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1 Introduction
Hard disk drives (HDDs) are storage devices that
store encoded data on rotating platters, which are
turned by spindle motors or spindle shafts. Today,
most HDDs on the market, especially in desktop
computers and servers, use the spindle motor
technology known as the ball bearing (BB) design.
However, the usage of HDDs is swiftly expanding to
consumer electronics products, such as mobile
devices, which require higher performance HDDs.
For this reason, the old bearing design in HDDs has
shifted to a new technology, fluid dynamic bearing
(FDB), because HDDs with FDB technology can
effectively reduce acoustical noise. Other
advantages of FDB include higher capacity, faster
spindle speed and improved reliability [3]. One of
the key components of the FDB design is the sleeve
of the spindle motor, which contains ester oil to
lubricate the rotating shaft of motors. The contact
stress (source of acoustical noise) between the shaft
and sleeve can be significantly reduced if there is a
conformance between these two components. The
FDB sleeve is manufactured by a turning process,
and the surface quality of sleeve is known to depend
on the irregularities of materials resulting from
machining operations or surface roughness, which is
a critical quality characteristic. Therefore, if the
relationship between turning process parameters and
ISSN: 1790-2769
2 Literature Review
Among the most basic operations performed by
machine tools are drilling, milling, grinding and
turning or lathing. The turning process is a
machining method that removes material from the
surface using a rotating cutting tool that moves to a
workpiece. The surface quality, which is measured
in terms of surface roughness, is utilized to evaluate
the performance of the turning operation. The
surface roughness is known to be significantly
affected by different cutting parameters, i.e., the
depth of cut, spindle speed and feed rate [8].
Therefore, the surface roughness will be
minimized if the appropriate cutting conditions are
selected. Experimental design methods, such as the
two-levels (2k) factorial design, are frequently
utilized to model the surface roughness, so the
desired levels of machining parameters are achieved.
There are numerous works reporting the success of
implementing factorial design to study the
relationship between machining factors and surface
roughness. Among these works, Choudhury and ElBaradie [4] utilized a factorial design technique to
study the effect of cutting speed, feed rate and depth
of cut on surface roughness. The experimental study
67
ISBN: 978-960-474-121-2
Proceedings of the 1st International Conference on Manufacturing Engineering, Quality and Production Systems (Volume I)
b
+
C
a
b
-
(1
a
+
4 Process Description
The sleeves of fluid dynamic bearing (FDB) spindle
motors which have a dimension of 65 mm in
diameter and 58 mm in length are the specimens in
this experiment. The workpieces material used were
free cutting stainless steel, grade AISI 12L14, and
their chemical composition is 20% Cr and 2% Mo.
3 Methodology
ISSN: 1790-2769
ab
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ISBN: 978-960-474-121-2
Proceedings of the 1st International Conference on Manufacturing Engineering, Quality and Production Systems (Volume I)
Standard
order
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
5 Design of Experiment
The experiment was conducted to analyze the effect
of depth of cut, spindle speed and feed rate on the
surface roughness (Ra). As a result, each factor was
set to the low (-1) and high (+1) levels as shown in
Table 1.
Table 1 Factor levels.
Factor
Coded levels
Depth of cut (mm)
Spindle speed (rpm)
Feed rate (mm/rev)
Low
-1
0.01
5000
0.002
High
+1
0.02
8000
0.008
Depth of
cut
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
0.02
0.02
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
0.02
0.02
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
0.02
0.02
0.01
0.01
0.01
0.01
0.01
0.02
0.02
0.02
0.02
0.02
Spindle
speed
5000
5000
5000
5000
5000
5000
5000
5000
5000
5000
8000
8000
8000
8000
8000
8000
8000
8000
8000
8000
5000
5000
5000
5000
5000
5000
5000
5000
5000
5000
8000
8000
8000
8000
8000
8000
8000
8000
8000
8000
Feed
rate
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.002
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
0.008
Ra
(m)
0.07699
0.07592
0.07682
0.07535
0.07504
0.08521
0.08405
0.08596
0.08488
0.08424
0.07431
0.07584
0.07674
0.07661
0.07407
0.07792
0.07843
0.07893
0.07724
0.07824
0.0728
0.07323
0.07328
0.07463
0.07561
0.07424
0.07376
0.07377
0.07413
0.07333
0.06444
0.06525
0.06502
0.06695
0.06595
0.07095
0.07092
0.06902
0.06931
0.06952
ISSN: 1790-2769
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ISBN: 978-960-474-121-2
Proceedings of the 1st International Conference on Manufacturing Engineering, Quality and Production Systems (Volume I)
Source
Sum of
squares
0.00113
0.000157
0.000238
0.000614
1.85E-06
3.17E-05
1.6E-05
7.14E-05
2.64E-05
0.001156
Model
A-Depth
B-Speed
C-Feed
AB
AC
BC
ABC
Pure Error
Total
Df
Mean
square
0.000161
0.000157
0.000238
0.000614
1.85E-06
3.17E-05
1.6E-05
7.14E-05
8.26E-07
7
1
1
1
1
1
1
1
32
39
Prob > F
195.3932
189.8734
288.2275
743.0893
2.238777
38.40623
19.40623
86.51109
< 0.0001
< 0.0001
< 0.0001
< 0.0001
0.1444
< 0.0001
0.0001
< 0.0001
99
95
Value
0.9771
0.9721
4.129E-005
Normal % Probability
Statistics
R-Squared
Adj R-Squared
Prediction Error Sum of
Squared (PRESS)
F value
90
80
70
50
30
20
10
5
99
Half-Normal % Probability
C
B
95
-1.78
-0.81
0.16
1.12
2.09
A
90
AB
80
BC
AC
ABC
Internally Studentized Residuals
70
50
3.00
0.000
0.002
0.004
0.006
30
20
10
0
0.008
|Standardized Effect|
ISSN: 1790-2769
1.50
0.00
-1.50
-3.00
0.066
0.070
0.075
0.080
0.085
Predicted
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ISBN: 978-960-474-121-2
Proceedings of the 1st International Conference on Manufacturing Engineering, Quality and Production Systems (Volume I)
0.069732
0.007
0.069944
0.067627
C: Feed
Ra
0.008 5
0.071837
0.005
0.073942
0.004
B+: 8000.00
0.075514
0.078152
0.076047
B: Speed
0.002 5
0.07391
0.073846
0.010
5
0.012
0.015
0.017
0.020
C+: 0.008
A: Depth
C: Feed
5
B-: 5000.00
0.076024
A-: 0.01
A: Depth
C-: 0.002
0.084868
A+: 0.02
Ra
0.008 5
0.0672723
0.0690227
0.007
0.070773
Ra
8000.00 5
C: Feed
0.0725233
0.005
0.0742737
0.004
0.06692
0.002 5
5000.00
0.068318
5
5750.00
6500.00
7250.00
8000.00
7250.00
B: Speed
0.069716
B: Speed
0.071114
6 Confirmation Experiment
5750.00
0.072512
5000.00 5
0.010
0.012
0.015
0.017
0.020
A: Depth
ISSN: 1790-2769
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ISBN: 978-960-474-121-2
Proceedings of the 1st International Conference on Manufacturing Engineering, Quality and Production Systems (Volume I)
Predicted
average
Ra
0.06552
Depth of cut
Spindle speed
Feed rate
Ra
Before
optimization
0.015 mm
8000 rpm
0.005 mm/rev
0.07416 m
0.06444
Factors
Observed
average
After
optimization
0.01 mm
8000 rpm
0.008 mm/rev
0.06444 m
8 Conclusion
The purpose of this research is to quantify the effect
of depth of cut, spindle speed and feed rate on
surface roughness of the FDB sleeve in HDD. The
factorial design was utilized to obtain the best
cutting condition which leads to the minimization of
the surface roughness. The half normal plot and
ANOVA indicate that the feed rate (C) is the most
significant factor followed by spindle speed (B) and
feed rate (A). Moreover, it is interesting to note that
there are interactions among these three factors with
the highest order term, ABC. Regarding the model
validation, the regression model developed proves to
be accuracy and has the capability to predict the
value of response within the limits of factors
investigated. After the optimal cutting condition is
implemented, the surface roughness is significantly
reduced about 8%.
References:
[1] Arbizu, I.P. and Luis Perez, C.J. (2003),
Surface Roughness Prediction by Factorial
Design of Experiments in Turning Processes,
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ISBN: 978-960-474-121-2