Abstract
Bearing Housing is the critical part in Air end assembly of Screw compressor, because it determines the Discharge end clearance (DEC) which in term determine the volumetric and adiabatic efficiency. For setting a DEC in air end assembly, it is important to maintain the shoulder thickness of bearing housing within close tolerance of 10 µm. If not maintained so, metallic shim to be added in assembly process to maintain the clearance. Metallic shim selection for each assembly involves iteration method which is time consuming process. However due to machining constraint the current tolerance which achieved is 100 µm but the requirement is 10microns. If the improvement is done to achieve the required tolerance, DEC setting time can be reduced by eliminating iteration shim setting process. The aim of this project is to achieve the linear & Geometric dimensions within deserved critical tolerance in milling thin wall areas of housings in CNC milling machine by optimizing the process parameters using Design of experiments (DOE) and Finite element analysis (FEA). DOE with cutting parameters using Response surface modeling (RSM) with face centered design is used to obtain the significance level of Cutting speed, feed and Depth of cut. Optimize the tool cutting parameters to minimize the tool and part deflection during machining. FEA is used to reach the optimum clamping area and force to minimize the part deflection & deformation.