Welcome to ePrints Sriwijaya University - UNSRI Online Institutional Repository ASM QIR UI 2011
PREFACE
WELCOME FROM THE RECTOR OF UNIVERSITAS INDONESIA
I am honoured to have the opportunity to officially welcome
you to the 12th International Conference on QiR (Quality in
Research) 2011. As we are all aware that the impact of
globalization has resulted in a very competitive business
environment; a condition that makes the fulfillment of the
needs of customer/clients’ ever–sophisticated project,
product, or service most challenging. Without any doubt, a
sustainable design and technology is the key factors in assisting our industries to
enhance their contributions to the future development of humanity. Therefore, it is
our hope that this conference will be able to provide an international forum for
exchanging knowledge and research expertise as well as creating a prospective
collaboration and networking on various fields of sustainable engineering and
architecture.
In order to achieve business objectives and benefits, engineering products or
projects require various resources, skills, and technology. Accordingly, we need an
application of knowledge, tools, and techniques necessary to develop sustainable
products or projects, which are environmentally friendly, produced through efficient
processes, and adapted to local conditions. And this may be achieved by ecotechnology. Eco-technology is a technology that will give consumers what they
want; lower cost, convenience, save money and deliver what people everywhere
needs: less waste, less pollution, and green environment. Eco-technology practices
can facilitate to conserve and restore the environment through the integration of
engineering and ecological principles. However, eco-technology requires
multidisciplinary synthesis of knowledge and skills; and the development and
application of this technology in the sector of industry and services is therefore a
crucial requirement for sustainable development process. For this reason, we
urgently need new technologies and practical applications to be further developed
based on the current knowledge.
Accordingly, I hope this conference can be a kick-off for the strengthened action
and partnerships on creating a platform for us; national and international thinkers,
academics, government officials, business executives and practitioners, to present
and discuss the pivotal role of engineers in creating sustainable development.
I would like to thank the Faculty of Engineering of Universitas Indonesia for organizing
this meaningful and timely event, and supporting organizations for their participation
and contributions. I am sure that you will all find this conference stimulating and
rewarding and with this, I wish you all a fruitful conference.
Prof. Dr. der. Soz. Gumilar Rusliwa Somantri
Rector
Universitas Indonesia
ii
PREFACE
WELCOME FROM THE DEAN OF FACULTY OF ENGINEERING
UNIVERSITAS INDONESIA
On behalf of the Faculty of Engineering, University of Indonesia,
it is my greatest pleasure to extend our warmest welcome to all
of you to the 12th International Conference on QiR (Quality in
Research) 2011. As we know that this conference is conducted
to cover a wide range of sustainable design and technology
issues, I hope this two days-conference will be spent in
interesting discussions and exchange of ideas. I also hope that
this conference will be able to provide a state-of-the-art information and knowledge
in this challenging world of sustainable design and technology. The growing success
of our institutions and expertise should urge us to develop our competitive
capabilities, especially when we face certain challenges which should be
overcome with hard work, cooperation, and working together hand in hand. We will
work together to develop a common path and develop collaboration opportunities
for future action and research on multi-disciplinary engineering areas for quality of
life and humanity.
I am delighted that you have accepted our invitation to this conference in such a
large numbers as indicated and that we will have many international speakers and
papers from various countries to be presented and discussed in these two days. We
will explore various issues on sustainable development and we must widen the scope
of sustainability from a product-, system-, or an individual building-scale to the whole
community-scale. At the same time, we have to widen the focus from ecological
aspects to social and economic aspects. This means that environmental solutions
should always be considered from the aspects of human health and well-being,
safety, and economic point of view. This conference provides an excellent forum for
engineering professionals, business executives, industry practitioners, and
academicians to exchange ideas and to share their experience, knowledge and
expertise to each other.
I would like to thank our sponsors, supported bodies, and various contributors for their
generous support of this conference. I would also like to thank our distinguished
speakers for agreeing to share their insights with us. To our friends from overseas and
other provinces of Indonesia, I would also like to extend a warm welcome to you
and wish you an enjoyable stay in Bali. Last but not least, I would invite you to join
me in thanking the committed staff that made this conference happen and to
make it success.
I wish us much success in the deliberations, discussions, and exchange of ideas
which we will have within this conference and I wish you a very pleasant and
enjoyable stay here in Bali.
Prof. Dr. Ir. Bambang Sugiarto, M.Eng
Dean Faculty of Engineering
Universitas Indonesia
iii
PREFACE
WELCOME FROM THE QiR 2011 ORGANIZING COMMITTEE
On behalf of the Organizing Committee, it is my greatest
pleasure to extend our warmest welcome to all of you to the
12th International Conference on QiR (Quality in Research)
2011. The selected theme for this year’s conference is
“Integrated Design in Urban Eco-Technology for Quality of Life
and Humanity”. With this theme, the conference focuses on
the scientific analysis and design of the key factors explaining
the success applications of integrated design in urban eco-technology, their market
perspectives, and their contributions to the existing and future development of
humanity. In line with this theme, it is our utmost pleasure to hold the QiR 2011 in
conjunction with the 2nd International Conference on Saving Energy in Refrigeration
and Air Conditioning (ICSERA 2011).
With its continuous presence for 12 years, QiR has become an icon for Faculty of
Engineering Universitas Indonesia in serving the objectives to provide engineering
excellence for both national and international in all aspects of engineering, design,
and architecture. For the first time, the QiR 2011 is held in a famous beautiful island of
Indonesi - Bali. The QiR 2011 is supported by Universitas Udayana, in the spirit of
strengthening of cooperation and mutual growth to be world class institution. I am
delighted to inform you that we have such a large number of participants today, as
indicated, that we will have 21 invited speaker presentation and more than 520
papers from more than 20 countries to be presented and discussed during these two
days-conference. We are fortunate to have a lot of good quality papers belong to:
32 papers on ICSERA
39 papers on Chemical Engineering
115 papers on Electrical Engineering
37 papers on Mechanical and Naval Architecture Engineering
101 papers on Materials Engineering
54 papers on Architecture & Planning
75 papers on Industrial Engineering
72 papers on Civil Engineering
I would like to thank all contributors, speakers and participants for your generous
support to this conference. It is my pleasant duty to thank all the members of
Organizing Committee and the International Board of Reviewers for their advices
and help. We are grateful to all Sponsors, Supporters, Exhibitors, Partner Universities
and Professional Associations, for their spontaneous response and encouragement
through committing funds and extending help in kind. I would like to sincerely thank
the Rector of Universitas Indonesia and the Dean of Faculty of Engineering, for fully
supporting the Committee and providing all supports to make this conference
happen and to make it a success.
I wish you a very pleasant stay here in Bali; and finally, let me wish all of you a
meaningful and fruitful conference. Thank you and we hope to see you again at the
QiR 2013.
Prof. Dr. Ir. Bondan T. Sofyan, M.Si.
Chairman of QiR 2011 Organizing Committee
iv
Proceeding of the 12th International Conference on QiR (Quality in Research)
Faculty of Engineering, University of Indonesia, Depok, Indonesia, 4-7 July 2011
ISSN 114-1284
TABLE OF CONTENTS
SYMPOSIUM A
A1.1_Masafumi Yohda_Catalytic Mechanism of Nitrile Hydratase Proposed by Time-Resolved X-Ray
Crystallography…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……1
A1.2_Siswa Setyahadi_Bioconversion of Extraction Chitin from Penaeus Vannamei Shell Waste………….3
A1.3_Indu Shekhar Thakur_Bioremediation and bioconversion of chromium and pentachlorophenol in
tannery effluent by microorganisms…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……...10
A1.4_Mukh Syaifudin_Pre-Erythrocytic Stage of Plasmodium as the Best Choice of Vaccine Development
for Malaria with Nuclear Technology…..…..…..…..…..…..…..…..…..…..…..…..………………………..11
A1.5_Misri Gozan_Cellulase Immobilization Using Reversible Soluble-Insoluble Polymer……………….20
A1.7_Muhammad Sahlan_Organic Co-Solvent Stability of the Chaperones from Hyperthermophilic Archaea
Thermococcus sp…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………............................21
A2.1_Mahmud Sudibandriyo_Effect of Adsorbed Phase Density on High Pressure Adsorption Isotherms..22
A2.3_Sutrasno Kartohardjono_Ammonia Removal from Aqueous Solution through Hollow Fiber Membrane
Contactor Using Natural Hot Spring Water (NHSW) as Absorbent…..…..…..…..…..…..…..…..…………29
A2.5_Yuliusman_Producing Activated Carbon from Corn Cob for Cu, Pb, and Ammonia Adsorption……30
A2.6_Herliati_Simulation of Epichlorohydrin Synthesis from Dichloropropanols in Reactive Distillation
Column Using Aspen Plus………….…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……39
A2.7_Setiadi_A Study On The Crystallization Stage Of The ZSM-5 Crystal Structure For Improving The
Zeolite Synthesis Route…………..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………......43
A2.8_Yuswan Muharam_Model to Predict Species Concentrations from the Oxidation and Combustion of
the Mixture of N-Heptane and Iso-Octane…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…...50
A3.1_Yurita Puji_Optimization of Pipeline Network for Gas Distribution using Genetic Algorithm………59
A3.2_Rita Arbianti_Production of Electricity Energy in Microbial Fuel Cell System Using Saccharomyces
Cerevisiae…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………...…..…..…..…..…..…..65
A3.3_Dianursanti_The Effects of Cells Density Arrangement in Chlorella vulgaris Culture to CO2 Fixation
and Essential Substances Production. …..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……72
A3.4_Heri Hermansyah_Esterification of Oleic Acid with Octanol to Produce Wax Ester using Candida
rugosa lipase.. …..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………................................77
A3.5_Listio Sambono_Application Analysis of Underground Storage As an Alternative For Natural Gas
Storage Facilities in West Java Pipeline Distribution Network……………………………………………...83
A4.1_Suripto Dwi Yuwono_Lactic Acid Production From Fresh Cassava Roots by Streptococcus bovis
using Single stage membrane bioreactor. …..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……86
A4.2_Muhammad Zakir_Amino Acid Composition of Rice Bran Concentrate from Several Local Rice
Varieties as a Potential Source of Bio-emulsifier Material. …..…..…..…..…..…..…..…..…..…..…..……..92
A4.3_Edita Martini_Bead Formation Mechanism In Cellulase Entrapment Using Calcium Alginate……...98
A4.5_Edi Iswanto Wiloso_Environmental Impacts of Bioethanol from Oil Palm Lignocellulosic Biomass An LCA Perspective…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……….....................104
A5.1_Nelson Saksono_Hydrogen Production Using Non-Thermal Plasma Electrolysis…………………..112
A5.2_Eva F. Karamah_Degradation of Phenol By Combination of Ozonation and Cavitation……………119
A5.4_Eny Kusrini_Micro and Nanoparticle of Lanthanide Complexes for Photosensor Application……..127
A6.1_Praswasti PDK Wulan_Production Of CO2-Free Hydrogen and Nanocarbon Using Carbon FoamSupported Nickel Catalyst……..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………........128
A6.2_Yuswan Muharam_Simulation of Ignition Delay Times in the Oxidation and Combustion of the
Mixture of n-Heptane and Isooctane………………………………………………………………………..133
A6.3_Muhammad Sahlan_Rapid Purification of Phospholipase A2 from Acanthaster Planci……………138
A6.4_Nuryetti_Characteristical Bionanocomposites Cassava StarchZnO With added glycerol…………...139
v
Proceeding of the 12th International Conference on QiR (Quality in Research)
Faculty of Engineering, University of Indonesia, Depok, Indonesia, 4-7 July 2011
ISSN 114-1284
E5.5_Efendi Mabruri_Phase Identification and Microstructure of Ni-Ti-Cu..............................................1379
E5.6_A.S. Mohruni_Optimization of Cutting Conditions.... ......................................... .............................1384
E5.7 _R.D. Ramdan_Shear Mechanisms During Cryogenic ... .................................................................1390
E6.1 _(Invited) Jinn P Chu_Amorphization and Fatigue Property Enhancements .....................................1397
E6.2 _IN Sudiana_Study of high quality......................................................................................................1399
E6.3 _Alva E.Tontowi_Effect of PVA coating............................................................................................1403
E6.4 _Anne Zulfia_Al-SiSiC Metal Matrix Composites.............................................................................1410
E6.6 _V. Vekky R. Repi_Permittivity and Permeability of Mn-Ti.... .........................................................1411
E7.1 _(Invited) Eung-Ryul Baek_Surface Modification of Hot-Dip Aluminized HPF Steel……………..1414
E7.2 _(Invited) Fazwar Bujang_Production of HSLA Steel for Sour Service .... ……………………….1415
E7.3 _Irfan P. Hidayat_Neural Networks with Radial Basis Function .... ...................................................1423
E7.4 _Rini Riastuti_Grain size refinement.... ..............................................................................................1424
E7.5 _K. M. Hafez_Failure Investigation of a Bypass Elbow Tube .... ………………………………...1428
E7.6 _Effect of the Base Metal.....................................................................................................................1435
E8.1 _Juliewatty J.M_Effect of Milling on the Synthesis............................................................................1436
E8.2 _Bambang Suharno_The Effects of Plates Position in Vertical Casting .... ………………………1440
E8.3 _Myrna Ariati_Comparison of Two Calculation Methods .................................................................1441
E8.4 _Parikin_Crystalline Structure, Hardness and Microstructure of ZrNbMoGe All
oy…………..1446
E8.6 _Suyitno_Fracture study of As-cast.... ……………………………………………………………..1456
E8.7 _Dwi Rahmalina_Development of Steel Wire Rope - Reinforced Aluminium Composite ...............1451
E8.8 _I.K. Gede Sugita_Mechanical Properties and Damping....................................................................1452
E9.1 _Masumi Obara_Slowly Relaxing Structural Defects of Zinc Films .................................................1468
E9.2 _A. Djehiche_Colloid particles Deposition in.... ……………………………………………………1469
E9.3 _Hadi Suwarno_Analysis of TheFe-Ti and Mg-Ti-Fe Alloys .... ………………………………...1474
E9.4 _M. Hikam_Characterization of BST Thin Films doped by Indium .................................................1475
E9.5 _M.K. Herliansyah_Development and Characterization of Bovine Hydroxyapatite ......................1481
E9.6 _Adianto_Low pressure deposition.... ……………………………………………………………..1482
Plenary Lecture 1 Joe Greene_Design Strategies for the Growth of Self-organized 3D Thin Film............1489
Plenary Lecture 4 Akhmad Herman Yuwono_Sol-Gel derived TiO2 - PMMA Nanocomposites .............1490
SYMPOSIUM F
F1.1_Jiat Hwee_Notes on a few Tropical Variants of Sustainable Architecture……………………….....1492
F1.2_Marcus Gartiwa_Reactualization of Sustainable Wisdom of Vernacular Architecture Case study
Sustainable Wisdom. ........................................................................... .......................................................1506
F1.3_Kemas R. Kurniawan_Tropical Ideas on Designing National Architecture in Indonesia a Case of
Friedrich Silaban. ........................................................................................................................................1514
F1.4_Nangkula Utaberta_Study and Classification on the Apllication of Tanggam System in the Traditional
Malay House of Malaysia. ...........................................................................................................................1519
F10.1_Nangkula Utaberta_Campus Sustainability Design in Malaysia An Evaluation of Students Perception
on Four Research Universities Campus in Malaysia. ..................................................................................1526
F10.2_Siti Handjarinto_Study of Building Information Modeling (BIM) Towards Multidiscipline Integrated
and Sustainable Design. ..............................................................................................................................1533
F10.3_Mohd.Syarif Hidayat_Reorientation of Architectural Education in Indonesia Integration of Building
Physics Substance in Architectural Design Process.. ..................................................................................1540
F11.3_Agung Murti Nugroho_A Ventilated Building Envelope...A Ventilated Building Envelope as A
Passive Cooling Strategy in The Hot Humid Tropics. ................................................................................1547
xii
Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
Optimization of Cutting Conditions when End Milling
Aeronautic Materials (Ti-6Al-4V) using Genetic Algorithm
and Response Surface Methodology
A.S. Mohrunia, S. Sharifb, M.Y. Noordinb, R. Hansona
a
Faculty of Engineering,
Sriwijaya University,
Indralaya, 30662 OI-Indonesia
Tel. +62-711-580062 Fax. +62-711-580741
E-mail : mohrunias@yahoo.com, mohrunias@unsri.ac.id
b
Faculty of Mechanical Engineering,
Universiti Teknologi Malaysia, 81310-UTM Skudai,
Johor, Malaysia
ABSTRACT
The present work was initiated to explore the optimum tool performance in machining of Ti-6Al-4V using Super-Nitride (SNTR)
coated WC-Co end mills under wet conditions. Ti-alloys, particularly α + β alloys such as Ti-6Al-4V, have been the focus of
considerable research recently because of their high specific strength to weight ratio, which is even maintained at elevated
temperatures, excellent fracture toughness, extensive ductility and corrosion resistance. These properties make Ti-alloys the
most attractive metallic materials for metal working, aeronautic industry, chemical industry, marine environments, and
biomaterials applications. The Response Surface Methodology (RSM) and Genetic Algorithm (GA) were used in finding the
optimum machining conditions. It was proven that overall performance using GA delivers better results than RSM, when the
experimental trials were conducted according to design of experiments (DOE).
Keywords
Optimum Tool Performance, Super-Nitride, Titanium Alloys, Response Surface Methodology, Genetic Algorithm
1. INTRODUCTION
As mentioned above, ti-alloys, particularly α + alloys such as Ti-6Al-4V, have been the focus of considerable research
recently, because of their excellent fracture toughness, extensive ductility, corrosion resistance and high specific strength to
weight ratio (E/ρ), which is even maintained at elevated temperatures (250 oC – 600 oC). These properties make Ti-alloys the
most attractive metallic materials for metal working, aeronautic industry, chemical industry, marine environments, and
biomaterials applications [1]-[2]. On the other hand previous studies have shown that titanium alloys are considered as the
difficult to machine materials because of its low thermal conductivity, its high heat capacity and high chemical reactivity,
regardless of the type materials used[3]-[5]. To overcome such situation, the optimum cutting conditions play a significant role
in machining of difficult to cut materials. One of the optimum cutting conditions that result in the best tool performance using
RSM was reported by[6]. Another investigation were carried out by [7] and [8] using genetic algorithms for machining
processes. They reported that genetic algorithm can be utilized for investigating the optimum machining conditions. None of
previous studies were focused for optimizing of cutting conditions on aerospace materials using this algorithm. This challenge
was taken into consideration in this study, to fill the lack of information in this field. Therefore, further investigation of
utilization of a genetic algorithm, was employed for optimizing of machining conditions on titanium alloys.
2. EXPERIMENTAL SET-UP
The tests were carried out with a constant aa (axial depth of cut) 5mm and ae (radial depth of cut) 2mm under flood conditions
with a 6% concentration of water base coolant using MAHO 700S CNC machining center for side milling operation. The grade
K-30 solid carbide end mill cutters, with PVD Super Nitride coated which were prepared with different radial rake angle
according to Design of Experiment (DOE), were used for experimentation
The reference workpiece material was a rectangular bar (110 x 110 x 270 mm) of Ti-6Al-4V. Tool life criteria used were
VBmax ≥ 0.25 mm, chipping VBave ≥ 0.β0 mm and catastrophic failure.
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Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
Tool wear was measured using a Nikon tool makers’ microscope with γ0x magnification. The measurements of tool wear
according to ISO 8688-2 were carried out for each cutting edge at initial cut and continuously after a particular length of cut
(depend on wear progressive of each tool) until the end of tool life was achieved.
The independent variables such as cutting speed, feed, and radial rake angle coded with the following equation by taking into
consideration the capacity and limiting cutting conditions of milling machine.
(1)
Where x is the coded variable of any factor corresponding to its natural ,
is the natural value at the +1 level and , is the
natural value of the factor corresponding to the base or zero level[9]. The level of independent variables and coding
identification are illustrated in Table 1.
Table 1: Levels of independent variables for end milling Ti6Al4V
Independent
Variable
V (m.mm-1)
x1
fz (mm.tooth-1)
x2
o
o ( )
x3
-α
-1
Level in coded form
0
1
+α
124.53
130
144.22
160
167.03
0.025
0.03
0.046
0.07
0.083
6.2
7.0
9.5
13.0
14.8
3.RESEARCH METHODOLOGY
The mathematical models which were built using RSM will be utilized to find the optimum cutting condition using GA. The
results delivered by using GA, were compared to the results using RSM[10]. The models can be described as 3F1 and 2nd CCD
mathematical model.
The 3F1 mathematical model can be illustrated as:
(2)
with the following ranges of cutting speed Vc, feed per tooth fzand radial rake angle
0.03 ≤ fz ≤ 0.07mm tooth-1 ; and 7 ≤ o≤ 13 (º).
while the 2nd CCD mathematical model illustrated as follow:
o:
1γ0≤ Vc≤ 160m.min-1;
(3)
with the following ranges of cutting speed Vc, feed per tooth fz and radial rake angle
≥0.08γmm tooth-1 ; and 6.β ≤ o ≥ 14.8 (º).
o:1β4.5γ≤
Vc ≥ 167.0γm.min-1; 0.0β5≤ fz
GA form a class of adaptive heuristics base on principles derived from the dynamic of natural population genetic. The
searching process simulates the natural evaluation of biological creatures and turns out to be an intelligent exploitation of a
random search.
The problem to be solved using GA is coded to binary numbers known as chromosomes. Each chromosome contains the
information of a set of possible process parameters. The population of chromosomes is formed randomly. The fitness of each
chromosome is then evaluated using an objective function after the chromosome has been decoded. Selected individuals are
then reproduced; the selecting occurs usually in pairs through the application of genetic operator. This operator is applied to
pairs of individuals with a given probability, and result in a new offspring. The offspring from reproduction are then further
perturbed by mutation. These new individuals then make up the next generation. These processes of selection, reproduction
and evaluation are repeated until some termination criteria are satisfied. The representing of GA is illustrated in Figure 1.
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Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
In order to optimize the present problem using GA, the following parameters such as population size, maximum number of
generation, total string length, crossover probability, mutation probability, and elitism probability have to be selected to obtain
optimal solution with less computational efforts.
Figure 1: Flow chart of GA methodology approach.
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Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
4. RESULTS AND DISCUSSION
Tool life experimental results for SNTR coated carbide tools are illustrated in Table 2These results are used to validate the
comparison between the optimization using RSM and GA.
Table 2: Tool life result for SNTR coated carbide tools
Std
Or
der
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Type
Cutting speed V
[m/min]
Factorial
Factorial
Factorial
Factorial
Factorial
Factorial
Factorial
Factorial
Center
Center
Center
Center
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
-1
1
-1
1
-1
1
-1
1
0
0
0
0
-1.4142
-1.4142
1.4142
1.4142
0
0
0
0
0
0
0
0
Feed rate fz
[mm/th]
Radial Rake
angle [°]
Tool Life [min]
-1
-1
1
1
-1
-1
1
1
0
0
0
0
0
0
0
0
-1.4142
-1.4142
1.4142
1.4142
0
0
0
0
-1
-1
-1
-1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
-1.4142
-1.4142
1.4142
1.4142
20.09
8.85
2.41
0.41
22.2
9.68
2.72
0.46
5.77
6.04
5.69
5.94
16.12
15.95
2.56
2.70
16.44
16.03
0.44
0.43
4.94
4.43
5.55
5.29
Table 3: The optimization results using RSM and GA
Std
Order
Experimental Results
(min)
Response Surface
Methodology (min)
Genetic Algorithm
(min)
1
20.09
20.02
20.09
2
8.85
8.78
8.88
3
2.41
2.43
2.28
4
0.41
0.41
0.53
5
22.2
22.27
22.12
6
9.68
9.76
9.94
7
2.72
2.70
2.73
8
0.46
0.46
0.50
9
5.77
3.84
3.82
10
6.04
3.84
3.82
11
5.69
3.84
3.82
12
5.94
3.84
3.82
13
16.12
16.14
15.64
14
15.95
16.14
15.64
15
2.56
2.61
2.58
16
2.7
2.61
2.58
17
16.44
19.59
15.38
18
16.03
19.59
15.38
19
0.44
0.52
0.43
20
0.43
0.52
0.43
21
4.94
4.67
4.55
22
4.43
4.67
4.55
23
5.55
5.42
5.27
24
5.29
5.42
5.27
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Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
Table 4: Comparison between RSM and GA validated using the experimental results.
Experimental
RSM
Results
(min)
(min)
1
20.09
20.02
2
8.85
8.78
3
2.41
2.43
4
0.41
0.41
5
22.2
22.27
6
9.68
9.76
7
2.72
2.70
8
0.46
0.46
9
5.77
3.84
10
6.04
3.84
11
5.69
3.84
12
5.94
3.84
13
16.12
16.14
14
15.95
16.14
15
2.56
2.61
16
2.7
2.61
17
16.44
19.59
18
16.03
19.59
19
0.44
0.52
20
0.43
0.52
21
4.94
4.67
22
4.43
4.67
23
5.55
5.42
24
5.29
5.42
MSE (Mean Square Error)
RMSE (Root Mean Square Error)
Std
Order
GA
(min)
Error of RSM
20.09
8.88
2.28
0.53
22.12
9.94
2.73
0.50
3.82
3.82
3.82
3.82
15.64
15.64
2.58
2.58
15.38
15.38
0.43
0.43
4.55
4.55
5.27
5.27
Error of GA
0.0043
0.0054
0.0003
0.0000
0.0053
0.0066
0.0004
0.0000
4.0815
4.0815
4.0815
4.0815
0.0106
0.0106
0.0005
0.0005
11.2526
11.2526
0.0065
0.0065
0.0002
0.0002
0.0000
0.0000
1.620391906
1.272946152
0.0000
0.0011
0.0159
0.0140
0.0060
0.0662
0.0001
0.0014
4.1811
4.1811
4.1811
4.1811
0.1564
0.1564
0.0021
0.0021
0.7328
0.7328
0.0001
0.0001
0.0188
0.0188
0.0230
0.0230
0.778974202
0.882595152
The optimization results using RSM and GA are shown in Table 3. The Mean Square Error (MSE) of both methods are figured
out in Table 4. From this table, it can be concluded that the optimization using GA delivered better results than that using
RSM. It can be recognized from the value of MSE of each approach.
E XP E R IME NTAL VS R S M VS AG
30
Umur Pahat (min)
25
20
15
Experiment
RSM
10
AG
5
0
0
5
10
15
20
25
30
-5
Std Order
Figure 2: Error Distribution of both optimization methods validated by experimental results.
To provide easier observation of errors, the occured errors was represented and visualized in Figure 2. Finally, it can be
concluded from the optimization results that GA has the ability and is suitable for achieving the best possible tool life when
end milling Ti-64 in combination of cutting speed, feed rate, and radial rake angle.
5. CONCLUSIONS
1) The better overall performance in finding the optimum cutting conditions was delivered by GA compared to RSM. This
can be recognized from its accuracy using the validation tests.
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Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
2) The best results of GA was produced using following parameters:
- Population size
: 80
- Number of generation
:5
- Total string length
: 34
- Crossover probability (Pc) : 0.8
- Mutation probability (Pm) : 0.03
- Elitism probability
: 0.5
3) Even GA delivers better results than RSM, the difference between them was not significant.
4) It was found that GA can only give better results when the optimum parameters were taken in the iterations.
REFERENCES
[1] A.W. El-Morsy, “Microstructural Characterization of Ti-6Al-4V Machining Chips after Remelting and Severe Deformation”, Materials
and Design, Vol. 30, pp. 1825-1829, 2009.
[2] N. Corduan et.al., “Wear Mechanism of New Tool Materials for Ti-6Al-4V High Performance Machining”, CIRP AnnalsManufacturing Technology, Vol. 52 Issue 1, pp. 073-076, 2003.
[3] W. Koenig, “Applied Research on the Machinability of Titanium and Its Alloys”, Proceeding 47th Meeting of AGARD Structural and
Materials Panel, Florence, AGARD CP256, London, pp. 1-10, 1979
[4] M. Calamaz, et.al., “Toward a Better Understanding of Tool Wear Effect through a Comparison between Experiments and SPH
Numerical Modeling of Machining Hard Materials”, International Journal of Refractory Metals & Hard Materials, Vol. 27, pp. 595604, 2009.
[5] P.J. Arrazola, A. Garay, L.M. Iriarte, M. Armendia, S. Marya, F. Le Maitre, “Machinability of Titanium Alloys (Ti6Al4V and
Ti555.γ)”, Journal of Materials Processing Technology, Vol. 209, pp. 2223-2230, 2009.
[6] A.S. Mohruni, S. Sharif, M.Y. Noordin, V.C. Venkatesh, “Application of Response Surface Methodology in the Development of Tool
Life Prediction Models when End Milling Ti-6Al-4V”, Proceeding 10th Quality in Research ISSN: 1411-1284, 4-6 December 2007,
Jakarta, pp. 1-6, IMM-20, 2007.
[7] N.S.K. Reddy and P.V. Rao, “A Genetic Algorithm Approach for Optimization of Surface Roughness prediction Model in Dry
Milling”, Machining Science and Technology, Vol. 9, pp. 63-84, 2005.
[8] N.K. Jain, V.K. Jain, K. Deb, “Optimization of process Parameters of Mechanical Type Advanced Machining Processes using Genetic
Algorithms”, International Journal of Machine Tools & Manufacture, Vol. 47, pp. 900-919, 2007.
[9] M. Alauddin, M.A. El Baradie and M.S.J. Hasmi, “Prediction of Tool Life in End Milling by Response Surface Methodology”, Journal
of Material Processing Technology, Vol. 71, No. 1, pp. 456-465, 1997.
[10] A.S. Mohruni, “Performance Evaluation of Uncoated and CoatedCarbideTools when EndMilling of TitaniumAlloy using
ResponseSurfaceMethodology. Thesis for Doctor of Philosophy, UniversitiTeknologi Malaysia, Skudai, Johor, Malaysia,2008.
Page 1389
WELCOME FROM THE RECTOR OF UNIVERSITAS INDONESIA
I am honoured to have the opportunity to officially welcome
you to the 12th International Conference on QiR (Quality in
Research) 2011. As we are all aware that the impact of
globalization has resulted in a very competitive business
environment; a condition that makes the fulfillment of the
needs of customer/clients’ ever–sophisticated project,
product, or service most challenging. Without any doubt, a
sustainable design and technology is the key factors in assisting our industries to
enhance their contributions to the future development of humanity. Therefore, it is
our hope that this conference will be able to provide an international forum for
exchanging knowledge and research expertise as well as creating a prospective
collaboration and networking on various fields of sustainable engineering and
architecture.
In order to achieve business objectives and benefits, engineering products or
projects require various resources, skills, and technology. Accordingly, we need an
application of knowledge, tools, and techniques necessary to develop sustainable
products or projects, which are environmentally friendly, produced through efficient
processes, and adapted to local conditions. And this may be achieved by ecotechnology. Eco-technology is a technology that will give consumers what they
want; lower cost, convenience, save money and deliver what people everywhere
needs: less waste, less pollution, and green environment. Eco-technology practices
can facilitate to conserve and restore the environment through the integration of
engineering and ecological principles. However, eco-technology requires
multidisciplinary synthesis of knowledge and skills; and the development and
application of this technology in the sector of industry and services is therefore a
crucial requirement for sustainable development process. For this reason, we
urgently need new technologies and practical applications to be further developed
based on the current knowledge.
Accordingly, I hope this conference can be a kick-off for the strengthened action
and partnerships on creating a platform for us; national and international thinkers,
academics, government officials, business executives and practitioners, to present
and discuss the pivotal role of engineers in creating sustainable development.
I would like to thank the Faculty of Engineering of Universitas Indonesia for organizing
this meaningful and timely event, and supporting organizations for their participation
and contributions. I am sure that you will all find this conference stimulating and
rewarding and with this, I wish you all a fruitful conference.
Prof. Dr. der. Soz. Gumilar Rusliwa Somantri
Rector
Universitas Indonesia
ii
PREFACE
WELCOME FROM THE DEAN OF FACULTY OF ENGINEERING
UNIVERSITAS INDONESIA
On behalf of the Faculty of Engineering, University of Indonesia,
it is my greatest pleasure to extend our warmest welcome to all
of you to the 12th International Conference on QiR (Quality in
Research) 2011. As we know that this conference is conducted
to cover a wide range of sustainable design and technology
issues, I hope this two days-conference will be spent in
interesting discussions and exchange of ideas. I also hope that
this conference will be able to provide a state-of-the-art information and knowledge
in this challenging world of sustainable design and technology. The growing success
of our institutions and expertise should urge us to develop our competitive
capabilities, especially when we face certain challenges which should be
overcome with hard work, cooperation, and working together hand in hand. We will
work together to develop a common path and develop collaboration opportunities
for future action and research on multi-disciplinary engineering areas for quality of
life and humanity.
I am delighted that you have accepted our invitation to this conference in such a
large numbers as indicated and that we will have many international speakers and
papers from various countries to be presented and discussed in these two days. We
will explore various issues on sustainable development and we must widen the scope
of sustainability from a product-, system-, or an individual building-scale to the whole
community-scale. At the same time, we have to widen the focus from ecological
aspects to social and economic aspects. This means that environmental solutions
should always be considered from the aspects of human health and well-being,
safety, and economic point of view. This conference provides an excellent forum for
engineering professionals, business executives, industry practitioners, and
academicians to exchange ideas and to share their experience, knowledge and
expertise to each other.
I would like to thank our sponsors, supported bodies, and various contributors for their
generous support of this conference. I would also like to thank our distinguished
speakers for agreeing to share their insights with us. To our friends from overseas and
other provinces of Indonesia, I would also like to extend a warm welcome to you
and wish you an enjoyable stay in Bali. Last but not least, I would invite you to join
me in thanking the committed staff that made this conference happen and to
make it success.
I wish us much success in the deliberations, discussions, and exchange of ideas
which we will have within this conference and I wish you a very pleasant and
enjoyable stay here in Bali.
Prof. Dr. Ir. Bambang Sugiarto, M.Eng
Dean Faculty of Engineering
Universitas Indonesia
iii
PREFACE
WELCOME FROM THE QiR 2011 ORGANIZING COMMITTEE
On behalf of the Organizing Committee, it is my greatest
pleasure to extend our warmest welcome to all of you to the
12th International Conference on QiR (Quality in Research)
2011. The selected theme for this year’s conference is
“Integrated Design in Urban Eco-Technology for Quality of Life
and Humanity”. With this theme, the conference focuses on
the scientific analysis and design of the key factors explaining
the success applications of integrated design in urban eco-technology, their market
perspectives, and their contributions to the existing and future development of
humanity. In line with this theme, it is our utmost pleasure to hold the QiR 2011 in
conjunction with the 2nd International Conference on Saving Energy in Refrigeration
and Air Conditioning (ICSERA 2011).
With its continuous presence for 12 years, QiR has become an icon for Faculty of
Engineering Universitas Indonesia in serving the objectives to provide engineering
excellence for both national and international in all aspects of engineering, design,
and architecture. For the first time, the QiR 2011 is held in a famous beautiful island of
Indonesi - Bali. The QiR 2011 is supported by Universitas Udayana, in the spirit of
strengthening of cooperation and mutual growth to be world class institution. I am
delighted to inform you that we have such a large number of participants today, as
indicated, that we will have 21 invited speaker presentation and more than 520
papers from more than 20 countries to be presented and discussed during these two
days-conference. We are fortunate to have a lot of good quality papers belong to:
32 papers on ICSERA
39 papers on Chemical Engineering
115 papers on Electrical Engineering
37 papers on Mechanical and Naval Architecture Engineering
101 papers on Materials Engineering
54 papers on Architecture & Planning
75 papers on Industrial Engineering
72 papers on Civil Engineering
I would like to thank all contributors, speakers and participants for your generous
support to this conference. It is my pleasant duty to thank all the members of
Organizing Committee and the International Board of Reviewers for their advices
and help. We are grateful to all Sponsors, Supporters, Exhibitors, Partner Universities
and Professional Associations, for their spontaneous response and encouragement
through committing funds and extending help in kind. I would like to sincerely thank
the Rector of Universitas Indonesia and the Dean of Faculty of Engineering, for fully
supporting the Committee and providing all supports to make this conference
happen and to make it a success.
I wish you a very pleasant stay here in Bali; and finally, let me wish all of you a
meaningful and fruitful conference. Thank you and we hope to see you again at the
QiR 2013.
Prof. Dr. Ir. Bondan T. Sofyan, M.Si.
Chairman of QiR 2011 Organizing Committee
iv
Proceeding of the 12th International Conference on QiR (Quality in Research)
Faculty of Engineering, University of Indonesia, Depok, Indonesia, 4-7 July 2011
ISSN 114-1284
TABLE OF CONTENTS
SYMPOSIUM A
A1.1_Masafumi Yohda_Catalytic Mechanism of Nitrile Hydratase Proposed by Time-Resolved X-Ray
Crystallography…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……1
A1.2_Siswa Setyahadi_Bioconversion of Extraction Chitin from Penaeus Vannamei Shell Waste………….3
A1.3_Indu Shekhar Thakur_Bioremediation and bioconversion of chromium and pentachlorophenol in
tannery effluent by microorganisms…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……...10
A1.4_Mukh Syaifudin_Pre-Erythrocytic Stage of Plasmodium as the Best Choice of Vaccine Development
for Malaria with Nuclear Technology…..…..…..…..…..…..…..…..…..…..…..…..………………………..11
A1.5_Misri Gozan_Cellulase Immobilization Using Reversible Soluble-Insoluble Polymer……………….20
A1.7_Muhammad Sahlan_Organic Co-Solvent Stability of the Chaperones from Hyperthermophilic Archaea
Thermococcus sp…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………............................21
A2.1_Mahmud Sudibandriyo_Effect of Adsorbed Phase Density on High Pressure Adsorption Isotherms..22
A2.3_Sutrasno Kartohardjono_Ammonia Removal from Aqueous Solution through Hollow Fiber Membrane
Contactor Using Natural Hot Spring Water (NHSW) as Absorbent…..…..…..…..…..…..…..…..…………29
A2.5_Yuliusman_Producing Activated Carbon from Corn Cob for Cu, Pb, and Ammonia Adsorption……30
A2.6_Herliati_Simulation of Epichlorohydrin Synthesis from Dichloropropanols in Reactive Distillation
Column Using Aspen Plus………….…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……39
A2.7_Setiadi_A Study On The Crystallization Stage Of The ZSM-5 Crystal Structure For Improving The
Zeolite Synthesis Route…………..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………......43
A2.8_Yuswan Muharam_Model to Predict Species Concentrations from the Oxidation and Combustion of
the Mixture of N-Heptane and Iso-Octane…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…...50
A3.1_Yurita Puji_Optimization of Pipeline Network for Gas Distribution using Genetic Algorithm………59
A3.2_Rita Arbianti_Production of Electricity Energy in Microbial Fuel Cell System Using Saccharomyces
Cerevisiae…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………...…..…..…..…..…..…..65
A3.3_Dianursanti_The Effects of Cells Density Arrangement in Chlorella vulgaris Culture to CO2 Fixation
and Essential Substances Production. …..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……72
A3.4_Heri Hermansyah_Esterification of Oleic Acid with Octanol to Produce Wax Ester using Candida
rugosa lipase.. …..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………................................77
A3.5_Listio Sambono_Application Analysis of Underground Storage As an Alternative For Natural Gas
Storage Facilities in West Java Pipeline Distribution Network……………………………………………...83
A4.1_Suripto Dwi Yuwono_Lactic Acid Production From Fresh Cassava Roots by Streptococcus bovis
using Single stage membrane bioreactor. …..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……86
A4.2_Muhammad Zakir_Amino Acid Composition of Rice Bran Concentrate from Several Local Rice
Varieties as a Potential Source of Bio-emulsifier Material. …..…..…..…..…..…..…..…..…..…..…..……..92
A4.3_Edita Martini_Bead Formation Mechanism In Cellulase Entrapment Using Calcium Alginate……...98
A4.5_Edi Iswanto Wiloso_Environmental Impacts of Bioethanol from Oil Palm Lignocellulosic Biomass An LCA Perspective…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..……….....................104
A5.1_Nelson Saksono_Hydrogen Production Using Non-Thermal Plasma Electrolysis…………………..112
A5.2_Eva F. Karamah_Degradation of Phenol By Combination of Ozonation and Cavitation……………119
A5.4_Eny Kusrini_Micro and Nanoparticle of Lanthanide Complexes for Photosensor Application……..127
A6.1_Praswasti PDK Wulan_Production Of CO2-Free Hydrogen and Nanocarbon Using Carbon FoamSupported Nickel Catalyst……..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..…..………........128
A6.2_Yuswan Muharam_Simulation of Ignition Delay Times in the Oxidation and Combustion of the
Mixture of n-Heptane and Isooctane………………………………………………………………………..133
A6.3_Muhammad Sahlan_Rapid Purification of Phospholipase A2 from Acanthaster Planci……………138
A6.4_Nuryetti_Characteristical Bionanocomposites Cassava StarchZnO With added glycerol…………...139
v
Proceeding of the 12th International Conference on QiR (Quality in Research)
Faculty of Engineering, University of Indonesia, Depok, Indonesia, 4-7 July 2011
ISSN 114-1284
E5.5_Efendi Mabruri_Phase Identification and Microstructure of Ni-Ti-Cu..............................................1379
E5.6_A.S. Mohruni_Optimization of Cutting Conditions.... ......................................... .............................1384
E5.7 _R.D. Ramdan_Shear Mechanisms During Cryogenic ... .................................................................1390
E6.1 _(Invited) Jinn P Chu_Amorphization and Fatigue Property Enhancements .....................................1397
E6.2 _IN Sudiana_Study of high quality......................................................................................................1399
E6.3 _Alva E.Tontowi_Effect of PVA coating............................................................................................1403
E6.4 _Anne Zulfia_Al-SiSiC Metal Matrix Composites.............................................................................1410
E6.6 _V. Vekky R. Repi_Permittivity and Permeability of Mn-Ti.... .........................................................1411
E7.1 _(Invited) Eung-Ryul Baek_Surface Modification of Hot-Dip Aluminized HPF Steel……………..1414
E7.2 _(Invited) Fazwar Bujang_Production of HSLA Steel for Sour Service .... ……………………….1415
E7.3 _Irfan P. Hidayat_Neural Networks with Radial Basis Function .... ...................................................1423
E7.4 _Rini Riastuti_Grain size refinement.... ..............................................................................................1424
E7.5 _K. M. Hafez_Failure Investigation of a Bypass Elbow Tube .... ………………………………...1428
E7.6 _Effect of the Base Metal.....................................................................................................................1435
E8.1 _Juliewatty J.M_Effect of Milling on the Synthesis............................................................................1436
E8.2 _Bambang Suharno_The Effects of Plates Position in Vertical Casting .... ………………………1440
E8.3 _Myrna Ariati_Comparison of Two Calculation Methods .................................................................1441
E8.4 _Parikin_Crystalline Structure, Hardness and Microstructure of ZrNbMoGe All
oy…………..1446
E8.6 _Suyitno_Fracture study of As-cast.... ……………………………………………………………..1456
E8.7 _Dwi Rahmalina_Development of Steel Wire Rope - Reinforced Aluminium Composite ...............1451
E8.8 _I.K. Gede Sugita_Mechanical Properties and Damping....................................................................1452
E9.1 _Masumi Obara_Slowly Relaxing Structural Defects of Zinc Films .................................................1468
E9.2 _A. Djehiche_Colloid particles Deposition in.... ……………………………………………………1469
E9.3 _Hadi Suwarno_Analysis of TheFe-Ti and Mg-Ti-Fe Alloys .... ………………………………...1474
E9.4 _M. Hikam_Characterization of BST Thin Films doped by Indium .................................................1475
E9.5 _M.K. Herliansyah_Development and Characterization of Bovine Hydroxyapatite ......................1481
E9.6 _Adianto_Low pressure deposition.... ……………………………………………………………..1482
Plenary Lecture 1 Joe Greene_Design Strategies for the Growth of Self-organized 3D Thin Film............1489
Plenary Lecture 4 Akhmad Herman Yuwono_Sol-Gel derived TiO2 - PMMA Nanocomposites .............1490
SYMPOSIUM F
F1.1_Jiat Hwee_Notes on a few Tropical Variants of Sustainable Architecture……………………….....1492
F1.2_Marcus Gartiwa_Reactualization of Sustainable Wisdom of Vernacular Architecture Case study
Sustainable Wisdom. ........................................................................... .......................................................1506
F1.3_Kemas R. Kurniawan_Tropical Ideas on Designing National Architecture in Indonesia a Case of
Friedrich Silaban. ........................................................................................................................................1514
F1.4_Nangkula Utaberta_Study and Classification on the Apllication of Tanggam System in the Traditional
Malay House of Malaysia. ...........................................................................................................................1519
F10.1_Nangkula Utaberta_Campus Sustainability Design in Malaysia An Evaluation of Students Perception
on Four Research Universities Campus in Malaysia. ..................................................................................1526
F10.2_Siti Handjarinto_Study of Building Information Modeling (BIM) Towards Multidiscipline Integrated
and Sustainable Design. ..............................................................................................................................1533
F10.3_Mohd.Syarif Hidayat_Reorientation of Architectural Education in Indonesia Integration of Building
Physics Substance in Architectural Design Process.. ..................................................................................1540
F11.3_Agung Murti Nugroho_A Ventilated Building Envelope...A Ventilated Building Envelope as A
Passive Cooling Strategy in The Hot Humid Tropics. ................................................................................1547
xii
Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
Optimization of Cutting Conditions when End Milling
Aeronautic Materials (Ti-6Al-4V) using Genetic Algorithm
and Response Surface Methodology
A.S. Mohrunia, S. Sharifb, M.Y. Noordinb, R. Hansona
a
Faculty of Engineering,
Sriwijaya University,
Indralaya, 30662 OI-Indonesia
Tel. +62-711-580062 Fax. +62-711-580741
E-mail : mohrunias@yahoo.com, mohrunias@unsri.ac.id
b
Faculty of Mechanical Engineering,
Universiti Teknologi Malaysia, 81310-UTM Skudai,
Johor, Malaysia
ABSTRACT
The present work was initiated to explore the optimum tool performance in machining of Ti-6Al-4V using Super-Nitride (SNTR)
coated WC-Co end mills under wet conditions. Ti-alloys, particularly α + β alloys such as Ti-6Al-4V, have been the focus of
considerable research recently because of their high specific strength to weight ratio, which is even maintained at elevated
temperatures, excellent fracture toughness, extensive ductility and corrosion resistance. These properties make Ti-alloys the
most attractive metallic materials for metal working, aeronautic industry, chemical industry, marine environments, and
biomaterials applications. The Response Surface Methodology (RSM) and Genetic Algorithm (GA) were used in finding the
optimum machining conditions. It was proven that overall performance using GA delivers better results than RSM, when the
experimental trials were conducted according to design of experiments (DOE).
Keywords
Optimum Tool Performance, Super-Nitride, Titanium Alloys, Response Surface Methodology, Genetic Algorithm
1. INTRODUCTION
As mentioned above, ti-alloys, particularly α + alloys such as Ti-6Al-4V, have been the focus of considerable research
recently, because of their excellent fracture toughness, extensive ductility, corrosion resistance and high specific strength to
weight ratio (E/ρ), which is even maintained at elevated temperatures (250 oC – 600 oC). These properties make Ti-alloys the
most attractive metallic materials for metal working, aeronautic industry, chemical industry, marine environments, and
biomaterials applications [1]-[2]. On the other hand previous studies have shown that titanium alloys are considered as the
difficult to machine materials because of its low thermal conductivity, its high heat capacity and high chemical reactivity,
regardless of the type materials used[3]-[5]. To overcome such situation, the optimum cutting conditions play a significant role
in machining of difficult to cut materials. One of the optimum cutting conditions that result in the best tool performance using
RSM was reported by[6]. Another investigation were carried out by [7] and [8] using genetic algorithms for machining
processes. They reported that genetic algorithm can be utilized for investigating the optimum machining conditions. None of
previous studies were focused for optimizing of cutting conditions on aerospace materials using this algorithm. This challenge
was taken into consideration in this study, to fill the lack of information in this field. Therefore, further investigation of
utilization of a genetic algorithm, was employed for optimizing of machining conditions on titanium alloys.
2. EXPERIMENTAL SET-UP
The tests were carried out with a constant aa (axial depth of cut) 5mm and ae (radial depth of cut) 2mm under flood conditions
with a 6% concentration of water base coolant using MAHO 700S CNC machining center for side milling operation. The grade
K-30 solid carbide end mill cutters, with PVD Super Nitride coated which were prepared with different radial rake angle
according to Design of Experiment (DOE), were used for experimentation
The reference workpiece material was a rectangular bar (110 x 110 x 270 mm) of Ti-6Al-4V. Tool life criteria used were
VBmax ≥ 0.25 mm, chipping VBave ≥ 0.β0 mm and catastrophic failure.
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Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
Tool wear was measured using a Nikon tool makers’ microscope with γ0x magnification. The measurements of tool wear
according to ISO 8688-2 were carried out for each cutting edge at initial cut and continuously after a particular length of cut
(depend on wear progressive of each tool) until the end of tool life was achieved.
The independent variables such as cutting speed, feed, and radial rake angle coded with the following equation by taking into
consideration the capacity and limiting cutting conditions of milling machine.
(1)
Where x is the coded variable of any factor corresponding to its natural ,
is the natural value at the +1 level and , is the
natural value of the factor corresponding to the base or zero level[9]. The level of independent variables and coding
identification are illustrated in Table 1.
Table 1: Levels of independent variables for end milling Ti6Al4V
Independent
Variable
V (m.mm-1)
x1
fz (mm.tooth-1)
x2
o
o ( )
x3
-α
-1
Level in coded form
0
1
+α
124.53
130
144.22
160
167.03
0.025
0.03
0.046
0.07
0.083
6.2
7.0
9.5
13.0
14.8
3.RESEARCH METHODOLOGY
The mathematical models which were built using RSM will be utilized to find the optimum cutting condition using GA. The
results delivered by using GA, were compared to the results using RSM[10]. The models can be described as 3F1 and 2nd CCD
mathematical model.
The 3F1 mathematical model can be illustrated as:
(2)
with the following ranges of cutting speed Vc, feed per tooth fzand radial rake angle
0.03 ≤ fz ≤ 0.07mm tooth-1 ; and 7 ≤ o≤ 13 (º).
while the 2nd CCD mathematical model illustrated as follow:
o:
1γ0≤ Vc≤ 160m.min-1;
(3)
with the following ranges of cutting speed Vc, feed per tooth fz and radial rake angle
≥0.08γmm tooth-1 ; and 6.β ≤ o ≥ 14.8 (º).
o:1β4.5γ≤
Vc ≥ 167.0γm.min-1; 0.0β5≤ fz
GA form a class of adaptive heuristics base on principles derived from the dynamic of natural population genetic. The
searching process simulates the natural evaluation of biological creatures and turns out to be an intelligent exploitation of a
random search.
The problem to be solved using GA is coded to binary numbers known as chromosomes. Each chromosome contains the
information of a set of possible process parameters. The population of chromosomes is formed randomly. The fitness of each
chromosome is then evaluated using an objective function after the chromosome has been decoded. Selected individuals are
then reproduced; the selecting occurs usually in pairs through the application of genetic operator. This operator is applied to
pairs of individuals with a given probability, and result in a new offspring. The offspring from reproduction are then further
perturbed by mutation. These new individuals then make up the next generation. These processes of selection, reproduction
and evaluation are repeated until some termination criteria are satisfied. The representing of GA is illustrated in Figure 1.
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Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
In order to optimize the present problem using GA, the following parameters such as population size, maximum number of
generation, total string length, crossover probability, mutation probability, and elitism probability have to be selected to obtain
optimal solution with less computational efforts.
Figure 1: Flow chart of GA methodology approach.
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Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
4. RESULTS AND DISCUSSION
Tool life experimental results for SNTR coated carbide tools are illustrated in Table 2These results are used to validate the
comparison between the optimization using RSM and GA.
Table 2: Tool life result for SNTR coated carbide tools
Std
Or
der
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Type
Cutting speed V
[m/min]
Factorial
Factorial
Factorial
Factorial
Factorial
Factorial
Factorial
Factorial
Center
Center
Center
Center
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
Axial
-1
1
-1
1
-1
1
-1
1
0
0
0
0
-1.4142
-1.4142
1.4142
1.4142
0
0
0
0
0
0
0
0
Feed rate fz
[mm/th]
Radial Rake
angle [°]
Tool Life [min]
-1
-1
1
1
-1
-1
1
1
0
0
0
0
0
0
0
0
-1.4142
-1.4142
1.4142
1.4142
0
0
0
0
-1
-1
-1
-1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
-1.4142
-1.4142
1.4142
1.4142
20.09
8.85
2.41
0.41
22.2
9.68
2.72
0.46
5.77
6.04
5.69
5.94
16.12
15.95
2.56
2.70
16.44
16.03
0.44
0.43
4.94
4.43
5.55
5.29
Table 3: The optimization results using RSM and GA
Std
Order
Experimental Results
(min)
Response Surface
Methodology (min)
Genetic Algorithm
(min)
1
20.09
20.02
20.09
2
8.85
8.78
8.88
3
2.41
2.43
2.28
4
0.41
0.41
0.53
5
22.2
22.27
22.12
6
9.68
9.76
9.94
7
2.72
2.70
2.73
8
0.46
0.46
0.50
9
5.77
3.84
3.82
10
6.04
3.84
3.82
11
5.69
3.84
3.82
12
5.94
3.84
3.82
13
16.12
16.14
15.64
14
15.95
16.14
15.64
15
2.56
2.61
2.58
16
2.7
2.61
2.58
17
16.44
19.59
15.38
18
16.03
19.59
15.38
19
0.44
0.52
0.43
20
0.43
0.52
0.43
21
4.94
4.67
4.55
22
4.43
4.67
4.55
23
5.55
5.42
5.27
24
5.29
5.42
5.27
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Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
Table 4: Comparison between RSM and GA validated using the experimental results.
Experimental
RSM
Results
(min)
(min)
1
20.09
20.02
2
8.85
8.78
3
2.41
2.43
4
0.41
0.41
5
22.2
22.27
6
9.68
9.76
7
2.72
2.70
8
0.46
0.46
9
5.77
3.84
10
6.04
3.84
11
5.69
3.84
12
5.94
3.84
13
16.12
16.14
14
15.95
16.14
15
2.56
2.61
16
2.7
2.61
17
16.44
19.59
18
16.03
19.59
19
0.44
0.52
20
0.43
0.52
21
4.94
4.67
22
4.43
4.67
23
5.55
5.42
24
5.29
5.42
MSE (Mean Square Error)
RMSE (Root Mean Square Error)
Std
Order
GA
(min)
Error of RSM
20.09
8.88
2.28
0.53
22.12
9.94
2.73
0.50
3.82
3.82
3.82
3.82
15.64
15.64
2.58
2.58
15.38
15.38
0.43
0.43
4.55
4.55
5.27
5.27
Error of GA
0.0043
0.0054
0.0003
0.0000
0.0053
0.0066
0.0004
0.0000
4.0815
4.0815
4.0815
4.0815
0.0106
0.0106
0.0005
0.0005
11.2526
11.2526
0.0065
0.0065
0.0002
0.0002
0.0000
0.0000
1.620391906
1.272946152
0.0000
0.0011
0.0159
0.0140
0.0060
0.0662
0.0001
0.0014
4.1811
4.1811
4.1811
4.1811
0.1564
0.1564
0.0021
0.0021
0.7328
0.7328
0.0001
0.0001
0.0188
0.0188
0.0230
0.0230
0.778974202
0.882595152
The optimization results using RSM and GA are shown in Table 3. The Mean Square Error (MSE) of both methods are figured
out in Table 4. From this table, it can be concluded that the optimization using GA delivered better results than that using
RSM. It can be recognized from the value of MSE of each approach.
E XP E R IME NTAL VS R S M VS AG
30
Umur Pahat (min)
25
20
15
Experiment
RSM
10
AG
5
0
0
5
10
15
20
25
30
-5
Std Order
Figure 2: Error Distribution of both optimization methods validated by experimental results.
To provide easier observation of errors, the occured errors was represented and visualized in Figure 2. Finally, it can be
concluded from the optimization results that GA has the ability and is suitable for achieving the best possible tool life when
end milling Ti-64 in combination of cutting speed, feed rate, and radial rake angle.
5. CONCLUSIONS
1) The better overall performance in finding the optimum cutting conditions was delivered by GA compared to RSM. This
can be recognized from its accuracy using the validation tests.
Page 1388
Proceeding of the 12th International Conference on QiR (Quality in Research)
Bali, Indonesia, 4-7 July 2011
ISSN 114-1284
2) The best results of GA was produced using following parameters:
- Population size
: 80
- Number of generation
:5
- Total string length
: 34
- Crossover probability (Pc) : 0.8
- Mutation probability (Pm) : 0.03
- Elitism probability
: 0.5
3) Even GA delivers better results than RSM, the difference between them was not significant.
4) It was found that GA can only give better results when the optimum parameters were taken in the iterations.
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