L16 Orthogonal Array For Tool Life, IRAQ Univ.
L16 Orthogonal Array For Tool Life, IRAQ Univ.
L16 Orthogonal Array For Tool Life, IRAQ Univ.
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ABSTRACT:
The present work studied the performance of a carbide tool with a chemical composition of
(65% W, 14 % Ti, 9 % Co and 12 % C). Turning tests were conducted on a workpiece of mild steel
(AISI 1020) using four spindle speeds (80, 315, 500 and 800 rpm), two feed rates (0.2 and 0.5
mm/rev) and two depth of cut (0.5 and 0.7 mm). Taguchi method is a statistical approach to
optimize the process parameters and improve the quality of components that are manufactured. The
objective of this study is using Taguchi method to optimize the machining conditions of a turning
operation such as spindle speed; feed rate and depth of cut. Orthogonal array, signal-to-noise ratio,
and analysis of variance were employed using Mtb14 software to study the performance
characteristics on turning operation represented by the tool life. Accordingly, a suitable mixed
orthogonal array L16 (3×4) was selected. The tool life was measured basing on a maximum flank
wear width of 0.3 mm.Optimum parameter values were obtained and confirmation experiments
were carried out. The analysis results showed that the parameter design of the Taguchi method
provides a simple, systematic, and efficient methodology for optimizing the process parameters.
Only 6.4 % error was recorded. The regression analysis was applied using Datafit ver.9 software.
The results of the analysis showed that the non-linear quadratic polynomial appears to be more
suitable to represent the relation of the spindle speed, feed rate and depth of cut with the tool's wear
life. .
Key words: Tool life, Machining parameters, Taguchi method, Flank wear, Optimization, Modeling.
(AISI 1020)طﺮﯾﻘﺔ ﺗﺎﻛﻮﺟﻲ ﻷﻣﺜﻠﯿﺔ طﺮق اﻟﺘﺸﻐﯿﻞ اﻟﻤﺆﺛﺮة ﻋﻠﻰ ﻋﻤﺮ اﻟﺒﻠﻰ ﻟﻠﻌﺪد اﻟﻜﺎرﺑﯿﺪﯾﺔ اﻟﻤﺴﻤﻨﺘﺔ ﻓﻲ ﺧﺮاطﺔ اﻟﻔﻮﻻذ
:اﻟﺨﻼﺻﺔ
65% W, 14 %Ti, 9 % Co and 12 ) اﻟﻌﻤﻞ اﻟﺤﺎﻟﻲ ﯾﺪرس أداء اﻟﻌﺪة اﻟﻜﺎرﺑﯿﺪﯾﺔ ذو ﺗﺮﻛﯿﺐ ﻛﯿﻤﯿﺎﺋﻲ ﯾﺘﻀﻤﻦ
( ﺑﺎﺳﺘﻌﻤﺎل ارﺑﻌﺔ ﺳﺮعAISI 1020) اﺧﺘﺒﺎرات اﻟﺨﺮاطﺔ ﻗﺪ اﺟﺮﯾﺖ ﻋﻠﻰ ﻣﺸﻐﻮﻟﺔ ﻣﻦ ﻓﻮﻻذ ﻣﻄﯿﻠﻲ. (% C
وﻗﯿﻤﺘﯿﻦ, دورة/( ﻣﻠﻢ0.2 and 0.5) ﻗﯿﻤﯿﺘﯿﻦ ﻟﻤﻌﺪل اﻟﺘﻐﺬﯾﺔ, دﻗﯿﻘﺔ/( دورة80, 315, 500, 800 ) دوراﻧﯿﺔ
طﺮﯾﻘﺔ ﺗﺎﻛﻮﺟﻲ ھﻲ ﻣﻨﮭﺞ إﺣﺼﺎﺋﻲ ﻟﺘﺤﺴﯿﻦ ﻣﺤﺪدات اﻟﻌﻤﻠﯿﺔ وﺗﺤﺴﯿﻦ ﻧﻮﻋﯿﺔ. ( ﻣﻠﻢ0.5 and 0.7 ) ﻟﻌﻤﻖ اﻟﻘﻄﻊ
ھﺪف ھﺬه اﻟﺪراﺳﺔ ھﻮ ﺗﻮﺿﯿﺢ اﻷﺟﺮاء اﻟﻤﺴﺘﻌﻤﻞ ﻓﻲ اﺳﺘﺨﺪام طﺮﯾﻘﺔ ﺗﺎﻛﻮﺟﻲ ﻟﺘﺤﺴﯿﻦ.اﻟﻤﺮﻛﺒﺎت اﻟﻤﺼﻨﻌﺔ
, اﻟﻤﺼﻔﻮﻓﺔ اﻟﻤﺘﻌﺎﻣﺪة. ﻣﻌﺪل اﻟﺘﻐﺬﯾﺔ وﻋﻤﻖ اﻟﻘﻄﻊ,ظﺮوف اﻟﺘﺸﻐﯿﻞ ﻓﻲ ﻋﻤﻠﯿﺔ اﻟﺨﺮاطﺔ ﻣﺜﻞ اﻟﺴﺮﻋﺔ اﻟﺪوراﻧﯿﺔ
ﻟﺪراﺳﺔ ﻣﻤﯿﺰات اﻻداة ﻓﻲ ﻋﻤﻠﯿﺔMtb 14 ﻧﺴﺒﺔ اﻷﺷﺎرة اﻟﻰ اﻟﻀﻮﺿﺎء وﺗﺤﻠﯿﻞ اﻟﺘﺒﺎﯾﻦ ﻗﺪ ﺗﻢ اﺳﺘﺨﺪاﻣﮭﺎ ﺑﺄﺳﺘﻌﻤﺎل
ﻋﻤﺮ. ﻗﺪ ﺗﻢ اﺧﺘﯿﺎرھﺎL16 (3×4) ﻣﺼﻔﻮﻓﺔ ﻣﺘﻌﺎﻣﺪة ﻣﺨﺘﻠﻄﺔ وﻣﻨﺎﺳﺒﺔ, وﻓﻘﺎ ً ﻟﺬﻟﻚ.اﻟﺨﺮاطﺔ ﻣﺘﻤﺜﻠﺔ ﺑﻌﻤﺮ اﻻداة
اﻟﻈﺮوف اﻟﻤﺜﻠﻰ ﻗﺪ ﺗﻢ اﻟﺤﺼﻮل. (0.3 mm) اﻟﻌﺪة ﻗﺪ ﺗﻢ ﻗﯿﺎﺳﮫ اﻋﺘﻤﺎدا ﻋﻠﻰ ﻋﺮض اﻟﺒﻠﻰ اﻟﺨﻠﻮﺻﻲ اﻻﻗﺼﻰ
ﺗﺤﻠﯿﻞ اﻟﻨﺘﺎﺋﺞ اﻟﺘﺠﺮﯾﺒﯿﺔ اظﮭﺮت أن ﺗﺼﻤﯿﻢ اﻟﻤﻌﻠﻤﺔ ﺑﻄﺮﯾﻘﺔ ﺗﺎﻛﻮﺟﻲ. ﻋﻠﯿﮭﺎ واﺧﺘﺒﺎرات اﻟﺘﺤﻘﻖ ﻗﺪ ﺗﻢ ﺗﻨﻔﯿﺬھﺎ
ﺗﺤﻠﯿﻞ. ﻧﺴﺒﺔ ﺧﻄﺄ ﻗﺪ ﺳﺠﻠﺖ6.4 % ﻓﻘﻂ. ﻣﻨﮭﺠﯿﺔ وﻓﻌﺎﻟﺔ ﻟﺠﻌﻞ ظﺮوف اﻟﻌﻤﻠﯿﺔ ﻣﺜﺎﻟﯿﺔ,زودت طﺮﯾﻘﺔ ﺑﺴﯿﻄﺔ
ﻧﺘﺎﺋﺞ ھﺬا اﻟﺘﺤﻠﯿﻞ اظﮭﺮت ان اﻟﻤﺘﻌﺪد اﻟﺤﺪود ﻣﻦ. اﻟﺘﺮاﺟﻊ ﻗﺪ ﺗﻢ اﺿﺎﻓﺘﮫ ﺑﺎﺳﺘﻌﻤﺎل ﺑﺮﻧﺎﻣﺞ داﺗﺎﻓﺖ اﻟﻨﺴﺨﺔ اﻟﺘﺎﺳﻌﺔ
ﻣﻌﺪل اﻟﺘﻐﺬﯾﺔ وﻋﻤﻖ اﻟﻘﻄﻊ ﻣﻊ, اﻟﺪرﺟﺔ اﻟﺜﺎﻧﯿﺔ ﻏﯿﺮ اﻟﺨﻄﻲ ھﻮ اﻛﺜﺮ ﻣﻼﺋﻤﺔ ﻟﺘﻤﺜﯿﻞ اﻟﻌﻼﻗﺔ ﺑﯿﻦ اﻟﺴﺮﻋﺔ اﻟﺪوراﻧﯿﺔ
. . ﻋﻤﺮ اﻷداة
1. INTRODUCTION:
The tool is an important part required in material removal process in order to produce the
components. It not only provides product but also maintains the geometricaltolerances, dimensional
accuracies and surface finish of the outcome. The manufacturing industry is striving to improve the
productivity, quality and longer tool life. Achievement of longer tool life depends on different factors
such as cutting parameters, tool wear, hardness of the work piece and machine tool materials [1,2].
Many improvements can be done to obtain longer tool life duration like changing the tool material,
tool geometry, tool edge honing, optimizing machining conditions, using coolants and applying thin
layer coating. Tool wear influences cutting power, machining quality, tool life and machining cost.
Whentool wear reaches a certain value, variation in cutting force and cutting temperature will
causesurface integrity deteriorated and dimension error greater than tolerance. When machining steel
with uncoated carbide tools, different tool wear mechanisms occur, such as: abrasion, adhesion,
oxidation and even some diffusion, which act simultaneously and mainly depending on the
temperature [3,4]. Bala Murugan Gopalsamy et al. in 2009 [5] applied Taguchi method and analysis
of variance ANOVA for machining parameters optimization during machining hardened steel.
ANOVA, signal-to-noise ratio, and L18 array had been used to study the performance characteristics
of the machining conditions ( feed rate, cutting speed and depth of cut ) with consideration of tool
life and surface roughness. S.R. Das et al. in 2014 [6] experimentally investigated the effects of the
machining conditions on the behaviour characteristics (surface roughness, cutting force and flank
wear) by using multi layer coated carbide insert in hard turning of AISI 4340 steel. Taguchi standard
has been used to develop the regression models for machining response. Results showed that, the
most significant factor on flank wear is the cutting speed and that the feed rate has statistical
significance on the surface roughness.
The objective of the present work is studying the optimization process of the machining
conditions that affecting the tool wear. Basing on the analyses of multiple regression method,
mathematical predictive model was designed and validated to select an optimum combination of the
studied parameters.Taguchi design is successfully used for optimizing the cutting conditions that
affecting tool life. To achieve the analysis of the present work, Datafit ver9 and Mtb14 softwares had
been employed.
2. EXPERIMENTAL PROCEDURE :
Both fundamental and empirical approaches can be used to establish models or equations for
quantitatively predicting the cutting performance such as tool life and surface roughness. In the case
of the empirical approach, the machining characteristic values which experimentally measured (tool
life) are related to the cutting conditions by regression analysis. Several forms of mathematical
models, as linear, exponential, power function, and non- linear quadratic polynomial were used to
exam the approach. .
T=2.3931+5.5524X1+13.4310X2+13.3856X3+8.6831X12+10.9889X22+6.6217X32+7.2496X1X2
Fig.(4) shows the matching between the experimental values of the tool life and their predicted
values due to the designed models. The figure indicates their close matching.
5.TAGUCHI APPROACH :
i= 1, 2, … n ………………………..…. (2)
Where: η = signal to noise ratio (S/N), yi = observed value of the response, n = number of
observation in a trial.
Table (5) shows the experimental results and the corresponding S/N for tool life. Table (6) shows
the response values for signal- to-noise ratios and the response values formeans for tool life. Figure
(5) shows the results of Taguchi design analysis (main effect plot for Means and main effect plots for
S/N ratio) for tool life. Also, Taguchi orthogonal array is demonstrated in Table (5). Figure (5)
indicate that the optimal machining conditions representing the conditions at which the tool life will
be maximum are: spindle speed, Vc =315 rpm, feed rate, f= 0.4 mm/rev, and depth of cut, t= 0.6 mm.
=∑ ( − ) …………………………………………… (3)
Where η i is the mean S/N ratio for the ith experiment and n is the number of experiment in the
orthogonal array. Table (7) shows the ANOVA (with 95% confidence level) and F-test values with
the P- value which reflects effectiveness of the individual studied parameters on the tool life. The table
indicates that the feed rate is the most significant parameter for maximum tool life.
6. CONCLUSIONS:
In this study, the Taguchi method was used to predict the most turning conditions of the AISI 1020
steel affecting the cemented carbide tool life, according to the results obtained, the following points
can be concluded:
1-The Taguchi method is a robust orthogonal array design method, suitable for analysis of the tool
machining parameters have an effect on the tool life. Among these parameters feed rate has the
largest effect on the tool life.
2- Multiple regression analysis can be applied to develop a mathematical model for tool life
prediction. The models developed are found to be reliable. An assessment of turning of AISI 1020
steel can be achieved by the designed empirical model for selecting the appropriate machining
conditions for a required carbide tool life.
3- An optimum machining combination of AISI 1020 steel for maximum tool life is spindle speed of
315 rpm, feed rate of 0.4 mm/rev., and depth of cut of 0.6 mm.
C Si Mn P S Cr Mo Ni Al Co Cu Fe
0.15 0.004 0.38 0.018 0.020 0.024 0.005 0.017 0.007 0.015 0.01 99.3
6 8 6 1 0 8 1 6 7 7 39 (Balance)
Table (2) : Results of machining experiment for the used tool.
Table (5): Experimental results and the corresponding S/N for tool life.
Table (6) : Response values for signal- to-noise ratios and the response values for means.
Response values for Signal to Noise Ratios Response Values for Means
(Larger is better)
Level Vc F t Level Vc F t
1 13.90 11.57 11.72 1 5.325 4.038 4.506
2 14.65 15.49 15.63 2 5.831 6.300 6.288
3 14.01 16.39 12.98 3 5.613 6.900 5.138
4 12.58 11.69 14.81 4 4.919 4.450 5.756
Delta 2.07 4.82 3.92 Delta 0.912 2.863 1.781
Rank 3 1 2 Rank 3 1 2
Table (7) : One way ANOVA results.
T versus Vc T versus f T versus t
Vc 3 7.46 2.49 0.46 0.709 f 3 93.07 31.02 7.88 0.00 t 3 28.49 9.50 1.89 0.140
(micro)
200 500 rpm
100 800 rpm
0
0 1 2 3 4 5
cutting time ,(min).
DOC = 0.7 mm
500
80 rpm
400
(micro)
315 rpm
300
500 rpm
200
800 rpm
100
0
0 1 2 3 4 5
Cutting Time ,(min)
Figure (3) : The flank wear of the tools during the machining process.
6
3
Tool Material : P 10
Fig.(4): Scatter plot of the experimental and predicted values of tool life.
Fig.(5): Results of Taguchi design analysis: (a) main effect plot for Means; (b)main effect plots
for S/N ratio for tool life.
7. REFERENCES:
[2] B. Fnides, S. Boutabba, M. Fnides, H. Aouici, M. A. Yallese, Cutting Tools Flank Wear and
Productivity Investigation In Straight Turning of X38crmov5-1 (50 HRc), International Journal of
Applied Engineering and Technology, 2013, Vol. 3 (1) January-March, PP (1-10).
[3] Bin Li, A Review Of Tool Wear Estimation Using Theoretical Analysis and Numerical
Simulation Technologies, Int. Journal of Refractory Metals and Hard Materials 35, 2012, PP (143–
151).
[4] Abdul Kareem Jaleel, Kareem Abdulla Hadi, Coated Carbide Cutting Tools Performance In
High Speed Machining Processes, The Iraqi Journal For Mechanical and Materials Engineering,
Vol.12, No.1, 2012.
[5] Bala Murugan Gopalsamy, BiswanathMondal and Sukamal Ghosh, Taguchi Method and
ANOVA: An Approach For Process Parameter Optimization of Hard Machining While Machining
Hardened Steel, Journal of Scientific and Industrial Research Vol. 68, August 2009, PP(686-695).
[6] S. R. Das1, R.P. Nayak, D. Dhupal, A. Kumar, Surface Roughness, Machining Force and Flank
Wear in Turning of Hardened AISI 4340 Steel With Coated Carbide Insert: Cutting Parameters
Effects, International Journal of Automotive Engineering Vol. 4, Number 3, Sept 2014.
[7] Rajesh Nayak, Raviraj Shetty, Sawan Shetty, Investigation of Cutting Force In Elastomer
Machining Using Taguchi’s Design of Experiments”, International Journal of Advanced Technology
& Engineering Research (IJATER), ,Volume 4, Issue 4, July 2014.
[8] Roy Ranjit K, Design of Experiments Using The Taguchi Approach : 16 Steps To Product and
Process Improvement, John Wiley & Sons, Inc. (US),2001.
[9] Haydar A. H. Al-Ethari, Kadhim Finteel Alsultani, Nesreen Dakhel F., Optimization of Chemical
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