Papers by Rajamani Devaraj
This paper focuses on determination of optimum cutting conditions for the efficient hard milling ... more This paper focuses on determination of optimum cutting conditions for the efficient hard milling performance of the selected process parameters using hybrid method of response surface methodology and evolutionary computing approaches. A central composite rotatable design is used to design the experimentations. The responses of cutting temperature, tool wear and metal removal rate are measured and analysed the data to develop the mathematical models. The adequacies of the models are tested at 95% confidence level. To achieve the set goal of this study, genetic and simulated annealing algorithms are used for predicting and optimizing the process parameters. The result shows that the simulated annealing algorithm is effectively produced better optimal solutions than the genetic algorithm. The actual experimental results were in agreement with the prediction.
This paper proposes the prediction of cutting temperature, tool wear and metal removal
rate using... more This paper proposes the prediction of cutting temperature, tool wear and metal removal
rate using fuzzy and regression modeling techniques for the hard milling process. The feed per
tooth, radial depth of cut, axial depth of cut and cutting speed were used as process state
variables.The experiements were conducted using RSM based central composite rotatable design
methodology. Regression and fuzzy modeling were used to evaluate the input – output relationship
in the process. It is interesting to observe that the R2 and average error values for each response are
very consistent with small variations were obtained.Also, the confirmation results show that very
less relative error varitions. Thus, the developed fuzzy models directly integrated in manufacturing
systems to reduce the more computational complexity in the process planning activities.
In metal cutting process, chip formation is a phenomenon needed to investigate in detail to explo... more In metal cutting process, chip formation is a phenomenon needed to investigate in detail to explore the
machining characteristics of materials. This paper describes, the performance of the coated carbide tool is studied by
varying the cutting speeds i.e. 140m/min, 200m/min and 300m/min with constant feed 0.11mm/rev and depth of cut
1mm. The commercial DEFORM 2D finite element software with special remeshing capabilities enabling the
simulations has been used in this work. The fully coupled thermal-mechanical finite element analysis accurately
simulates the formation of chip and predicts the cutting load and temperature distribution. The simulation results of
cutting forces, cutting edge temperatures and chip formation are presented and discussed. Also, from the FEA results
show clearly that the relationship between input variables with output responses.
In metal cutting process, chip formation is a phenomenon needed to investigate in detail to explo... more In metal cutting process, chip formation is a phenomenon needed to investigate in detail to explore the machining characteristics of materials. This paper describes, the performance of the coated carbide tool is studied by varying the cutting speeds i.e. 140m/min, 200m/min and 300m/min with constant feed 0.11mm/rev and depth of cut 1mm. The commercial DEFORM 2D finite element software with special remeshing capabilities enabling the simulations has been used in this work. The fully coupled thermal-mechanical finite element analysis accurately simulates the formation of chip and predicts the cutting load and temperature distribution. The simulation results of cutting forces, cutting edge temperatures and chip formation are presented and discussed. Also, from the FEA results show clearly that the relationship between input variables with output responses.
Keywords: Finite Element Analysis, Machining, Simulation, Cutting force, Temperature distribution.
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Papers by Rajamani Devaraj
rate using fuzzy and regression modeling techniques for the hard milling process. The feed per
tooth, radial depth of cut, axial depth of cut and cutting speed were used as process state
variables.The experiements were conducted using RSM based central composite rotatable design
methodology. Regression and fuzzy modeling were used to evaluate the input – output relationship
in the process. It is interesting to observe that the R2 and average error values for each response are
very consistent with small variations were obtained.Also, the confirmation results show that very
less relative error varitions. Thus, the developed fuzzy models directly integrated in manufacturing
systems to reduce the more computational complexity in the process planning activities.
machining characteristics of materials. This paper describes, the performance of the coated carbide tool is studied by
varying the cutting speeds i.e. 140m/min, 200m/min and 300m/min with constant feed 0.11mm/rev and depth of cut
1mm. The commercial DEFORM 2D finite element software with special remeshing capabilities enabling the
simulations has been used in this work. The fully coupled thermal-mechanical finite element analysis accurately
simulates the formation of chip and predicts the cutting load and temperature distribution. The simulation results of
cutting forces, cutting edge temperatures and chip formation are presented and discussed. Also, from the FEA results
show clearly that the relationship between input variables with output responses.
Keywords: Finite Element Analysis, Machining, Simulation, Cutting force, Temperature distribution.
rate using fuzzy and regression modeling techniques for the hard milling process. The feed per
tooth, radial depth of cut, axial depth of cut and cutting speed were used as process state
variables.The experiements were conducted using RSM based central composite rotatable design
methodology. Regression and fuzzy modeling were used to evaluate the input – output relationship
in the process. It is interesting to observe that the R2 and average error values for each response are
very consistent with small variations were obtained.Also, the confirmation results show that very
less relative error varitions. Thus, the developed fuzzy models directly integrated in manufacturing
systems to reduce the more computational complexity in the process planning activities.
machining characteristics of materials. This paper describes, the performance of the coated carbide tool is studied by
varying the cutting speeds i.e. 140m/min, 200m/min and 300m/min with constant feed 0.11mm/rev and depth of cut
1mm. The commercial DEFORM 2D finite element software with special remeshing capabilities enabling the
simulations has been used in this work. The fully coupled thermal-mechanical finite element analysis accurately
simulates the formation of chip and predicts the cutting load and temperature distribution. The simulation results of
cutting forces, cutting edge temperatures and chip formation are presented and discussed. Also, from the FEA results
show clearly that the relationship between input variables with output responses.
Keywords: Finite Element Analysis, Machining, Simulation, Cutting force, Temperature distribution.