1):61–64

    Article  Google Scholar 

  3. Khettabi R, Songmene V, Zaghbani I, Masounave J (2010) Modeling of particle emission during dry orthogonal cutting. J Mater Eng Perform 19(6):776–789

    Article  Google Scholar 

  4. Jawahir IS, Wanigarathne PC, Wang X (2006) Product design and manufacturing processes for sustainability. Mech Eng Handb Manuf Manag 3:414–443

    Google Scholar 

  5. Eckhoff RK (1996) Prevention and mitigation of dust explosions in the process industries: a survey of recent research and development. J Loss Prev Process Ind 9(1):3–20

    Article  MathSciNet  Google Scholar 

  6. Machinability Data Center (1980) Machining data handbook, 3rd edition, volume 2. Metcut Research Associates, Inc., Cincinnati. ISBN 0936974001

    Google Scholar 

  7. Poey J, Philibert C (2000) Toxicite des metaux. Rev Fr Lab 2000(323):35–43, In French

    Google Scholar 

  8. Songmene V, Balout B, Masounave J (2008) Clean machining: experimental investigation on dust formation part 1: influence of machining parameters and chip formation. Int J Env Conscious Des Manuf 14(1):1–16

    Google Scholar 

  9. Malshe AP, Naseem HA, Brown WD (1998) Apparatus for and method of polishing and planarizing polycrystalline diamonds, and polished and planarized polycrystalline diamonds and products made therefrom. Patent, United States (inv.). 5725413.

  10. Dasch J, D’Arcy J, Gundrum A, Sutherland J, Johnson J, Carlson D (2005) Characterization of fine particles from machining in automotive plants. J Occup Environ Hyg 2(12):609–625

    Article  Google Scholar 

  11. Arumugam PU, Malshe AP, Batzer SA (2006) Dry machining of aluminum–silicon alloy using polished CVD diamond-coated cutting tools inserts. Surf Coat Technol 200:3399–3403

    Article  Google Scholar 

  12. Songmene V, Balout B, Masounave J (2008) Clean machining: experimental investigation on dust formation. Part II: influence of machining strategies and drill condition. Int J Environ Conscious Des Manuf 14:17–33

    Google Scholar 

  13. Sutherland J, Kulur VN, King NC, Von Turkovich BF (2000) An experimental investigation of air quality in wet and dry turning. CIRP Ann Manuf Technol 49:61–64

    Article  Google Scholar 

  14. World Health Organisation (WHO) (1999) Hazard prevention and control in the work environment: airborne dust. Occupational and Environmental Health Department of Protection of the Human Environment. WHO, Geneva

    Google Scholar 

  15. Jerôme Garcia et Jacques Colosio (2001) Les indices de la qualité de l’air, élaboration, usages et comparaison internationale. Paris, Les Presses de l’École des Mines, Transvalor Presses des Mines, In Frensh

  16. Sreejith PS, Ngoi BKA (2000) Dry machining: machining of the future. J Mater Process Technol 101:287–291

    Article  Google Scholar 

  17. Kalss W, Reiter A et al (2006) Modern coatings in high performance cutting applications. Int J Refract Metals and Hard Mater 24:399–404

    Article  Google Scholar 

  18. Bagur F (1999) Matériaux pour outils de coupe. Article BM7080. Technique de l’ingénieur 1:1–16

    Google Scholar 

  19. Rech J, Moisan A (2003) Surface integrity in finish hard turning of case-hardened steels. Int J Mach Tool Manuf 43:543–550

    Article  Google Scholar 

  20. Benardos PG, Vosniakos G-C (2003) Predicting surface roughness in machining. Int J Mach Tool Manuf 43:833–844

    Article  Google Scholar 

  21. Rene K, Songmene V, Kenne JP, Tahan A (2011) Surface quality of 7075-T6 aluminum alloy machined using high-speed milling process. Conference of metallurgists. Hilton Bonaventure Hotel, Montréal, Quebec

    Google Scholar 

  22. Choudhury IA, El-Baradie MA (1999) Machinability assessment of inconel 718 by factorial design of experiment coupled with response surface methodology. J Mater Process Technol 116:395–401

    Google Scholar 

  23. Songmene V, Stefan M, Stephenson TF, Warner AEM (1998) Turning and honing of GrA-Ni® MMC cylinder liners: experimental investigation on surface texture. Proceedings of the Canadian Society for Mechanical Engineers, vol 4. Manufacturing, Automation and Robotics, Theory of Machines and Mechanisms, Toronto, pp 186–193

    Google Scholar 

  24. Kamguem R, Songmene V, Kenne JP, Tahan SA (2012) Vision-based surface roughness inspection of machined aluminium parts. Int J Mach Mach Mater 12(3):215–235

    Google Scholar 

  25. Alauddin M, El-Baradie MA (1997) Tool life model for end milling steel (190BHN). J Mater Process Technol 68:50–59

    Article  Google Scholar 

  26. Antonio CA, Davim JP (2005) Optimal machining parameters based on surface roughness experimental data and genetic search. Ind Lubr Tribol 57(6):249–254

    Article  Google Scholar 

  27. Lu ZS, Wang MH (2006) Optimization of cutting conditions in ultra-precision turning based on mixed genetic-simulated annealing algorithm. Key Eng Mater 315–316:617–622

    Article  Google Scholar 

  28. Pendse DM, Joshi SS (2004) Modelling and optimization of machining process in discontinuously reinforced aluminium matrix. Mach Sci Technol 8(1):85–102

    Article  Google Scholar 

  29. Bataineh O, Dalalah D (2010) Strategy for optimising cutting parameters in the dry turning of 6061-T6 aluminium alloy based on design of experiments and the generalised pattern search algorithm. Int J Mach Mach Mater 7:39–57

    Google Scholar 

  30. Djebara, Abdelhakim (2012) Métrologie des particules ultrafines d'usinage: optimisation de la caractérisation et de la mesure. Thèse de doctorat électronique, École de technologie supérieure, Montréal, Canada (http://espace.etsmtl.ca/1014/). In Frensh

  31. Ulutan D, Ozel T (2011) Machining induced surface integrity in titanium and nickel alloys. Int J Mach Tool Manuf 51:250–280

    Article  Google Scholar 

  32. Derringer G, Suich R (1980) Simultaneous optimization of several response variables. J Qual Technol 12(4):214–219

    Google Scholar 

  33. Songmene V, Khettabi R, Kouam J (2012) Dry high speed machining: a cost effective and green process. Int J Manuf Res 7(3):229–256

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to V. Songmene.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Kamguem, R., Djebara, A. & Songmene, V. Investigation on surface finish and metallic particle emission during machining of aluminum alloys using response surface methodology and desirability functions. Int J Adv Manuf Technol 69, 1283–1298 (2013). https://doi.org/10.1007/s00170-013-5105-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-013-5105-8

Keywords

Navigation