Exploration Of Surface Roughness And Profile Error In Single Point Diamond Turning Of Mold Insert Material - Copper Alloy C18000

Abstract

Due to rapid development of science & technology machining of different materials and polymers are need of the day. Surface roughness being major Parameter while machining, we do perform to make use of SPDT (Single point diamond tool) with that of the regular CNC machine tool. There is great requirement of ultra-precision components with micro-structured surfaces in a field of mechanical, medical, optical, biological. Single point diamond turning is certainly superior in machining precision and intricate micro-structured surfaces in nano wavelength. Generally errors in the single point diamond turning causes form error to the machined micro-structured surfaces. This work describes a parametric analysis of nanosurface generation in single point diamond turning (SPDT). A series of face and profile cutting experiments are undertaken on a Copper Alloy “C18000” under different machining conditions using Taguchi Method L9 (Orthogonal array). The effects of various cutting parameters such as spindle speed , depth of cut, tool feed , tool rake angle, nose radius on the surface roughness and profile accuracy of the machined micro-structured surfaces(flat and spherical) of thermal conductive , ductile material copper alloy C18000 are identified and analyzed. This study presents an optimization method of the machining parameters by using design of experiment technique of Taguchi and ANOVA methods. Results were analyzed for the optimization process using S/N ratio response analysis and Pareto analysis. The use of Grey Relational Analysis for optimizing the turning process parameters for the work-piece surface roughness and the Peak to Valley is also introduced.