Temperature Optimization by Using Response Surface Methodology and Desirability Analysis of Aluminium 6061
Abstract
:1. Introduction
1.1. Response Surface Methodology
1.2. Desirability Function Analysis—DFA
2. Experimentation Design
2.1. Experimental Set-Up
2.2. Temperature Prediction Using a Response Surface Model
− 0.260417 × Vc × Dc + 0.431250 × Vc × Rn − 23.26389 × Fz × Dc + 23.95833 × Fz × Rn − 28.59375 × Dc × Rn +
0.009097 × Vc2 + 44.36728 × Fz2 + 14.60937 × Dc2 + 7.42187 × Rn2
3. Results and Discussions
3.1. Interaction Effect
3.2. Implementation of DFA
4. Validation of the Model
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Sl. No | Parameter Considered | Factorial Levels | ||||
---|---|---|---|---|---|---|
−2 | −1 | 0 | 1 | 2 | ||
1 | Cutting speed, Vc (m/min) | 75 | 90 | 105 | 120 | 130 |
2 | Rate of feed, Fz (mm/rev) | 0.09 | 0.18 | 0.27 | 0.36 | 0.45 |
3 | Cutting depth, Dc (mm) | 0.2 | 0.4 | 0.6 | 0.8 | 1.0 |
4 | Tool Nose radius, Rn (mm) | 0.2 | 0.4 | 0.6 | 0.8 | 1.0 |
Sl. No | Vc (m/min) | Fz (mm/rev) | Dc (mm) | Rn (mm) | Temperature Rise °C Tob (Observed) | Temperature Rise °C (TRSM) (Pred. by RSM) |
---|---|---|---|---|---|---|
1 | 120 | 0.36 | 0.8 | 0.4 | 28.8 | 28.77 |
2 | 90 | 0.18 | 0.8 | 0.4 | 29.8 | 29.84 |
3 | 105 | 0.27 | 1.0 | 0.6 | 26.6 | 26.55 |
4 | 105 | 0.27 | 0.6 | 0.6 | 25.8 | 25.77 |
5 | 90 | 0.36 | 0.8 | 0.8 | 24.9 | 24.76 |
6 | 105 | 0.27 | 0.6 | 0.2 | 26.8 | 26.80 |
7 | 120 | 0.36 | 0.8 | 0.8 | 29.7 | 30.10 |
8 | 105 | 0.27 | 0.6 | 0.6 | 28.2 | 25.77 |
9 | 75 | 0.27 | 0.6 | 0.6 | 29.3 | 29.58 |
10 | 90 | 0.18 | 0.4 | 0.4 | 27.1 | 26.71 |
11 | 90 | 0.36 | 0.8 | 0.4 | 28.6 | 28.61 |
12 | 105 | 0.27 | 0.6 | 0.6 | 25.6 | 25.77 |
13 | 105 | 0.27 | 0.2 | 0.6 | 29.6 | 29.66 |
14 | 120 | 0.18 | 0.8 | 0.8 | 29.8 | 29.73 |
15 | 120 | 0.18 | 0.4 | 0.4 | 30.1 | 30.12 |
16 | 105 | 0.27 | 0.6 | 0.6 | 25.6 | 25.77 |
17 | 90 | 0.36 | 0.4 | 0.8 | 27.8 | 27.88 |
18 | 90 | 0.36 | 0.4 | 0.4 | 27.2 | 27.16 |
19 | 105 | 0.27 | 0.6 | 1.0 | 27.1 | 27.11 |
20 | 120 | 0.18 | 0.4 | 0.8 | 34.2 | 34.30 |
21 | 90 | 0.18 | 0.4 | 0.8 | 25.8 | 25.71 |
22 | 105 | 0.45 | 0.6 | 0.6 | 27.6 | 27.61 |
23 | 105 | 0.09 | 0.6 | 0.6 | 26.8 | 26.80 |
24 | 120 | 0.36 | 0.4 | 0.4 | 30.4 | 30.45 |
25 | 105 | 0.27 | 0.6 | 0.6 | 25.8 | 25.77 |
26 | 120 | 0.18 | 0.8 | 0.4 | 30.1 | 30.13 |
27 | 135 | 0.27 | 0.6 | 0.6 | 38.8 | 38.33 |
28 | 90 | 0.18 | 0.8 | 0.8 | 24.2 | 24.26 |
29 | 120 | 0.36 | 0.4 | 0.8 | 36.5 | 36.34 |
30 | 105 | 0.27 | 0.6 | 0.6 | 25.6 | 25.77 |
Source | Sum of Squares Value | df | Mean Square Value | F-Value | p-Value | |
---|---|---|---|---|---|---|
Model | 311.21 | 14 | 22.23 | 786.09 | <0.0001 | significant |
Vc | 49.56 | 1 | 49.56 | 1752.53 | <0.0001 | |
Fz | 1.01 | 1 | 1.01 | 35.72 | <0.0001 | |
Dc | 9.70 | 1 | 9.70 | 343.14 | <0.0001 | |
Rn | 0.4290 | 1 | 0.4290 | 15.17 | 0.0014 | |
Vc Fz | 0.0156 | 1 | 0.0156 | 0.5526 | 0.4688 | |
Vc Dc | 9.77 | 1 | 9.77 | 345.35 | <0.0001 | |
Vc Rn | 26.78 | 1 | 26.78 | 947.06 | <0.0001 | |
Fz Dc | 2.81 | 1 | 2.81 | 99.22 | <0.0001 | |
Fz Rn | 2.98 | 1 | 2.98 | 105.23 | <0.0001 | |
Dc Rn | 20.93 | 1 | 20.93 | 740.18 | <0.0001 | |
Vc2 | 114.92 | 1 | 114.92 | 4063.88 | <0.0001 | |
Fz2 | 3.54 | 1 | 3.54 | 125.27 | <0.0001 | |
Dc 2 | 9.37 | 1 | 9.37 | 331.24 | <0.0001 | |
Rn2 | 2.42 | 1 | 2.42 | 85.49 | <0.0001 | |
Residual | 0.4242 | 15 | 0.0283 | |||
Lack of Fit | 0.1508 | 10 | 0.0151 | 0.2759 | 0.9606 | Insignificant |
Pure Error | 0.2733 | 5 | 0.0547 | |||
Cor Total | 311.63 | 29 |
Sl. No | Input Parameter | Goal | Lower Limit | Upper Limit |
---|---|---|---|---|
1 | Vc | In range | 75 | 130 |
2 | Fz | In range | 0.09 | 0.45 |
3 | Dc | In range | 0.2 | 1.0 |
4 | Rn | In range | 0.2 | 1.0 |
5 | Temperature rise Observed (Tob) | Minimize | 24.2 | 38.8 |
Sl. No | Input Parameter | Goal | Optimum Value |
---|---|---|---|
1 | Vc | In range | 98.0 (m/min) |
2 | Fz | In range | 0.26 (mm/rev) |
3 | Dc | In range | 0.893 (mm) |
4 | Rn | In range | 0.84 (mm) |
5 | Temperature rise Observed (Tob) | Minimize | 23.615 °C |
Sl. No | Vc | Fz | Dc | Rn | Confirmatory Test (Temp., °C) | % Error | |
---|---|---|---|---|---|---|---|
Optimum Value by DFA | Exp. Value | ||||||
1 | 98.0 | 0.258 | 0.893 | 0.84 | 23.615 | 23.610 | 0.021 |
2 | 90.3 | 0.136 | 0.654 | 0.86 | 23.943 | 23.896 | 0.196 |
3 | 94.7 | 0.199 | 0.730 | 0.78 | 24.098 | 24.061 | 0.154 |
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Gutema, E.M.; Gopal, M.; Lemu, H.G. Temperature Optimization by Using Response Surface Methodology and Desirability Analysis of Aluminium 6061. Materials 2022, 15, 5892. https://doi.org/10.3390/ma15175892
Gutema EM, Gopal M, Lemu HG. Temperature Optimization by Using Response Surface Methodology and Desirability Analysis of Aluminium 6061. Materials. 2022; 15(17):5892. https://doi.org/10.3390/ma15175892
Chicago/Turabian StyleGutema, Endalkachew Mosisa, Mahesh Gopal, and Hirpa Gelgele Lemu. 2022. "Temperature Optimization by Using Response Surface Methodology and Desirability Analysis of Aluminium 6061" Materials 15, no. 17: 5892. https://doi.org/10.3390/ma15175892