CHAPTER 1

INTRODUCTION
1.1 Metal cutting
Machining is the process of removing unwanted material from a work piece in the form of
chips. If the work piece is metal, the process is often called metal cutting or metal removal.
Metal cutting is one of the most significant manufacturing process in the area of metal removal
(Chang and Smith, 1997). However, Black (1979) defined metal cutting as the removal of metal
chips from a work piece in order to obtain a finish product with desired attributes of size, shape
and surface roughness.

The process of metal cutting is complex because it has such a wide variety inputs. These
variables are:

1. The machine tool selected to perform the process.

2. The cutting tool selected (geometry & material).
3. The properties and parameters of the work piece.
4. The cutting parameters selected (speed, feed & depth of cut).
5. The work piece holding devices or fixtures or jigs.

In all machining processes, the work piece is a shape that can entirely cover the final part shape.
The objective is to cut away the excess material and obtain the final part. This cutting usually
requires to be completed in several steps – in each step, the part is held in a fixture, and the
exposed portion can be accessed by the tool to machine in that portion. Common fixtures
include vice, clamps, 3-jaw or 4-jaw chucks, etc. Each position of holding the part is called a
setup. One or more cutting operations may be performed, using one or more cutting tools, in
each setup. To switch from one setup to the next, we must release the part from the previous
fixture, change the fixture on the machine, clamp the part in the new position on the new fixture,
set the coordinates of the machine tool with respect to the new location of the part, and finally
start the machining operations for this setup. Therefore, setup changes are time-consuming and
expensive, and so we should try to do the entire cutting process in a minimum number of setups.

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In modern industry the goal is to manufacture low cost, high quality products in short time.
Automated and flexible manufacturing systems were employed for that purpose along with
computerized numerical control (CNC) machines that are capable of achieving high accuracy
and very low processing time. Turning was the most common method for cutting and especially
for the finishing machined parts. Furthermore, in order to produce any product with desired
quality by machining, cutting parameters should be selected properly (Chorng et. al., 2012).
The accelerated application of computer aided manufacturing (CAM) to machining by the use
of CNC machine tools as focussed on developing reliable machining data systems to ensure
optimum production using expensive equipment.

1.2 Metal cutting operations

Common metal cutting operations include:

1. sawing
2. shaping (or planing)
3. broaching
4. drilling, reaming, boring and tapping
5. grinding
6. milling, and
7. turning

1. Sawing: It is a cutting operation in which the cutting tool is a blade having a series of small
teeth (saw), each tooth removing a small amount of material. It is used to cut the correct sized
work piece from a large raw material stock. This process is used for all metallic and non-
metallic materials that are machine able by other cutting processes and is capable of producing
various shapes.

2. Shaping (or planing): Shaping uses a single-point tool that is moved horizontally in a
reciprocating motion along a slide. It is used to create a planar surface, usually to prepare
rectangular blocks that can later be used as work pieces for machining on a milling machine
etc.

3. Broaching: Broaching is capable of mass-production of complex geometry parts, especially

when complicated hole-shapes are required to be machined. The broach tool has a series of

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cutting teeth along the axis of the tool. As the broaching tool is pulled with force along the part
to be cut, each tooth cuts a tiny chip. Thus the first few sets of teeth to engage the part remove
most of the material, which the last few provide a finishing cut with very small amount of
material removal. The geometric shape of the last set of teeth is identical to the required
geometry of the designed part.

4. Drilling, reaming, boring and tapping: These four methods all produce holes of different
types. Drilling produces round holes of different types; reaming is used to improve the
dimensional tolerance on a drilled hole; boring uses a special machine operating like a lathe,
to cut high precision holes; and tapping creates screw-threads in drilled holes.

5. Grinding: It is a process of removing material by the abrasive action of a revolving wheel

on the surface of a work piece, in order to bring it to the required shape and size. The wheel
used for performing the grinding operation is known as grinding wheel. It consists of sharp
crystals, called abrasives, held together by a binding material or bond. In most case, it is a
finishing operation and a very small amount of material is removed from the surface during the
operation.

6. Milling: It is one of the most versatile machining processes, and can be used to produce a
very large variety of shapes. It is a process in which a rotating, multitooth cutter removes
material while traveling along various axes with respect to the work piece. The multitooth
cutter, called a milling cutter, produces a number chips in one revolution. The most common
milling operations include: slab milling, face milling, and end milling. These are distinguished
easily by the different cutting tools they utilize.

7. Turning: It is the removal of metal from the outer diameter of a rotating cylindrical work
piece. Turning is used to reduce the diameter of the work piece, usually to a specified
dimension, and to produce a smooth finish on the metal. Often the work piece will be turned
so that adjacent sections have different diameters. It is the machining operation that produces
cylindrical parts. In its basic form, it can be defined as the machining of an external surface:

 With the work piece rotating.

 With a single-point cutting tool, and

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  With the cutting tool feeding parallel to the axis of the work piece and at a distance that
will remove the outer surface of the work.

In a turning operation, it is important task to select cutting parameters for achieving high cutting
performance. Cutting parameters are reflected on surface roughness, surface texture and
dimensional deviations of the product (Nalbant et. al., 2007). Surface finish obtained in
manufacturing processes mainly depends on the combination of two aspects: the ideal surface
finish provided by marks that manufacturing process produces on the surface and the actual
surface finish which is generated taking into account irregularities and deficiencies that may
appear in the process, changing manufacturing initial conditions (Arbizu et. al., 2003).

Three cutting parameters, i.e., spindle speed, feed rate, and depth of cut, must be known in a
turning operation. Common methods of evaluating machining performance in a turning
operation are based on the following performance characteristics: tool life, cutting force,
surface roughness and material removal rate. Basically, tool life, cutting force, and surface
roughness are strongly correlated with cutting parameters such as cutting speed, feed rate, and
depth of cut (Niana et. al., 1999). In a turning operation, it is very difficult to select the cutting
parameters to achieve the high surface finish and high material removal rate. Parameters
optimization for surface roughness and material removal rate is a hard-solving issue because
of the interactions between parameters. Problems related to the enhancement of product quality
and production efficiency can always be related to the optimization procedures. This study
would help the operator to select the cutting parameters.

1.3 Performance measures

In a turning operation, a number of methods are available for evaluating machining

performance characteristics such as tool life, cutting force, surface roughness, material removal
rate etc. Among the available machining performance characteristics surface roughness and
material removal rate are considered for the present study.

1.3.1 Surface roughness

In metal cutting and manufacturing industries, surface finish of a product is very crucial in
determining the quality. Good surface finish not only assures quality, but also reduces
manufacturing cost. Surface finish is important in terms of tolerances, it reduces assembly time
and avoids the need for secondary operation, thus reduces operation time and leads to overall

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cost reduction. Besides, good-quality turned surface is significant in improving fatigue
strength, corrosion resistance, and creep life.

Surface roughness also affects several functional attributes of parts, such as contact causing
surface friction, wearing, light reflection, heat transmission, ability of distributing and holding
a lubricant, load bearing capacity, coating or resisting fatigue. Therefore, the desired surface
finish is usually specified and the appropriate processes are selected to reach the required
quality. It is clear now that surface roughness geometry strongly influences the manner in
which the contacting surfaces are interacting. Furthermore, it is well known that the final
geometry of surface roughness is influenced by various machining conditions such as spindle
speed, feed rate and depth of cut.

1.3.2 Material removal rate

The material removal rate (MRR) is defined as the volume of material removed per unit time
(such as mm3/min or in.3/min or gm/sec). For each revolution of the work piece, a ring shaped
layer of material is removed with a cross-sectional area that equals the product of the distance
the tools travels in one revolution (feed, f) and the depth of cut (d). The volume of this ring is
the product of cross-sectional area (f) (d) and the average circumference of the ring, πDavg,
where Davg = [ (Do+Df)/2] , Do and Df are the outer and final diameters of the ring. The rotational
speed of the work piece is N, and the material removal rate per revolution is (π) (Davg) (d) (f).
Since we have N revolutions per minute, the material removal rate is

MRR = (π) (Davg) (d) (f) (N) (1.1)

The cutting time ‘t’ for a work piece of length ‘l’ can be calculated by noting that the tool
travels at a feed rate of ‘fN’ mm/min. Since the distance travelled is ‘l’ mm, the cutting time is

t= (l/fN) min. (1.2)

1.4 Machining parameters in turning process

The three primary factors in any basic turning operation are spindle speed, feed, and depth of
cut. Other factors such as kind of material and type of tool have a large influence, of course,
but these three are the ones the operator can change by adjusting the controls, right at the
machine.

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 Depth of cut

Speed

Feed

Figure 1.1: Machining parameters in turning process

1.4.1 Speed

Speed always refers to the spindle and the work piece. When it is stated in revolutions per
minute (rpm) it tells their rotating speed. But the important feature for a particular turning
operation is the surface speed, or the speed at which the work piece material is moving past the
cutting tool. It is simply the product of the rotating speed times the circumference of the work
piece before the cut is started. It is expressed in meter per minute (m/min), and it refers only to
the work piece. Every different diameter on a work piece will have a different cutting speed,
even though the rotating speed remains the same.

𝜋𝐷𝑁
v= m/min (1.3)
1000

Here, v is the cutting speed in m/min; D is the initial diameter of the work piece in mm, and N
is the spindle speed in rpm.

1.4.2 Feed

Feed always refers to the cutting tool, and it is the rate at which the tool advances along its
cutting path. On most power-fed lathes, the feed rate is directly related to the cutting speed and
is expressed in mm (of tool advance) per revolution (of the spindle), or mm/rev.

F = f.N mm/min. (1.4)

Here, F is the feed in mm per minute, f is the feed in mm/rev and N is the spindle speed in rpm.

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1.4.3 Depth of cut

Depth of cut is practically self-explanatory. It is the thickness of the layer being removed (in a
single pass) from the work piece or the distance from the uncut surface of the work to the cut
surface, expressed in mm. It is important to note, though, that the diameter of the work piece
is reduced by two times the depth of cut because this layer is being removed from both sides
of the work.

𝐷−𝑑
DOC = mm (1.5)
2

Here, D and d represent initial and final diameter (in mm) of the job respectively.

1.5 Factors influencing the surface roughness and material removal rate
in turning operation

Whenever two machined surfaces come in contact with one another the quality of the mating
parts plays an important role in the performance and wear of the mating parts. The height,
shape, arrangement and direction of these surface irregularities on the work piece depend upon
a number of factors such as:

1.5.1 Cutting speed

It is found that an increase of cutting speed generally improves surface quality as well as
material removal rate.

1.5.2 Feed rate

Experiments show that as feed rate increases surface roughness increases. It is due to the
increase in cutting force and vibration. In case of material removal rate, increase of feed rate
increases the MRR.

1.5.3 Depth of cut

Increasing the depth of cut increases the cutting resistance and the amplitude of vibrations. As
a result, cutting temperature also rises. Therefore, it is expected that surface quality will
deteriorate. However, experiments show that increase in depth of cut increases the material
removal rate.

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1.5.4 Cutting tool wears

The irregularities of the cutting edge due to wear are reproduced on the machined surface.
Apart from that, as tool wear increases, other dynamic phenomena such as excessive vibrations
will occur, thus further deteriorating surface quality.

1.5.5 Use of cutting fluid

The cutting fluid is generally advantageous in regard to surface roughness because it affects
the cutting process in three different ways. Firstly, it absorbs the heat that is generated during
cutting by cooling mainly the tool point and the work surface. In addition to this, the cutting
fluid is able to reduce the friction between the rake face and the chip as well as between the
flank and the machined surface. Lastly, the washing action of the cutting fluid is considerable,
as it consists in removing chip fragments and wear particles. Therefore, the quality of a surface
machined with the presence of cutting fluid is expected to be better than that obtained from dry
cutting.

Since, turning is the primary operation in most of the production process in the industry, surface
finish of turned components has greater influence on the quality of the product. Surface finish
in turning has been found to be influenced in varying amounts by a number of factors such as
feed rate, job hardness, unstable built up edge, speed, depth of cut, cutting time, use of cutting
fluids etc.

1.6 Computer Numerical Control (CNC)

Computer Numerical Control (CNC) is one in which the functions and motions of a machine
tool are controlled by means of a prepared program containing coded alphanumeric data. CNC
can control the motions of the work piece or tool, the input parameters such as feed, depth of
cut, speed, and the functions such as turning spindle on/off, turning coolant on/off.

1.6.1 Advantages and Limitations

The benefits of CNC are

1. High accuracy in manufacturing,

2. Short production time,
3. Greater manufacturing flexibility,
4. Simpler fixturing,

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 5. Contour machining (2 to 5 –axis machining),
6. Reduced human error.

The drawbacks include high cost, maintenance, and the requirement of skilled part
programmer.

1.6.2 Applications

The applications of CNC include both for machine tool as well as non-machine tool areas. In
the machine tool category, CNC is widely used for lathe, drill press, milling machine, grinding
unit, laser, sheet-metal press working machine, tube bending machine etc. Highly automated
machine tools such as turning center and machining center which change the cutting tools
automatically under CNC control have been developed. In the non-machine tool category, CNC
applications include welding machines (arc and resistance), coordinate measuring machine,
electronic assembly, tape laying and filament winding machines for composites etc.

1.7 Cutting tool materials

The classes of cutting tool materials currently in use for machining operation are high speed
tool steel, cobalt-base alloys, cemented carbides, ceramic, polycrystalline cubic boron nitride
and polycrystalline diamond. Different machining applications require different cutting tool
materials. The ideal cutting tool material should have all of the following characteristics:

 Harder than the work it is cutting

 High temperature stability
 Resists wear and thermal shock
 Impact resistant
 Chemically inert to the work material and cutting fluid

To effectively select tools for machining, a machinist or engineer must have specific
information about:

 the starting and finished part shape

 the work piece hardness
 the material's tensile strength
 the material's abrasiveness

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  the type of chip generated
 the work holding setup
 the power and speed capacity of the machine tool

Some common cutting tool materials are described below:

1.7.1 Carbon steels

Carbon steels have been used since the 1880s for cutting tools. However carbon steels start to
soften at a temperature of about 180 oC. This limitation means that such tools are rarely used
for metal cutting operations. Plain carbon steel tools, containing about 0.9% carbon and about
1% manganese, hardened to about 62 RC, are widely used for woodworking and they can be
used in a router to machine aluminium sheet up to about 3mm thick.

1.7.2 High speed steels (HSS)

HSS tools are so named because they were developed to cut at higher speeds. Developed around
1900 HSS are the most highly alloyed tool steels. The tungsten (T series) was developed first
and typically contains 12 - 18% tungsten, plus about 4% chromium and 1- 5% vanadium. Most
grades contain about 0.5% molybdenum and most grades contain 4 - 12% cobalt. It was soon
discovered that molybdenum (smaller proportions) could be substituted for most of the
tungsten resulting in a more economical formulation which had better abrasion resistance than
the T series and undergoes less distortion during heat treatment. Consequently about 95% of
all HSS tools are made from M series grades. These contain 5 - 10% molybdenum, 1.5 - 10%
tungsten, 1 - 4% vanadium, 4% Chromium and many grades contain 5 - 10% cobalt. HSS tools
are tough and suitable for interrupted cutting and are used to manufacture tools of complex
shape such as drills, reamers, taps, dies and gear cutters. Tools may also be coated to improve
wear resistance. HSS accounts for the largest tonnage of tool materials currently used. Typical
cutting speeds: 10 - 60 m/min.

1.7.3 Cast cobalt alloys

Introduced in early 1900s these alloys have compositions of about 40 - 55% cobalt, 30%
chromium and 10 - 20% tungsten and are not heat treatable. Maximum hardness values of 55 -
64 RC. They have good wear resistance but are not as tough as HSS but can be used at
somewhat higher speeds than HSS. Now only in limited use.

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1.7.4 Carbides

Also known as cemented carbides or sintered carbides were introduced in the 1930s and have
high hardness over a wide range of temperatures, high thermal conductivity, high Young's
modulus making them effective tool and die materials for a range of applications. The two
groups used for machining are tungsten carbide and titanium carbide; both types may be coated
or uncoated. Tungsten carbide particles (1 to 5 micro meter) are bonded together in a cobalt
matrix using powder metallurgy. The powder is pressed and sintered to the required insert
shape. Titanium and niobium carbides may also be included to impart special properties. A
wide range of grades are available for different applications. Sintered carbide tips are the
dominant type of material used in metal cutting. The proportion of cobalt (the usual matrix
material) present has a significant effect on the properties of carbide tools. 3 - 6% matrix of
cobalt gives greater hardness while 6 - 15% matrix of cobalt gives a greater toughness while
decreasing the hardness, wear resistance and strength.

Tungsten carbide tools are commonly used for machining steels, cast irons and abrasive non-
ferrous materials. Titanium carbide has a higher wear resistance than tungsten but is not as
tough. With a nickel-molybdenum alloy as the matrix, TiC is suitable for machining at higher
speeds than those which can be used for tungsten carbide. Typical cutting speeds are: 30 - 150
m/min or 100 - 250 when coated.

1.7.5 Coatings

Coatings are frequently applied to carbide tool tips to improve tool life or to enable higher
cutting speeds. Coated tips typically have lives 10 times greater than uncoated tips. Common
coating materials include titanium nitride, titanium carbide and aluminium oxide, usually 2 -
15 micro-m thick. Often several different layers may be applied, one on top of another,
depending upon the intended application of the tip. The techniques used for applying coatings
include chemical vapour deposition (CVD) plasma assisted CVD and physical vapour
deposition (PVD). Diamond coatings are also in use and being further developed.

1.7.6 Cermets

Developed in the 1960s, these typically contain 70% aluminium oxide and 30% titanium
carbide. Some formulation contains molybdenum carbide, niobium carbide and tantalum

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carbide. Their performance is between those of carbides and ceramics and coatings seem to
offer few benefits. Typical cutting speeds: 150 - 350 m/min.

1.7.7 Ceramics

Ceramics tools are produced by sintering process. The main constituent is aluminium oxide
(Al2O3 or alumina). Up to 10% addition of oxides of magnesium, titanium and chromium, are
often made to obtain superior properties. Ceramics tools retain their hardness up to 1400 oC.
They have better resistance to abrasion wear and crater formation than cemented carbides.
Also, they exhibit a low coefficient of friction with work materials. Due to these reasons,
ceramics tools can used at substantially higher cutting speeds and, therefore, help achieve
higher production rates. Their main drawback is their relatively low traverse rupture strength
which is about one-half to one-third that of carbides.

Alumina was introduced in the early 1950s. Two classes are used for cutting tools: fine
grained high purity aluminium oxide (Al2O3) and silicon nitride (Si3N4). Additions of titanium
carbide and zirconium oxide (ZrO2) may be made to improve properties. Typical cutting
speeds: 150-650 m/min. Silicon Nitride was introduced in 1970s, a tool material based on
silicon nitride. SiN has an affinity for iron and is not suitable for machining steels. A specific
type is 'Sialon', containing the elements: silicon, aluminium, oxygen and nitrogen. This has
higher thermal shock resistance than silicon nitride and is recommended for machining cast
irons and nickel based super alloys at intermediate cutting speeds. Cubic Boron Nitride (CBN)
was introduced in the early 1960s. This is the second hardest material available after diamond.
CBN tools may be used either in the form of small solid tips or as a 0.5 to 1 mm thick layer of
polycrystalline boron nitride sintered onto a carbide substrate under pressure. Cubic boron
nitride is the standard choice for machining alloy and tool steels with a hardness of 50 RC or
higher. Typical cutting speeds: 30 - 310 m/min.

1.7.8 Diamond

The hardest known substance is diamond. Although single crystal diamond has been used as a
tool, they are brittle and need to be mounted at the correct crystal orientation to obtain optimal
tool life. Single crystal diamond tools have been mainly replaced by polycrystalline diamond
(PCD). This consists of very small synthetic crystals fused by a high temperature high pressure
process to a thickness of between 0.5 and 1mm and bonded to a carbide substrate. The result is
similar to CBN tools. The random orientation of the diamond crystals prevents the propagation

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of cracks, improving toughness. Because of its reactivity, PCD is not suitable for machining
plain carbon steels or nickel, titanium and cobalt based alloys. PCD is most suited to light
uninterrupted finishing cuts at almost any speed and is mainly used for very high speed
machining of aluminium - silicon alloys, composites and other non - metallic materials. Typical
cutting speeds: 200 - 2000 m/min.

To improve the toughness of tools, developments are being carried out with whisker
reinforcement, such as silicon nitride reinforced with silicon carbide whiskers. As rates of metal
removal have increased, so has the need for heat resistant cutting tools. The result has been a
progression from high-speed steels to carbide, and on to ceramics and other super hard
materials. High-speed steels cut four times faster than the carbon steels they replaced. There
are over 30 grades of high-speed steel, in three main categories: tungsten, molybdenum, and
molybdenum-cobalt based grades. In industry today, carbide tools have replaced high-speed
steels in most applications. These carbide and coated carbide tools cut about 3 to 5 times faster
than high-speed steels. Cemented carbide is a powder metal product consisting of fine carbide
particles cemented together with a binder of cobalt. The major categories of hard carbide
include tungsten carbide, titanium carbide, tantalum carbide, and niobium carbide.

Ceramic cutting tools are harder and more heat-resistant than carbides, but more brittle. They
are well suited for machining cast iron, hard steels, and the super alloys. Two types of ceramic
cutting tools are available: the alumina-based and the silicon nitride-based ceramics. The
alumina-based ceramics are used for high speed semi- and final-finishing of ferrous and some
non-ferrous materials. The silicon nitride-based ceramics are generally used for rougher and
heavier machining of cast iron and the super alloys.

1.8 Taguchi experimental design

Taguchi is regarded as the foremost proponent of robust parameter design, which is an
engineering method for product or process design that focuses on minimizing variation and/or
sensitivity to noise. Taguchi‘s robust parameter design strategy provides a powerful and
efficient method for designing products and processes that operate consistently and optimally
over a variety of conditions. Robust design is capable of (i) making product performance
insensitive to raw material variation, thus allowing the use of lower grade alloys and
components in most cases; (ii) making designs robust against manufacturing variations, thus

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reducing labour and material cost for rework and scrap; (iii) making the design least sensitive
to the variation in operating environment, thus improving reliability and reducing operating
cost; and (iv) using a new structured development process so that engineering time is used
more product productively. Unal et al (1991) and Phadke M S (1989), Taguchi recommends a
three-stage process to achieve desirable product quality by design-system design, parameter
design and tolerance design. While system design helps to identify the working levels of the
design parameters, parameter design seeks to determine the parameter levels that produce the
best performance of the product or process under study. The optimum condition is selected so
that the influence of uncontrollable factors (noise factors) causes minimum variation to system
performance. The orthogonal arrays, variance and signal to noise analysis are the essential tools
of parameter design. Tolerance design is a step to fine-tune the results of parameter design.

1.9 Analysis of variance (ANOVA)

The ANOVA procedure performs analysis of variance (ANOVA) for balanced data from a
wide variety of experimental designs. In analysis of variance, a continuous response variable,
known as a dependent variable, is measured under experimental conditions identified by
classification variables, known as independent variables. The variation in the response is
assumed to be due to effects in the classification, with random error accounting for the
remaining variation.

Analysis of variance (ANOVA) is a method of apportioning variability of an output to various

inputs. The purpose of the analysis of variance is to investigate which machining parameters
significantly affect the performance characteristics. This is accomplished by separating the
total variability of the composite desirability value, which is measured by the sum of the
squared deviations from the total mean of the composite desirability value, into contributions
by each machining parameter and the error. First, the total sum of the squared deviations SST
from the total mean of the composite desirability value 𝜇𝑚 can be calculated as:

𝑆𝑆𝑇 = ∑𝑖𝑗=1(𝜇𝑗 − 𝜇𝑚 ) 2 (1.6)

Where i is the number of experiments in the orthogonal array and 𝜇𝑗 is the mean composite
desirability value for the jth experiment. The total sum of the squared deviations SST is
decomposed in to two sources: the sum of the squared deviations SSD due to each machining
parameter and its interaction effects and the sum of the squared error SSE. The percentage

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contribution by each of the machining parameter in the total sum of the squared deviations SSE
can be used to evaluate the importance of the machining parameter change on the performance
characteristic.

1.10 Surface structure and properties

Surface roughness is an important measure of product quality since it greatly influences the
performance of mechanical parts as well as production cost. Surface roughness has an impact
on the mechanical properties like fatigue behaviour, corrosion resistance, creep life, etc. It also
affects other functional attributes of parts like friction, wear, light reflection, heat transmission,
lubrication, electrical conductivity, etc. Before surface roughness, it is also necessary to discuss
about surface structure and properties, as they are closely related.

Upon close examination of the surface of a piece of metal, it can be found that it generally
consists of several layers (Figure 1.2). The characteristics of these layers are briefly outlined
here:

(i) The bulk metal, also known as the metal substrate, has a structure that depends on the
composition and processing history of the metal.

(ii) Above this bulk metal, there is a layer that usually has been plastically deformed and work-
hardened to a greater extent during the manufacturing process. The depth and properties of the
work-hardened layer (surface structure) depend on such factors as the processing method used
and how much frictional sliding the surface undergoes. The use of sharp tools and the selection
of appropriate processing parameters result in surfaces with little or no disturbance. For
example, if the surface is produced by machining using a dull and worn tool, or which takes
place under poor cutting conditions, or if the surface is ground with a dull grinding wheel, the
surface structure layer will be relatively thick. Also, non-uniform surface deformation or severe
temperature gradients during manufacturing operations usually cause residual stresses in the
work-hardened layer.

(iii) Unless the metal is processed and kept in an inert (oxygen-free) environment, or is a noble
metal such as gold or platinum, an oxide layer forms over the work hardened layer.

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(a) Iron has an oxide structure with FeO adjacent to the bulk metal, followed by a layer of
Fe3O4 and then a layer of Fe2O3, which is exposed to the environment.

(b) Aluminium has a dense, amorphous (without crystalline structure) layer of Al2O3, with a
thick, porous hydrated aluminium-oxide layer over it.

Figure 1.2: Schematic of a cross-section of the surface structure of metals

(iv) Under normal environmental conditions, surface oxide layers are generally covered with
absorbed layers of gas and moisture. Finally, the outermost surface of the metal may be covered
with contaminants such as dirt, dust, grease, lubricant residues, cleaning-compound residues,
and pollutants from the environment.

Thus, surfaces have properties that generally are very difficult from those of the substrate. The
oxide on a metal surface is generally much harder than the base metal. Consequently, oxides
tend to be brittle and abrasive. This surface characteristic has several important effects on
friction, wear, and lubrication in materials processing, and on products.

The surface quality is an important parameter for evaluating the productivity of machine tools
and the machined parts. Hence, the desired surface quality is to be achieved for the functional
behaviour of the mechanical parts. The surface roughness is the index of product quality and
has an influence on several properties, such as fatigue strength, coefficient of friction,
lubrication, corrosion resistance, and wears resistance of the machined components.
Nowadays, in the manufacturing industry, special attention is paid to dimensional accuracy and
surface finish. Thus, measuring and characterizing of the surface finish is considered to be the
predictor of the machining performance.

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1.11 Objectives of the study

1. Experimental investigation on surface roughness and MRR during turning operation on

CNC lathe machine.

2. Optimization of process parameters (speed, feed and depth of cut) for individual
performance characteristics.

3. To conduct various experiments based on Taguchi DOE technique.

4. To perform statistical analysis of variance (ANOVA) to judge the significance of

factors on response.

1.12 Conclusion
In this chapter, a brief introduction to the metal cutting and the various metal cutting operations
is discussed. Among the different metal cutting operations turning is one of the fundamental
machining operation observed in almost all manufacturing industries. In a turning operation, it
is very important to select the cutting parameters (speed, feed and depth of cut) to achieve high
surface finish and high material removal rate. In the next chapter, a detailed survey of the
literature related to the objective of this study is done.

17
 CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
A number of techniques have been developed by the researchers for optimizing multiple
characteristics of the products. The purpose of this work is to develop a methodology which
would allow determination of the cutting conditions (spindle speed, feed rate and depth of cut)
such that specified criterion for each of the several machining dependent parameters (surface
finish and material removal rate) could be achieved.

Cesarone (2001) shows that conducting an effective DOE requires review of literature
regarding turning parameters and similar studies as it is important to understand the process in
this type of study. Additionally, recent reviews of DOE studies by researchers and professionals
are helpful in determining what aspects of this method work best.

Shivade et al. (2014) presented the single response optimization of turning parameters for
Turning on EN8 Steel. Experiments are designed and conducted on conventional lathe machine
based on Taguchi’s 𝐿9 orthogonal array design. This paper discusses an investigation into the
use of Taguchi parameter Design optimize the surface roughness and tool tip temperature in
turning operations using single point carbide cutting Tool. The analysis of variance (ANOVA)
is employed to analyse the influence of process parameters during turning.

Ballal et al. (2013) presented the study of an application of Taguchi method for optimization
of surface roughness and material removal rate in turning gray cast iron brake drum. Machining
performance of a series of commercially available coated tungsten carbide inserts were
investigated during turning of gray cast iron brake drum on CNC lathe. The inserts tested had
a coating of TiCN and TiAlN respectively. For comparison, uncoated cemented tungsten
carbide insert of K10 grade was also tested under the same cutting conditions. Taguchi analysis
using ANOVA for 3 parameter, 3 level experimentation - full factorial (𝐿27 array) were done
with output response variables like surface roughness, material removal rate.

Govindan and Vipindas (2013) studied quality of machined surfaces in turning operation. The
comprehensive experimentation and analysis was performed on Al 6061 material based on

18
Taguchi 𝐿9 orthogonal array. The commonly used parameters speed, feed and depth of cut were
used for this assessment. The roughness values vary between 0.3 and 4.4 µm. A general linear
model was employed to evaluate the parametric effects. It was observed that feed is the
significant factor at 95% confidence level. Feed has the strongest influence on the quality of
machined surfaces in CNC turning.

Kumar et al. (2013) done an experimental work for the optimization of input parameters for
the improvement of quality of the product made by turning operation on CNC machine. Feed
rate, spindle speed & depth of cut were taken as the input parameters and the dimensional
tolerances as output parameter. 𝐿9 Array has been used in design of experiment for optimization
of input parameters and thus verifies experimentally as to how the Taguchi parameter design
could be used in identifying the significant processing parameters and optimizing the surface
roughness in the turning operation. They found that spindle speed is the key factor for
minimizing the dimensional variation for minimizing the surface roughness.

Kumar and Narang (2013) focused on the optimization of two response parameters (surface
roughness and material removal rate) by three machining parameters (cutting speed, feed rate
and depth of cut). These parameters were investigated in high speed turning of H13 in dry
conditions on CNC lathe. Taguchi’s 𝐿9 orthogonal array and analysis of variance (ANOVA)
were used for individual optimization. The simultaneous optimization was done by Grey
Relational Analysis approach.

Salvi et al. (2013) focused on hard turning of 20 MnCr5 steel to analyse optimum cutting
conditions to get lowest surface roughness in turning of 20 MnCr5 steel. Taguchi method for
design of experiment has been used for this purpose. Analysis of variance (ANOVA) was
employed to investigate the cutting characteristics. The results indicated that feed rate has
significant role to play in producing lower surface roughness followed by cutting speed. The
cutting insert used is ceramic based TNGA 160404.

Suresh and Krishnaiah (2013) investigated an optimal setting of process parameters in turning
operation for maximizing the material removal rate of the manufactured component. The
experiments were conducted on PSG A141 conventional lathe machine. Through Taguchi’s
“design of experiments”, the number of experiments to be conducted is finalized. The data for
calculating material removal rate in all the test conditions were observed and recorded. The

19
result of this analysis identifies the optimal values of process parameters for effective and
efficient machining. ANOVA has been carried out to find the percentage of each process
parameter on response characteristic i.e., MRR.

Shivrajnagnath et al. (2013) outlined an experimental study to optimize the effects of cutting
parameters on surface finish and MRR of EN8/HCHCR work material on CNC lathe by
employing Taguchi techniques. Three parameters were chosen as process variables: spindle
speed, feed rate, depth of cut, and dry cutting environment. Minitab 15 statistical software was
used. Optimal cutting parameters for, minimum surface roughness (SR) and maximum material
removal rate were obtained.

Uppal et al. (2013) performed an experimental investigation on the influence of cutting

conditions on material removal rate (MRR) during turning of AISI 4041 die alloy steel on
conventional lathe. Analysis of variance (ANOVA) is employed to investigate the influence of
cutting speed, feed rate, and depth of cut on material removal rate (MRR). Conducting the
experiments by varying the parameters of turning like cutting speed from 100 m/min to 300
m/min, feed 0.02 mm/rev to 0.06 mm/rev, and depth of cut from 0.2 mm to 0.7 mm were
studied in details according to Taguchi's design of experiments. Results were analysed using
Taguchi, ANOVA and parametric optimization was done for maximum material removal rate
(MRR). From the experimentation, it is concluded that for turning of AISI 4041 die alloy
steel optimum machining condition for higher material removal rate (MRR) with cutting speed
(300 m/min), feed rate (0.06 mm/rev), and depth of cut (0.2 mm).

Gunay et al. (2012) focused on optimizing the cutting conditions for the average surface
roughness (Ra) obtained in machining of high-alloy white cast iron (Ni-Hard) on CNC lathe at
two different hardness levels (50 HRC and 62 HRC). Taguchi’s 𝐿18 orthogonal array was used
to design the experiment. The effects of the cutting parameters and tool materials on surface
roughness were evaluated by the analysis of variance. The statistical analysis indicated that the
parameters that have the biggest effect on Ra for Ni-Hard materials with 50 HRC and 62 HRC
are the cutting speed and feed rate, respectively.

Hassana et al. (2012) investigated the effects of process parameters on material removal rate
(MRR) in turning of C34000. The single response optimization problems i.e. optimization of
MRR is solved by using Taguchi method. The optimization of MRR is done using twenty seven

20
experimental runs based on 𝐿27 orthogonal array of the Taguchi method which was performed
to derive objective functions to be optimized within the experimental domain. The machine
tool used was CNC lathe.

Korat and Agarwal (2012) outlined an experimental study to optimize the effects of cutting
parameters on surface finish and MRR of EN24/AISI4340 work material on CNC lathe by
employing Taguchi techniques. Five parameters were chosen as process variables: speed, feed,
depth of cut, nose radius and cutting environment (wet and dry). Taguchi’s 𝐿18 orthogonal
array (OA) and Minitab 16 statistical software is used. Optimal cutting parameters for,
minimum surface roughness (SR) and maximum material removal rate were obtained.

Kumar et al. (2012) investigates the effect of process parameters in turning of carbon alloy
steels in a CNC lathe. The parameters namely the spindle speed and feed rate are varied to
study their effect on surface roughness. The experiments were conducted using one factor at a
time approach. The five different carbon alloy steels used for turning were SAE8620, EN8,
EN19, EN24 and EN47. The study reveals that the surface roughness is directly influenced by
the spindle speed and feed rate. It is observed that the surface roughness increases with
increased feed rate and is higher at lower speeds and vice versa for all feed rates.

Khamel et al. (2012) investigated the effects of process parameters (cutting speed, feed rate
and depth of cut) on performance characteristics (tool life, surface roughness and cutting
forces) in finish hard turning of AISI 52100 bearing steel with CBN tool on conventional lathe
machine. The combined effects of the process parameters on performance characteristics are
investigated using ANOVA. The composite desirability optimization technique associated with
the response surface methodology (RSM) quadratic models is used as multi-objective
optimization approach. The results show that feed rate and cutting speed strongly influence
surface roughness and tool life. However, the depth of cut exhibits maximum influence on
cutting forces. The proposed experimental and statistical approaches bring reliable
methodologies to model, to optimize and to improve the hard turning process.

Krishankant et al. (2012) focussed on optimization of turning process by the effects of

machining parameters applying Taguchi methods to improve the quality of manufactured
goods. EN24 steel is used as the work piece material for carrying out the experimentation to
optimize the material removal rate on conventional lathe machine. The bars used are of

21
diameter 44mm and length 60mm. There are three machining parameters i.e. spindle speed,
feed rate, depth of cut. Taguchi orthogonal array is designed with three levels of turning
parameters with the help of software Minitab 15. The metal removal rate was considered as the
quality characteristic with the concept of "the larger-the-better".

Rodrigues et al. (2012) studied the effect of speed, feed and depth of cut on surface roughness
(Ra) and cutting force (Fc) in turning mild steel using high speed steel cutting tool. Experiments
were conducted on a precision centre lathe and the influence of cutting parameters was studied
using analysis of variance (ANOVA) based on adjusted approach. Based on the main effects
plots obtained through full factorial design, optimum level for surface roughness and cutting
force were chosen from the three levels of cutting parameters considered. Linear regression
equation of cutting force has revealed that feed, depth of cut, and the interaction of feed and
depth of cut significantly influenced the variance. In case of surface roughness, the influencing
factors were found to be feed and the interaction of speed and feed.

Patel et al. (2012) made an attempt to investigate the effect of cutting parameter (cutting speed,
feed, and depth of cut) on surface roughness (S.R) and material removal rate (MRR) during
machining of harden steel. The experiment were conduct on a CNC turning center using cubic
boron nitride (CBN) insert. The results were analysed using analysis of variance (ANOVA)
method.

Yadav et al. (2012) investigated the relation between change in hardness caused on the material
surface due the turning operation with respect to different machining parameters like spindle
speed, feed and depth of cut. Taguchi method has been used to plan the experiments and EN 8
metal selected as a work piece and coated carbide tool as a tool material and hardness after
turning has been measured on Rockwell scale. The conventional lathe machine was used to
perform the experimental work.

Yuvaraj et al. (2012) described the use and steps of Taguchi design of experiments and
orthogonal array to find a specific range and combinations of turning parameters like cutting
speed, feed rate and depth of cut to achieve optimal values of response variables like surface
finish, tool wear, material removal rate in CNC turning of Brake drum of FG 260 gray cast iron
material.

22
Asiltürk et al. (2011) focuses on optimizing turning parameters based on the Taguchi method
to minimize surface roughness (Ra and Rz). Experiments have been conducted using the 𝐿9
orthogonal array in a CNC turning machine. Dry turning tests are carried out on hardened AISI
4140 (51 HRC) with coated carbide cutting tools. The statistical methods of signal to noise
ratio (SNR) and the analysis of variance (ANOVA) are applied to investigate effects of cutting
speed, feed rate and depth of cut on surface roughness. Results of this study indicate that the
feed rate has the most significant effect on Ra and Rz. In addition, the effects of two factor
interactions of the feed rate-cutting speed and depth of cut-cutting speed appear to be important.

Kirby (2010) discussed an investigation into optimizing a quality characteristic, while

considering productivity, through the use of Taguchi’s parameter design. A turning operation
on CNC lathe was the subject of his study, and the output parameter selected is surface
roughness. He sought an actual target surface roughness value, which may allow for a higher
feed rate depending upon that specified target. He demonstrated that Taguchi’s parameter
design can be used to determine the optimal levels of controlled parameters to meet a quality
target without sacrificing productivity.

Motorcu et al. (2010) investigated the surface roughness in the turning of AISI 8660 hardened
alloy steels by ceramic based cutting tools in terms of main cutting parameters such as cutting
speed, feed rate, depth of cut in addition to tool’s nose radius, using a statistical approach.
Machining tests were carried out with PVD coated ceramic cutting tools on a CNC lathe under
different conditions. An orthogonal design, signal-to-noise ratio and analysis of variance were
employed to find out the effective cutting parameters and nose radius on the surface roughness.
The obtained results indicate that the feed rate was found to be the dominant factor among
controllable factors on the surface roughness, followed by depth of cut and tool’s nose radius.
However, the cutting speed showed an insignificant effect.

Bhattacharya, et al. (2009) investigated the effects of cutting parameters on finish and power
consumption by employing Taguchi techniques. A combined technique using orthogonal array
and analysis of variance was employed to investigate the contribution and effects of cutting
speed, feed rate and depth of cut on three surface roughness parameters and power
consumption. The results showed a significant effect of cutting speed on the surface roughness

23
and power consumption, while the other parameters did not substantially affect the responses.
The conventional lathe machine was used to perform the experimental work.

Chavoshi & Tajdari (2009) studied the influence of hardness (H) and spindle speed (N) on
surface roughness (Ra) in hard turning operation of AISI 4140 using CBN cutting tool on a
CNC lathe. Artificial neural network (ANN) and regression methods have been used for
modelling of surface roughness in hard turning operation of AISI 4140 using CBN cutting tool.
The results indicate that the reverse ANN model can predict hardness for the train data and
spindle speed for the test data with a good accuracy but the predicted spindle speed for the train
data and the predicted hardness for the test data don’t have acceptable accuracy.

Akhyar et al. (2008) has used the application of Taguchi method in optimization of cutting
parameters for surface roughness in turning Ti-6%Al-4%V extra low interstitial with various
tool grades coated and uncoated cemented carbide tools under dry cutting condition and high
cutting speed on a conventional lathe machine. The analysis of results show that the optimal
combination of parameters are at cutting speed of 75 m/min, feed rate of 0.15 mm/min, depth
of cut of 0.10 mm and tool grade of KC9225.

Thamizhmanii et al. (2007) presented the application of the Taguchi method for parameter
design to optimize the surface roughness, tool wear and cutting force by hard turning process.
The analyses showed that the material having hardness between 54-58 was considered and
three CBN cutting tool were used to conduct 18 tests on a CNC lathe. The response of surface
roughness and flank wear taken for discussion and analyses. The experimental results showed
that there is a good agreement between surface roughness and flank wear both by equations
and experiments by Taguchi method.

Singh and Rao (2006) conducted an experiment to determine the effects of cutting conditions
and tool geometry on the surface roughness in the finish hard turning of the bearing steel (AISI
52100). The study shows that the feed is the dominant factor determining the surface finish by
nose radius and cutting velocity. Though, the effect of the effective rake angle on the surface
finish is less, the interaction effects of nose radius and effective rake angle are considerably
significant. Mathematical models for the surface roughness were developed by using the
response surface methodology. A CNC lathe machine was used to perform the experimental
work.

24
Ozel et al. (2005) studied the effects of cutting edge geometry, work piece hardness, feed rate
and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI
H13 steel. The study shows that the effects of work piece hardness, cutting edge geometry,
feed rate and cutting speed on surface roughness are statistically significant. The effects of two
factor interactions of the edge geometry and the work piece hardness, the edge geometry and
the feed rate, and the cutting speed and feed rate also appeared to be important. A CNC lathe
machine was used to perform the experimental work.

Lin (2004) addressed an approach based on the Taguchi method with grey relational analysis
for optimizing turning operations with multiple performance characteristics. A grey relational
grade obtained from the grey relational analysis is used to solve the turning operations with
multiple performance characteristics. Optimal cutting parameters can then be determined by
the Taguchi method using the grey relational grade as the performance index. Tool life, cutting
force, and surface roughness are important characteristics in turning performed on a
conventional lathe machine. Using these characteristics, the cutting parameters, including
cutting speed, feed rate, and depth of cut are optimized in the study. Table 2.1 shows the
summary of the research papers reviewed during the dissertation work.

Table 2.1: Summary of research papers

Jour. Year Author’s Name Material Machine Input Output Significant

No. Tool Parameter Parameter

1 2011 Ilhan Asilturk AISI CNC Speed, Surface Feed DOC

Harun Akkus 4140 lathe feed, DOC roughness

(51
HRC)

2 2012 Rodrigues L.L.R. MDN250 Conv. Speed, Surface Feed DOC

Kantharaj A.N. steel lathe feed, DOC roughness

Kantharaj B. Cutting Feed Speed

Freitas W. R. C. force
Murthy B.R.N.

25
3 2007 Dilbag Singh . AISI Conv. Speed, Surface Feed Nose

P. Venkateswara 52100 lathe feed, roughness radius

Rao effective
rake angle,
nose radius

4 2010 Saeed Zare AISI CNC Hardness, Surface Hardn Speed

Chavoshi, Mehdi 4140 lathe speed roughness ess
Tajdari

5 2013 Patilshivrajnagna EN8/HC CNC Speed, Surface Feed Speed

thPimpalgaonkar HCR lathe feed, DOC roughness
D.S., Ade
MRR Feed DOC
Santoshlaxmanra
o

6 2013 R.K.Suresh EN41B Conv. Speed, MRR Feed Speed

G. Krishnaiah lathe feed, DOC

7 2013 Vipindas M P. Al 6061 CNC Speed, Surface Feed DOC

Dr. Govindan P lathe feed, DOC roughness

8 2012 Krishankant EN24 Conv. Speed, MRR Feed Speed

Jatin Taneja steel lathe feed, DOC

Mohit Bector

Rajesh Kumar

9 2014 Anand S.Shivade EN8 Conv. Speed, Surface Speed DOC

Shivraj Bhagat lathe DOC roughness
Suraj Jagdale
Tool tip DOC Speed
Amit Nikam temperature
Pramod londhe

10 2013 Mustafa Günay High- CNC Speed, Surface Speed Feed

Emre Yücel alloy lathe feed, DOC roughness
white

26
 cast iron
(50 HRC
and 62
HRC).

11 2012 Mahendra Korat EN24 CNC Speed, Surface Nose Feed

Neeraj Agarwal steel lathe Feed, DOC, roughness radius
Nose
MRR Nose DOC
radius,
radius
Cutting
environme
nt (wet and
dry).

12 2005 Tugrul Ozel , Hardened CNC Hardness, Surface Feed Edge

Tsu-Kong Hsu AISI H13 lathe edge roughness geome

steel geometry, try
Erol Zeren
feed and Cutting Speed Edge
speed) force geome
try

13 2009 Anirban AISI Conv. Speed, Surface Speed Feed

Bhattacharya 1045 lathe feed, DOC roughness
Santanu Das steel
Power Speed DOC
P. Majumder
consumptio
Ajay Batish
n

14 2012 Samir Khamel, AISI Conv. Speed, Tool life Speed Feed
Ouredine Ouelaa 52100 lathe feed, DOC
Surface Feed Speed
Khaider Bouacha roughness

Cutting Feed Speed

force

27
15 2012 Rakesh.K.Patel AISI CNC Speed, Surface Feed Speed

H.R.Prajapati 4340 lathe feed, DOC roughness

MRR Feed DOC

16 2013 S.B.Salvi 20 CNC Speed, Surface Feed Speed

R.R.Deshmukh MnCr5 lathe feed, DOC roughness

Steel.
Dr.S.D.Deshmuk
h

17 2012 H. K. Dave EN8 and CNC Insert type, Surface Insert DOC

L. S. Patel EN31 lathe Material roughness type

H. K. Raval type, MRR DOC Insert

Speed, type
feed, DOC

18 2013 Nirpaksh Uppal, AISI Conv. Speed, MRR Speed DOC

Rohit Rampal, 4041 lathe feed, DOC

Charanjeet Singh Die alloy

Sandhu steel

19 2013 Y.P.Ballal, Gray cast CNC Speed, Surface Tool Feed

A.R.Mane, iron lathe feed, DOC, roughness type

Brake tool type
Y.V.Patil , MRR Tool Speed
Drum (UN,
S.G.Bagi type
TiCN,
TiAlN)

20 2010 E. Daniel Kirby Al 6061 CNC Speed, Surface Feed Speed

lathe feed, DOC roughness

21 2012 Kamal Hassana medium CNC Speed, MRR Feed DOC

Anish Kumar Brass lathe feed, DOC

alloy
M.P.Garg
C34000

28
 22 2012 Ashish Yadav, EN8 Conv. Speed, Hardness Speed Feed

Ajay Bangar, lathe feed, DOC

Rajan Sharma,

Deepak Pal

23 2007 SThamizhmanii SCM 440 CNC Speed, Surface Speed Feed

K. Kamarudin alloy lathe feed, DOC roughness

steel
E. A. Rahim, Flank wear Speed DOC

A. Saparudin

S.Hasan

24 2013 Suha K. Shihab Hardened CNC Speed, cutting force DOC Speed

Zahid A. Khan alloy lathe feed, DOC

MRR DOC Speed
Aas Mohammad steel

Arshad Noor AISI

Siddiquee 52100

2.2 Conclusion

The literature survey depicts that a considerable amount of work has been carried out by
number of investigators for modelling, simulation and parametric optimization of surface
properties of the product in turning operation using different process parameters, different
cutting tools and various cutting condition. But very few work had been carried out by
considering material type of different grades of EN series steel as one of the input parameter.
So, in this study different EN series steels namely EN8, EN24, EN31 and EN47 are considered.
The cutting tool used for turning operation on these materials is carbide insert. The
investigation is performed for surface roughness and material removal rate. In the next chapter
based on the findings of the literature review problem is formulated and methodology to solve
the problems are discussed.

29
 CHAPTER 3
PROBLEM FORMULATION AND METHODOLOGY
3.1 Introduction
In machining operations, the quality of the surface finish plays an important role for particularly
turned work pieces. However, human operators or programmers normally inspects the surface
according to their experiences or refer to machining handbooks. Optimization of turning
parameters is usually a difficult work where the following aspects are important such as
knowledge of machining and the specification of machine tool capabilities. The level of
parameters is the main consideration because it will affect the surface of the work piece, and
avoid scratch marks or inaccuracies in the cut. In a turning operation, the important task is to
select a good combination of parameters level for achieving high cutting performance.

With regard to the quality characteristics of turning parts, some of the previous studies
concluded surface roughness, burr, and tool wear, etc. The machining parameters such as
cutting speed, feed rate, depth of cut, features of tools, work piece material and coolant
conditions highly affects the performance characteristics. It is necessary to select the most
appropriate machining parameters in order to improve cutting efficiency, process at low cost,
and produced high-quality products.

3.2 Taguchi based design of experiments

Among the available methods, Taguchi’s design is one of the most powerful design of
experiments methods for analysing of experiments. It is widely recognized in many fields
particularly in the development of new products and processes in quality control. The Taguchi
method involves reducing the variation in a process through robust design of experiments. The
overall objective of the method is to produce high quality product at low cost to the
manufacturer. The Taguchi method was developed by Dr. Genichi Taguchi of Japan who
maintained that variation. Taguchi developed a method for designing experiments to
investigate how different parameters affect the mean and variance of a process performance
characteristic that defines how well the process is functioning.

30
Taguchi method is one of the simplest and effective approaches for parameter design and
experimental planning. Taguchi defines as the quality of a product, in terms of the loss imparted
by the product to the society from the time the product is shipped to the customer. Some of
these losses are due to deviation of the products functional characteristic from its desired target
value, and these are called losses due to functional variation. The uncontrollable factors, which
cause the functional characteristics of a product to deviate from their target values, are called
noise factors, which can be classified as external factors (e.g. unit to unit variation in product
parameters) and product deterioration. In this method, the term ‗signal‘ represents the desirable
value (mean) for the output characteristic and the term ‗noise‘ represents the undesirable value
(S.D.) for the output characteristic. Therefore, the S/N ratio is the ratio of the mean to the S.D.
S/N ratios are expressed on a decibel scale. The overall aim of quality engineering is to make
products that are robust with respect to all noise factors.

Taguchi has empirically found that the two stage optimization procedure involving S/N ratios,
indeed gives the parameter level combination, where the standard deviation is minimum, while
keeping the mean on target .This implies that engineering systems behave in such a way that
the manipulated production factors that can be divided into three categories: (i). Control factors,
which affect process variability as measured by the S/N ratio. (ii). Signal factors, which do not
influence the S/N ratio or process mean. (iii). Factors, which do not affect the S/N ratio or
process mean.

In practice, the target mean value may change during the process development applications in
which the concept of S/N ratio is useful are the improvement of quality through variability
reduction and the improvement of measurement. There are three types of S/N ratio depending
on the type of characteristics:—

(1) Nominal-is-the-best:

𝑦̅
𝑆/𝑁ᴛ = 10.log (𝑠 2) (3.1)
𝑦

(2) Larger-is-the-better (maximize):

1 1
𝑆⁄𝑁𝐿 = -10.log ( 𝑛 ∑𝑛𝑖=1 𝑦 2) (3.2)
𝑖

31
(3) Smaller-is-the-better (minimize):

𝑆⁄ = −10. log( 1 ∑𝑛 𝑦 2 ) (3.3)

𝑁𝑠 𝑛 𝑖=1 𝑖

Where𝑦̅, is the average of observed data, 𝑠𝑦 2 is the variance of y, n is the number of

observations and y is the observed data. Notice that these S/N ratios are expressed on a decibel
scale.

An orthogonal array is a major tool used in the Taguchi design, which is used to study several
design parameters by means of a single quality characteristic. The purpose of conducting an
orthogonal experiment is to determine the optimum level for each controllable parameter and
to establish the relative significance of individual parameters in terms of their main effects on
the response. The conventional method involves one variable at a time, while keeping the other
parameters at fixed levels. This method is generally time consuming and requires a
considerable number of experiments to be performed. For example, if there are k factors with
l levels defined for each of the factors, then it is necessary to carry out k number of experiments.
On the other hand, the matrix experiments using orthogonal arrays enable to study the effect
of several factors simultaneously with reduced number of experiments. Depending on the
number of process parameters and setting levels, a suitable array is selected (Phadke M S 1989).
Each column of the orthogonal array designates a process parameter and its setting levels in
each experiment and each row designates an experiment with the level of different process
parameters in that experiment. Taguchi suggests S/N ratio, which is a logarithmic function of
desired response, serves as the objective function for optimization (Phadke M S 1989), The
S/N ratio is used to measure the performance characteristics and the significant process
parameters through analysis of variance (ANOVA).

The experimental design proposed by Taguchi involves using orthogonal arrays to organize the
parameters affecting the process and the levels at which they should vary. Instead of having to
test all possible combinations like in the factorial design, the Taguchi method tests pairs of
combinations. This allows for the collection of the necessary data to determine which factors
mostly affect product quality with a minimum amount of experimentation, thus saving time
and resources.

32
Taguchi method-based design of experiments involved following steps:

a. Definition of the problem

b. Identification of noise factors

c. Selection of response variables

d. Selection of control parameters and their levels

e. Selection of the orthogonal array

f. Conducting the matrix experiments (experimental procedure and set-ups)

g. Analysis of the data and prediction of optimum level

h. Confirmation experiment

a. Definition of the problem

A brief statement of the problem under investigation is “Determining the effect of cutting
parameters in CNC turning”

b. Identification of noise factors

The environment in which experiments are performed is the main external source of variation
of performance of turning process. Some examples of the environmental noise factors are
temperature, vibrations and human error in operating the process.

c. Selection of response variables

In any process, the response variables need to be chosen so that they provide useful information
about the performance of the process under study. As reported in the literature review as it is
seen that surface roughness (Ra) and material removal rate (MRR) are widely used response
variables. In this study also these are taken into consideration.

d. Selection of control parameters and their levels:

The process parameters affecting the characteristics of turned parts are: cutting tool parameters
-tool geometry and tool material; work piece related parameters- metallographic, hardness, etc.;
cutting parameters- cutting speed, feed, depth of cut, dry cutting and wet cutting.

33
Selection of cutting speed

Available literature on machining indicates that the influence of cutting speed on cutting forces
and surface roughness changes with the cutting speed. Most of the researchers have reported
improvement in surface roughness with an increase in cutting speed. Machine constraint is
another reason for selection of cutting speed.

Selection of feed

It is known from the fundamentals of metal cutting that feed rate influences the chip cross-
sectional area and hence the machining forces. An increase in feed rate increases the amount
of cracks, pits on the machined surfaces due to reinforcement pull-out and fracture, which then
deteriorates the surface quality/integrity and introduces higher thermal stresses on the
machined surfaces.

Selection of depth of cut

It is known that depth of cut influences the chip load by change in chip cross-sectional area and
hence the cutting forces, which in turn could influence the stability of the machining process
and machined surface characteristics. The surface roughness deteriorates with an increase in
depth of cut, which is attributed to the formation of unstable built-up edge at lower feed and
higher depth of cut. However, most of the investigations have reported that surface roughness
has little and/or no dependence on depth of cut.

Deciding the number of levels

Once the independent variables are decided, the number of levels for each variable is decided.
The selection of number of levels depends on how the performance parameter is affected due
to different level settings. If the performance parameter is a linear function of the independent
variable, then the number of level setting shall be 2. However, if the independent variable is
not linearly related, then one could go for 3, 4 or higher levels depending on whether the
relationship is quadratic, cubic or higher order. In the absence of exact nature of relationship
between the independent variable and the performance parameter, one could choose 2 level
settings. After analysing the experimental data, one can decide whether the assumption of level
setting is right or not based on the percent contribution and the error calculations. Each cutting
parameter is to be studied at four levels.

34
e. Selection of the orthogonal array

Using the array selector table shown in table 3.1, the name of the appropriate array can be
found by looking at the column and row corresponding to the number of parameters and
number of levels. In present scenario, we have targeted 4 process parameters with 4 levels each.
So, we have selected L16 orthogonal array.

Table 3.1: Array selector table (Website 1)

f. Conducting the matrix experiments (experimental procedure and set-ups)

Once the orthogonal array is selected, the experiments are conducted as per the level
combinations obtained by Taguchi’s L16 orthogonal array. It is necessary that all the
experiments be conducted. The detailed description regarding the experimentation is given in
chapter 4.

g. Analysis of the data and prediction of optimum level

Since each experiment is the combination of different factor levels, it is essential to segregate
the individual effect of independent variables. This can be done by summing up the
performance parameter values for the corresponding level settings. Once the mean value of
each level of a particular independent variable is calculated, the sum of square of deviation of
each of the mean value from the grand mean value is calculated. This sum of square deviation
of a particular variable indicates whether the performance parameter is sensitive to the change
in level setting. If the sum of square deviation is close to zero or insignificant, one may
conclude that the design variable is not influencing the performance of the process. In other

35
words, by performing analysis of variance (ANOVA), one can decide which independent factor
dominates over other and the percentage contribution of that particular independent variable.

Based on the results of the main effects plot and S/N ratio plot the optimum level combination
of process parameters is predicted which would give the optimum value of response
parameters.

h. Confirmation experiment

A confirmation experiment is the final step of Taguchi’s design of experiment. Its purpose is
to verify that the optimum conditions suggested by the matrix experiment do indeed give the
projected improvement.

3.3 Analysis of variance (ANOVA)

The ANOVA procedure performs analysis of variance (ANOVA) for balanced data from a
wide variety of experimental designs. In analysis of variance, a continuous response variable,
known as a dependent variable, is measured under experimental conditions identified by
classification variables, known as independent variables. The variation in the response is
assumed to be due to effects in the classification, with random error accounting for the
remaining variation.

Analysis of variance (ANOVA) is a method of apportioning variability of an output to various

inputs. The purpose of the analysis of variance is to investigate which machining parameters
significantly affect the performance characteristics. This is accomplished by separating the
total variability of the composite desirability value, which is measured by the sum of the
squared deviations from the total mean of the composite desirability value, into contributions
by each machining parameter and the error. First, the total sum of the squared deviations SST
from the total mean of the composite desirability value 𝜇𝑚 can be calculated as

𝑆𝑆𝑇 = ∑𝑖𝑗=1(𝜇𝑗 − 𝜇𝑚 ) 2 (3.4)

Where i is the number of experiments in the orthogonal array and 𝜇𝑗 is the mean composite
desirability value for the jth experiment. The total sum of the squared deviations SST is
decomposed in to two sources: the sum of the squared deviations SSD due to each machining
parameter and its interaction effects and the sum of the squared error SSE. The percentage
contribution by each of the machining parameter in the total sum of the squared deviations SST

36
can be used to evaluate the importance of the machining parameter change on the performance
characteristic. In addition, the Fisher‘s F- test can also be used to determine which machining
parameters have a significant effect on the performance characteristic. Usually, the change of
the machining parameters has a significant effect on performance characteristic when F is large.

3.4 Process parameters of turning operation

In order to identify the process parameters that affect the quality of the turned parts, an Ishikawa
cause-effect diagram was constructed as shown in figure 3.1. The Ishikawa cause- effect
diagram depicts that the following process parameters may affect the quality of the turned parts:

(i) Cutting parameters: spindle speed, feed rate, depth of cut.

(ii) Environment parameters: wet, dry.
(iii) Cutting tool parameters: tool geometry, tool material, type of coating
(iv) Work piece material: diameter, mechanical properties, type of material

Figure 3.1: Ishikawa cause–effect diagram of a turning process (Website 2)

The following process parameters are thus selected for the present work:

(i) Spindle speed – (A)

(ii) Feed rate – (B)

37
(iii) Depth of cut – (C)
(iv) Work material –EN8, EN24, EN31 and EN47 steels-(D)
(v) Tool material – Carbide inserts, and
(vi) Environment – wet cutting.

The selection of parameters of interest was based on some preliminary experiments and earlier
studies by the authors (Singh & Kumar, 2006).

Selected response parameters are:

(i) Surface Roughness (Ra), and
(ii) Material Removal Rate (MRR)

3.5 Work piece material

The work piece material selected for this study consists of four different grades of EN series
steels. These steels are listed below:

1. EN8 is a very popular grade of through-hardening medium carbon steel, which is readily
machinable in any condition. EN8 is suitable for the manufacture of parts such as general-
purpose axles and shafts, gears, bolts and studs.
2. EN24 steel is a difficult-to-machine material and finds its typical applications in the
manufacturing of automobile and machine tool parts.
3. EN 31 is a high carbon alloy steel which achieves a high degree of hardness with
compressive strength and abrasion resistance. Applications: For roller bearing components
such as brakes, cylindrical, conical & needle rollers.
4. EN47 is used widely in the motor vehicle industry and many general engineering
applications. Suitable for applications that require high tensile strength and toughness.
Typical applications include crankshafts, steering knuckles, gears, spindles and pumps.

Because of its wide application all the four different steels have been selected as the work
material in this study. The recently developed tool materials like coated carbides have
improved the productivity levels of difficult-to-machine materials. Thus coated carbide tool
has been selected to turn these steels. The process parameters, their designated symbols and
ranges are given in table 4.1. Each parameter is studied at four levels.

38
3.6 Software used

MINITAB 17 statistical software is to be used to analyse the data. Minitab is a statistics

package developed at the Pennsylvania State University by researchers Barbara F. Ryan,
Thomas A. Ryan, Jr., and Brian L. Joiner in 1972. Minitab is the package of choice for
instructors in more than 4,000 colleges and universities around the world because it is:

 Easy to use - Minitab leverages your students' existing software skills and has a highly
intuitive interface designed to complement how they learn statistics.
 Comprehensive - Minitab contains a complete set of sound, peer-reviewed methods;
you do not need to buy, learn, or maintain separate add-ins or modules.
 Compatible with any curriculum - The organization of statistics and graphs in
Minitab parallels the approach used in virtually all leading textbooks.
 Widely used in business and industry - Thousands of companies in more than 80
countries rely on Minitab for data analysis. Students who learn statistics with Minitab
acquire practical, real-world skills that can give them an advantage in the job market.

3.7 Conclusion

Keeping in view the wide range of application of turned components, an attempt has been made
in this dissertation work to optimize turning parameters such as spindle speed, feed and depth
of cut for response parameters. The Taguchi’s optimization technique is used to optimize the
turning parameters. Analysis of variance (ANOVA) is employed to determine the machining
parameters that significantly affect performance and also the percentage contribution of these
parameters. Minitab 17 statistical software is used to analyse the experimental data. In the next
chapter the experiments are carried out as per the orthogonal array matrix developed by
Taguchi’s design of experiment technique.

39
 CHAPTER 4
EXPERIMENTATION
4.1 Design of Experiment
The Taguchi method involves reducing the variation in a process through robust design of
experiments. The overall objective of the method is to produce high quality product at low cost
to the manufacturer. The Taguchi method was developed by Dr. Genichi Taguchi of Japan who
maintained that variation. Taguchi developed a method for designing experiments to
investigate how different parameters affect the mean and variance of a process performance
characteristic that defines how well the process is functioning.

The experimental design proposed by Taguchi involves using orthogonal arrays to organize the
parameters affecting the process and the levels at which they should be varies. Instead of having
to test all possible combinations like the factorial design, the Taguchi method tests pairs of
combinations. This allows for the collection of the necessary data to determine which factors
most affect product quality with a minimum amount of experimentation, thus saving time and
resources.

Analysis of variance on the collected data from the Taguchi design of experiments can be used
to select new parameter values to optimize the performance characteristic. The data from the
arrays can be analysed by plotting the data and performing a visual analysis, ANOVA.

In this study, an 𝐿16 orthogonal array with 16 rows (corresponding to the number of
experiments) was chosen for the experiments. With 𝐿16 array, the main effects of different
process parameters can be assessed with reasonable accuracy. According to the scheme of the
experimentation outlined in 𝐿16 orthogonal array table 4.7.

In full factorial design, the number of experimental runs exponentially increases with the
increase in the number of factors as well as their levels. This results in huge experimentation
cost and considerable time period (Rao et al., 2012). A full factorial experiment is an
experiment whose design consists of two or more factors, each with discrete possible values or
"levels", and whose experimental units take on all possible combinations of these levels across
all such factors. A full factorial design may also be called a fully crossed design. Such an

40
experiment allows studying the effect of each factor on the response variable, as well as the
effects of interactions between factors on the response variable. A common experimental
design is one with all input factors set at two levels each. If there are k factors, each at 2 levels;
a full factorial design has 2𝑘 runs. Experiments were conducted with the process parameters as
given in table 4.6, based on the Taguchi 𝐿16 orthogonal array consisting of 16 sets of array and
the experimental results for the responses is measured.

4.2 Plan of experiments

The design of experiments technique is a very powerful tool, which permits us to carry out the
modelling and analysis of the influence of process variables on the response variables. The
response variable is an unknown function of the process variables, which are known as design
factors. In a turning operation, there are a large number of factors that can be considered as the
machining parameters. But, the review of literature shows that the depth of cut (d, mm), spindle
speed (N, rpm) and feed rate (f, mm/rev) are the most widespread machining parameters taken
by the researchers. In the present study these are selected as design factors while other
parameters have been assumed to be constant over the experimental domain.

Figure 4.1: MAXTURN + CNC lathe front view

41
 Figure 4.2: CNC lathe setup

4.2.1 CNC lathe machine and its specifications

All experiments have been carried out on MAXTURN PLUS, CNC Lathe machine tool of
MTAB. MAXTURN PLUS is a numerically controlled machine tool used for machining parts
in every industrial field, featuring high speed, high accuracy and high productivity. It performs
operations using CNC programming and Siemens Controller Operation as shown in figure 4.1.
The specifications of the CNC lathe machine is given below:

Type MAXTURN PLUS CNC Lathe, MTAB

Controller Siemens (Sinumeric 828D )
Power Supply 3Ф,415V AC, 50 Hz
Control Voltage 24V DC
Spindle Speed 6000 rpm (Max. Speed)

4.2.2 Cutting tool and its specification

The cutting tool used during the experimentation is shown in figure 4.3. With all its standard
specification a tungsten carbide insert of VNMG160408 is employed for the machining
operation of the present study. The designation of the cutting tool is explained as under:

42
 Figure 4.3: Cutting tool insert

V: Turning Insert Shape for finishing operation

N: Turning Insert with 0° clearance angle
M: Turning Insert Tolerances like the tolerance in turning insert length, height etc.
G: Turning insert with Cylindrical hole and Double-Sided Chip breaker
16: Turning Insert Size i.e. cutting edge length of the turning insert.
04: Turning Insert Thickness
08: Turning Insert Nose Radius

4.2.3 Work piece material

The work piece material used is four different EN grade of steels i.e. EN8, EN24, EN31 and
EN47 using cutting fluid Water-soluble mineral oil (trade name: 68 Pentagon cutting oil). The
chemical composition and mechanical properties of the work piece materials are shown in table
4.1, table 4.2, table 4.3, table 4.4 and table 4.5 respectively. It is available in material hand
book. It is a bar of Ф34 × 150 mm.

Figure 4.4: Turned work pieces

43
 Table 4.1: Chemical composition of EN8, EN24, EN31 and EN47

Carbon %C %Si %Mn %P %S %Cr %Mo %Ni %V %Al

Steel

EN8 0.43 0.20 0.79 0.024 0.020 - - - - 0.56

EN24 0.45 0.22 0.57 0.040 0.040 1.5 0.30 1.55 - -

EN31 1.01 0.20 0.33 0.020 0.010 1.36 - - - -

EN47 0.49 0.24 0.66 0.040 0.033 0.93 - - 0.193 -

Table 4.2: Mechanical properties of EN8 Table 4.3: Mechanical properties of EN24

S. Mechanical Range S. Mechanical Range

No Property No Property
. .

1 Max Stress 700-850 N/𝑚𝑚2 1 Max Stress 850-1000 N/𝑚𝑚2

2 0.2% Proof 450 N/𝑚𝑚2 2 Tensile Strength 680 N/𝑚𝑚2

Stress

3 Yield Stress 465 N/𝑚𝑚2 3 Yield Stress 650 N/𝑚𝑚2

4 Elongation 16% 4 Elongation 13%

5 Density 7.8 gm/cc 5 Density 7.85 gm/cc

6 Hardness 201-255 Brinell 6 Hardness 248-302 Brinell

44
 Table 4.4: Mechanical properties of EN31 Table 4.5: Mechanical properties of EN47

S. Mechanical Range S. Mechanical Range

No Property No Property
. .

1 Modulus of 215000 N/𝑚𝑚2 1 Modulus of 200000 N/𝑚𝑚2

Elasticity Elasticity

2 Tensile Strength 750 N/𝑚𝑚2 2 Tensile Strength 650-880 N/𝑚𝑚2

3 Yield Stress 450 N/𝑚𝑚2 3 Yield Stress 350-550 N/𝑚𝑚2

4 Elongation 30% 4 Elongation 19%

5 Density 7.8 gm/cc 5 Density 7.7 gm/cc

6 Hardness 63 Brinell 6 Hardness 275 Brinell

4.3 Process variables and their limits

The working ranges of the parameters for subsequent design of experiment, based on Taguchi’s
𝐿16 Orthogonal Array (OA) design have been selected. Considering the literature review and
the available machine settings following process parameters were selected for the present work:

(i) Cutting speed

(ii) Feed
(iii) Depth of cut, and
(iv) Work material
Table 4.6 shows the process variables and their limits.

Table 4.6: Process variables and their limits

Parameter Symbol Unit Level 1 Level 2 Level 3 Level 4

Speed A rpm 900 1100 1300 1500
Feed B mm/rev 0.1 0.13 0.16 0.19
Depth of cut C mm 0.25 0.5 0.75 1.0
Work Material D EN8 EN24 EN31 EN47

45
 Table 4.7: Taguchi’s 𝐿16 orthogonal array (OA) design

Experiment Spindle Speed Feed Rate Depth of Cut Material Type

(A) (B) (C) (D)

1 1 1 1 1

2 1 2 2 2

3 1 3 3 3

4 1 4 4 4

5 2 1 2 3

6 2 2 1 4

7 2 3 4 1

8 2 4 3 2

9 3 1 3 4

10 3 2 4 3

11 3 3 1 2

12 3 4 2 1

13 4 1 4 2

14 4 2 3 1

15 4 3 2 4

16 4 4 1 3

46
4.3.1 Response parameters

The response parameters considered in this study are surface roughness and material removal
rate.

4.3.1.1 Surface roughness

The terms surface roughness and surface finish are widely used in manufacturing sector to
quantify the smoothness of the machined surface. A machined surface is a result of geometric
and kinematics reproduction of the tool point shape and trajectory. The final surface roughness
can be considered as the sum of two independent effects:

1) The ideal surface roughness is a result of the tool geometry and feed rate and
2) The natural surface roughness is a result of the irregularities in the cutting operation
(Boothroyd and Knight 1989).

Surface roughness of machined parts is described by several parameters. Some of the generally
used parameters of surface roughness specification are listed as follows:

 Root-mean-square roughness (Rq)

 Maximum peak-to-valley roughness height (Ry or Rmax)
 Average roughness (Ra)

4.3.1.1.1 Average roughness (Ra)

It is the arithmetic mean of the departure of surface roughness profile from the mean line, and
is the mostly used and universally recognized parameter of surface roughness. It is also known
as the arithmetic mean roughness value or arithmetic average (AA) or centre line average
(CLA).

Figure 4.5: Surface roughness profile of surface texture

47
 Ra = Average (y1,y4,y6,y8,y5,y2,y1,y4,y1,y2,y1,y4,y7,y4,y1,y2,y5,y8,y5,y2,y1,y4,y1,y1)

4.3.1.1.2 Surface roughness measurement

The surface roughness of all the specimens was measured using the portable Handy Surf (E-
35 A, Tokyo Seimitsu) surface texture measuring instrument (Figure 4.6), with 0.8 mm as cut-
off length. Measuring condition were as follows; stylus radius - 2 µm, Evaluation length – 4.0
mm, filter type – Gaussian and cut-off value, λ = 0.8 mm. Handy surf is a hand held device
used for measuring surface roughness values. It is a stylus based instrument. Stylus instruments
are based on the principle of running a probe across a surface in order to detect variations in
height as a function of distance. The next step in the development of the stylus instruments was
to incorporate a transducer, which converted vertical displacement into an electrical signal.
This signal can then be processed by the instrument electronics to calculate a suitable
roughness.

Figure 4.6: Portable handy surf (E-35 A, Tokyo Seimitsu)

The type of transducer used largely affects instrument performance. A piezoelectric crystal is
often used as the transducer in the less expensive instruments. Other transducer mechanisms
include moving coil transducers, capacitance transducers, and linear variable differential

48
transformers (LVDT). Some error can be introduced in roughness measurements when a stylus
instrument is used because of several factors. Some of these factors are the size of the stylus,
stylus load, stylus speed, and lateral deflection by asperities.

4.3.2 Material removal rate (MRR)

The material removal rate (MRR) can be defined as the volume of material removed divided
by the machining time. Another way to define MRR is to imagine an "instantaneous" material
removal rate as the rate at which the cross-section area of material being removed moves
through the work piece. The MRR is also calculated by determining the difference of weight
before and after machining. We use both these methods (eq. 4.1 and eq. 4.2) for calculating
MRR.
𝜋
∗(𝐷2 −𝑑2 )∗𝐿
4
MRR = (mm3/sec) (4.1)
𝑇𝑐
where,
D is initial diameter of work piece in mm,
d is final diameter of work piece in mm,
L is machining length in mm, and
Tc is machining time in sec.

The machining length (L) is held to be constant i.e. L = 50mm.

So, higher the material removal rate means lesser the machining time.
The MRR is also calculated by another formula using the difference of weight before and after
machining as,

Initial weigth of work piece(gm) - final weigth of work piece(gm)

MRR = gm (mm3/sec) (4.2)
density( )∗ machining time (sec)
mm3

4.4 Part program used for turning operation

NC/MPF/STRAIGHT TURNING

N5 WORKPIECE (,,,”CYLINDER”,192,0,-150,-50,35)
N10 G71G95
N15 G75X0Z0
N20 T=”FINISHING_TOOL” D1

49
N25 LIMS=900
N30 G96S900M03
N35 M08
N40 G00X35Z10
N45 G01Z2F0.1
N50 CYCLE 62 (“SURF”,0,)
N55 CYCLE 952 ("OD",,"",2101321,0.01,0,0,0.5,0.1,0.1,0.1,0.1,0.1,0.01,1,30,
2,,,,,2,2,,,0,1,,0,12,1101010,1,0)
N60 M09
N65 G75X0Z0
N70 M05
N75 M30

NC/SPF/SURF.SPF

N5 G01X34Z0
N10 G01Z-50
N15 M17 Figure 4.7: Drawing of work piece

4.5 Procedure of experiment

The objectives of the present work have already been mentioned in the forgoing chapter.
Accordingly the present study has been done through the following plan of experiment.

a) Checking and preparing the CNC Lathe ready for performing the machining operation.
b) Part program is written and fed into the CNC machine using the alphanumeric keys
available on the machine control panel.
c) Cutting the steel bars by power saw and performing initial turning operation on CNC
Lathe to get desired dimension of the work pieces.
d) Measure the initial weight and diameter (D) of the work piece.
e) Performing straight turning operation on specimens in the wet cutting environment
involving various combinations of process control parameters like: spindle speed, feed,
depth of cut and material type.

50
 f) Noting down the time taken to machine (𝑇𝑐 ) the work piece by a stop watch and measure
the final weight and diameter (d) of the machined part.
g) Noting the initial weight of the work piece before machining.
h) Noting the final weight of the work piece after machining.
i) Calculating the material removal rate of each machined piece using the formula given
in equation (4.1) and equation (4.2).
j) Measuring surface roughness with the help of a portable Handy Surf (E-35 A, Tokyo
Seimitsu).

4.6 Conclusion

In this chapter, the experimental work carried out as per the Taguchi’s design of experiments
is described. A plan of experiment was first prepared and then a detailed procedure of
experiment was written according to which all the 16 experiments were performed. The
specification of CNC lathe machine and cutting tool (carbide insert) used have also been
mentioned. The part program developed to carry out straight turning operation was fed into the
CNC machine using its control panel. In the next chapter, we will discuss the analysis done on
the results obtained during the experimental work.

51
 CHAPTER 5
ANALYSIS AND DISCUSSION ON EXPERIMENTAL
RESULTS
5.1 Determination of optimal settings of process parameters
The surface roughness (Ra) and material removal rate (MRR) for different combinations of
turning parameters of 16 experimental runs are listed in Table 5.1. The following sequential
steps were adopted to determine the optimal combination of the turning process parameters
based on Taguchi’s optimization technique:

a) S/N ratios for the experimental data are calculated.

b) The main effects plots and S/N ratios plots are drawn
c) ANOVA is carried out to determine the significant contribution of the factors.
d) Validation of ANOVA results is performed.
e) A confirmation experiment is conducted to verify the optimal process parameters obtained
from the parameter design.

As far as machining quality characteristics is concerned, the lower surface roughness and the
higher material removal rate (MRR) are indications of optimal performance. The S/N ratios of
the surface roughness and material removal rate (MRR) for 16 experimental runs calculated
using eq. (4.1) and eq. (4.2) are listed in Table 5.1 and Table 5.7 respectively.

5.2 Optimal parameter combination for surface roughness (Ra)

After conducting all the 16 experiments having different combinations of process parameters
designed by Taguchi’s orthogonal array, the surface roughness (Ra) is measured using a
portable Handy Surf (E- 35 A, Tokyo Seimitsu). Table 5.1 shows all the 16 experiments
performed along with their corresponding surface roughness values. The S/N ratios are
calculated using MINITAB 17 software and are tabulated in table 5.1.

52
 Table 5.1: Experimental design using 𝑳𝟏𝟔 orthogonal array for surface roughness (Ra)

Experiment Spindle Feed Rate Depth of Material Surface S/N Ratio

No. Speed (mm/rev.) Cut (mm) Type roughness (dB)
(rpm) Ra (µm)

1 900 0.1 0.25 EN8 1.25 -1.93820

2 900 0.13 0.5 EN24 1.95 -5.80069

3 900 0.16 0.75 EN31 1.59 -4.02794

4 900 0.19 1.0 EN47 1.81 -5.15357

5 1100 0.1 0.5 EN31 0.52 5.67993

6 1100 0.13 0.25 EN47 0.84 1.51441

7 1100 0.16 1.0 EN8 1.10 -0.82785

8 1100 0.19 0.75 EN24 1.63 -4.24375

9 1300 0.1 0.75 EN47 0.54 5.35212

10 1300 0.13 1.0 EN31 0.89 1.01220

11 1300 0.16 0.25 EN24 1.18 -1.43764

12 1300 0.19 0.5 EN8 1.32 -2.41148

13 1500 0.1 0.25 EN24 0.49 6.19608

14 1500 0.13 0.5 EN8 1.01 -0.08643

15 1500 0.16 1.0 EN47 1.03 -0.25674

16 1500 0.19 0.75 EN31 1.30 -2.27887

53
5.2.1 Main effects plots

The data is further analysed with the help of main effects plots using software package Minitab
17. The plots show the variation of individual response with three machining parameters;
spindle speed, feed rate, depth of cut and material type separately. In the plots, the x-axis
indicates the value of each machining parameters and material type at four level and y-axis
indicates the response value (surface roughness). The main effects plots are used to determine
the optimal design conditions to obtain the low surface roughness.

Figure 5.1: Main effects plot for surface roughness

Figure 5.1 shows the main effects plot for surface roughness. The results show that with the
increase in spindle speed there is a continuous decrease in surface roughness. On the other
hand, as the feed rate increases the surface roughness increases. However, with the increase in
depth of cut the surface roughness slightly increases and after that it decreases. But in case of
material type, surface roughness first increases and then decreases as there is a change of
material properties. It is also analysed through the work of Kumar and Narang, (2013) that as
speed increases surface roughness decreases, increase in feed rate result increase in surface
roughness and with increase in depth of cut surface roughness decreases. It is also observed
from figure 5.1 that low value of surface roughness is obtained at spindle speed of 1500 rpm
(level 4), feed rate of 0.1 mm/rev (level 1), depth of cut of 1.0 mm (level 4) and material type

54
of EN47 (level 4). From the response table of means (Table 5.2), it is clearly observed that feed
rate is having the greatest effect on surface roughness (rank 1) followed by spindle speed (rank
2), material type (rank 3) and depth of cut (rank 4).

Table 5.2: Response table for means

Level Spindle Speed Feed Rate Depth of Cut Material Type

1 1.6500 0.7000 1.1425 1.1700
2 1.0225 1.1725 1.2050 1.3125
3 0.9825 1.2250 1.1925 1.0750
4 0.9575 1.5150 1.0725 1.0550
Delta 0.6925 0.8150 0.1325 0.2575
Rank 2 1 4 3

5.2.2 Signal-to-Noise (S/N) ratio plots

Regardless of the category of the performance characteristics, a greater S/N value corresponds
to a better performance. Therefore, the optimal level of the machining parameters is the level
with the largest value. Figure 5.2, shows the predicted optimal parameter setting for minimum
surface roughness at spindle speed 1500 rpm (level 4), feed rate 0.1 mm/rev (level 1) and depth
of cut 1.0 mm (level 4) and material type EN47 (level 4).

Figure 5.2: S/N ratios plot for surface roughness

55
The advantage of S/N ratios plot is that it also provides the significant rank’s hierarchy of
machining (input) parameters. As it can be clearly observed from table 5.3 that feed rate having
(rank 1) has the greatest effect on the response parameter i.e. surface roughness, followed by
spindle speed (rank 2), material type (rank 3) and lastly depth of cut (rank 4).

Table 5.3: Response table of S/N ratios for surface roughness

Level Spindle Speed Feed Rate Depth of Cut Material Type

1 -4.23010 3.82248 -1.03507 -1.31599

2 0.53069 -0.84013 -0.69725 -1.32150

3 0.62880 -1.63755 -0.75150 0.09633

4 0.89351 -3.52192 0.30671 0.36406

Delta 5.12361 7.34440 1.34179 1.68556

Rank 2 1 4 3

On comparing the main effects plot (Figure 5.1) and S/N ratio plot (Figure 5.2) of surface
roughness, it can be concluded that the optimum machining (input) parameters combination is
same for both the plots i.e. spindle speed 1500 rpm, feed rate 0.1 mm/rev and depth of cut 1.0
mm and material type EN47.

5.2.3 Analysis of variance (ANOVA)

Analysis of variance (ANOVA) consists of simultaneous hypothesis tests to determine if any

of the effects are significant. Note that saying “factor effects are zero” is equivalent to saying
“the means for all levels of a factor are equal”. Thus, for each factor combination ANOVA
tests the null hypothesis that the population means of each level are equal, versus not all being
equal (alternate hypothesis). This analysis was carried out for significance level of α=0.5 i.e.
for a confidence level of 95%. When the p-value is small (i.e. less than 0.05) reject the null
hypothesis and conclude that the levels of the corresponding factor are significantly different
(i.e. conclude that the effect sizes of that factor are significantly large). The experimental results

56
from table 5.1 were analysed with analysis of variance (ANOVA), which was used for
determining the factors significantly affecting the performance measures (i.e. surface
roughness).The results of ANOVA for surface roughness is shown in table 5.4. The factors
with a p-value less than 0.05 (i.e. confidence level of 95%) are considered to have a statistically
significant contribution to the performance measure. The last column of the tables shows the
percent contribution of significant factor of the total variation and indicating the degree of
influence on the result. Table 5.4 shows the result of ANOVA for surface roughness. It is
observed from the ANOVA table that p-value of feed rate (0.016) and spindle speed (0.017)
are less than 0.05. It means that feed rate and spindle speed have statistically significant effect
on surface roughness. The feed rate and spindle speed contributions for the surface roughness
are 46.09% and 44.67% respectively. The contribution of depth of cut is 1.46% and material
type is 5.58% which are not statistically significant.

Table 5.4: Analysis of variance (ANOVA) for surface roughness

Source DOF SS MS F-value p-value C (%)

Spindle Speed 3 1.32532 0.44177 20.43 0.017 44.67

Feed Rate 3 1.36727 0.45576 21.08 0.016 46.09

Depth of Cut 3 0.04342 0.01447 0.67 0.625 1.46

Material Type 3 0.16567 0.05522 2.55 0.231 5.58

Error 3 0.06487 0.02162 2.19

Total 15 2.96654 100

(Significance level= 0.05)
Where, DOF- Degree of Freedom, SS- Sum of Squares, MS- Mean of Squares, F- A Statistical Parameter, P-
Significance Value and C- Percentage Contribution.

5.2.4 Normal probability plot

If at least one of the p-value in ANOVA analysis is below 0.05, it is necessary to check the
assumptions of ANOVA before we draw conclusions. Assumptions of this technique include

57
that the sampled populations are normally distributed and have equal variances. ANOVA
requires the population in each treatment from which you draw your sample be normally
distributed. The population normality can be checked with a normal probability plot of
residuals. If the distribution of residuals is normal, the plot will resemble a straight line. The
constant variance assumption is checked by the plot of residuals versus fitted values. If the plot
of residual vs. fitted values (treatment) does not show any pattern, the constant variance
assumption is satisfied. Figure 5.3 shows the normality plot of the residuals for surface
roughness. It is observed that the residuals follow a normal distribution. Figure 5.4, i.e. plot of
residuals versus fitted values for surface roughness, does not show any pattern. Thus,
assumptions of normality and constant variance are satisfied.

Figure 5.3: Normality plot of residuals for surface roughness

58
 Figure 5.4: Residuals versus fitted values plot for surface roughness

5.3 Optimal parameter combination for material removal rate (MRR)

After conducting all the 16 experiments having different combinations of process parameters
designed by Taguchi’s orthogonal array, the material removal rate (MRR) is calculated using
equation (4.1) and equation (4.2). The table 5.5 shows necessary observation values required
to calculate MRR by the two different formulas. Table 5.6 shows the cutting parameter
combination and difference in MRR values calculated by equation (4.1) and equation (4.2) of
all the 16 experiments with the percentage error. The S/N ratios are calculated using MINITAB
17 software and are tabulated in table 5.7.

59
 Table 5.5 Observation data matrix

Exp. No. Initial Final Dia. M/C Initial Final M/C Time
Dia. (mm) (mm) length Weight Weight (sec)
(mm) (g) (g)

1 34 33.75 50 1086 1079 35.42

2 34 33.50 50 1136 1125 28.84

3 34 33.25 50 1094 1079 22.57

4 34 33 50 1112 1091 19.11

5 34 33.50 50 1108 1096 27.98

6 34 33.75 50 1104 1097 22.49

7 34 33 50 1126 1103 17.35

8 34 33.25 50 1088 1072 15.01

9 34 33.25 50 1091 1075 23.54

10 34 33 50 1079 1060 19.09

11 34 33.75 50 1125 1121 16.63

12 34 33.50 50 1080 1069 12.34

13 34 33 50 1072 1049 20.30

14 34 33.25 50 1105 1090 17.04

15 34 33.50 50 1097 1086 12.96

16 34 33.75 50 1096 1089 10.86

60
 Table 5.6: Observation taken during experiment

Exp. Spindle Feed Rate Depth Material MRR by MRR by Difference % Error
No. Speed (mm/rev) of Cut Type Eq.(4.1) Eq.(4.2) of MRR
(rpm) (mm) (𝒎𝒎𝟑 / (𝒎𝒎𝟑 /
𝐬𝐞𝐜) 𝐬𝐞𝐜)

1 900 0.1 0.25 EN8 18.778 25.337 6.559 25.887

2 900 0.13 0.50 EN24 45.956 48.588 2.632 5.416

3 900 0.16 0.75 EN31 87.757 85.205 2.552 2.908

4 900 0.19 1.0 EN47 137.681 140.714 3.033 2.155

5 1100 0.1 0.50 EN31 47.368 54.984 7.616 13.851

6 1100 0.13 0.25 EN47 29.575 40.422 10.847 26.834

7 1100 0.16 1.0 EN8 151.647 169.955 18.308 10.772

8 1100 0.19 0.75 EN24 131.957 135.791 3.834 2.823

9 1300 0.1 0.75 EN47 84.141 87.272 3.131 3.587

10 1300 0.13 1.0 EN31 137.825 127.601 10.224 7.418

11 1300 0.16 0.25 EN24 39.996 30.641 9.355 23.389

12 1300 0.19 0.50 EN8 107.404 113.822 6.418 5.638

13 1500 0.1 1.0 EN24 129.610 144.332 14.722 10.200

14 1500 0.13 0.75 EN8 116.237 112.857 3.380 2.907

15 1500 0.16 0.50 EN47 102.265 109.229 6.964 6.375

16 1500 0.19 0.25 EN31 61.246 83.370 22.124 26.537

61
 Table 5.7: Experimental design using 𝐿16 orthogonal array for MRR with S/N ratio

Experiment Spindle Feed Rate Depth of Material Material S/N Ratio

No. Speed (mm/rev) Cut (mm) Type Removal Rate
(dB)
(rpm) by eq.(4.1)
(𝒎𝒎𝟑 /𝒔𝒆𝒄)

1 900 0.1 0.25 EN8 18.778 25.4732

2 900 0.13 0.50 EN24 45.956 33.2468

3 900 0.16 0.75 EN31 87.757 38.8656

4 900 0.19 1.0 EN47 137.681 42.7775

5 1100 0.1 0.50 EN31 47.368 33.5097

6 1100 0.13 0.25 EN47 29.575 29.4184

7 1100 0.16 1.0 EN8 151.647 43.6167

8 1100 0.19 0.75 EN24 131.957 42.4087

9 1300 0.1 0.75 EN47 84.141 38.5001

10 1300 0.13 1.0 EN31 137.825 42.7866

11 1300 0.16 0.25 EN24 39.996 32.0403

12 1300 0.19 0.50 EN8 107.404 40.6204

13 1500 0.1 1.0 EN24 129.610 42.2528

14 1500 0.13 0.75 EN8 116.237 41.3069

15 1500 0.16 0.50 EN47 102.265 40.1946

16 1500 0.19 0.25 EN31 61.246 35.7416

62
5.3.1 Main effects plots

The data is further analysed with the help of main effects plots using software package Minitab
17. The plots show the variation of individual response with the three machining parameters;
spindle speed, feed rate, depth of cut and material type separately. In the plots, the x-axis
indicates the value of each machining parameters at four level and y-axis indicates the response
value. The main effects plots are used to determine the optimal design conditions to obtain the
higher material removal rate. Figure 5.5 shows the main effects plot for material removal rate.
The results show that with the increase in spindle speed there is an increase in material removal
rate. On the other hand, as the feed rate increases the material removal rate shows a continuous
increase. However, with the increase in depth of cut the material removal rate increases at a
much faster rate as compared to other parameters. But in case of material type, the material
removal rate decreases and then increases slightly. It is observed from figure 5.5 that higher
material removal rate is obtained at spindle speed of 1500 rpm (level 4), feed rate of 0.19
mm/rev (level 4) and depth of cut of 1.0 mm (level 4) and material type of EN8 (level 1).

Figure 5.5: Main effects plot for MRR

From table 5.8, it is clearly observed that depth of cut is having the greatest effect on material
removal rate (rank 1) followed by feed rate (rank 2), spindle speed(rank 3) and material type
(rank 4).

63
 Table 5.8: Response table for means
Level Spindle Speed Feed Rate Depth of Cut Material Type
1 72.54 69.97 37.40 98.52
2 90.14 82.40 75.75 86.88
3 92.34 95.42 105.02 83.55
4 102.34 109.57 139.19 84.42
Delta 29.80 39.60 101.79 14.97
Rank 3 2 1 4

5.3.2 Signal-to-Noise (S/N) ratio plots

Regardless of the category of the performance characteristics, a greater S/N value corresponds
to a better performance. Therefore, the optimal level of the machining parameters is the level
with the largest value. On the basis of figure 5.6, the predicted optimal parameter setting for
maximum material removal rate is spindle speed 1500 rpm (level 4), feed rate 0.19 mm/rev
(level 4) and depth of cut 1.0 mm (level 4) and material type EN8 (level 1).

Figure 5.6: S/N ratios plot for MRR

The advantage of S/N ratios plot is that it also provides the significant rank’s hierarchy of
machining (input) parameters. As it can be clearly observed from table 5.9 that depth of cut is

64
having (rank 1) the greatest effect on the response parameter i.e. material removal rate,
followed by feed rate (rank 2), spindle speed (rank 3) and lastly material type (rank 4).

Table 5.9: Response table of S/N ratios for MRR

Level Spindle Speed Feed Rate Depth of Cut Material Type

1 35.09 34.93 30.67 37.75
2 37.24 36.69 36.89 37.49
3 38.49 38.68 40.27 37.73
4 39.87 40.39 42.86 37.72
Delta 4.78 5.45 12.19 0.27
Rank 3 2 1 4

On comparing the main effects plot (Figure 5.6) and S/N ratio plot (Figure 5.7) of material
removal rate, it can be concluded that the optimum machining (input) parameters combination
is same for both the plots i.e. spindle speed 1500 rpm, feed rate 0.19 mm/rev and depth of cut
1.0 mm and material type EN8.

5.3.3 Analysis of Variance (ANOVA)

Analysis of variance (ANOVA) consists of simultaneous hypothesis tests to determine if any

of the effects are significant. Note that saying “factor effects are zero” is equivalent to saying
“the means for all levels of a factor are equal”. Thus, for each factor combination ANOVA
tests the null hypothesis that the population means of each level are equal, versus them not all
being equal. This analysis was carried out for significance level of α=0.5 i.e. for a confidence
level of 95%. When the p-value is small (i.e. less than 0.05) reject the null hypothesis and
conclude that the levels of the corresponding factor are significantly different (i.e. conclude
that the effect sizes of that factor are significantly large). The experimental results from Table
5.7 were analysed with analysis of variance (ANOVA), which was used for determining the
factors significantly affecting the performance measures (i.e. material removal rate).The results
of ANOVA for material removal rate is shown in table 5.10. The factors with a P-value less
than 0.05 (i.e. confidence level of 95%) are considered to have a statistically significant
contribution to the performance measure. The last column of the tables shows the percent
contribution of significant factor of the total variation and indicating the degree of influence on

65
the result. Table 5.10 shows the result of ANOVA for material removal rate. It is observed
from the ANOVA table that p-value of depth of cut (0.004) is less than 0.05. It means that
depth of cut has statistically significant effect on material removal rate. The percentage
contributions of depth of cut for the material removal rate is 78.31%. However the contribution
of other factors such as feed rate is 12.13%, spindle speed is 6.43% and material type is 1.74%,
which are not statistically significant. Dave et al. (2012), showed that during the machining of
two different grades of EN materials i.e. EN8 & EN31, depth of cut is found to be the most
significant factor for material removal rate. They showed that the percentage contribution of
depth of cut is about 81.91%, followed by spindle speed 6.17%, feed rate 0.798%. Further
Kaladhar et al. (2012) investigated the effect of process parameters on MRR, and they showed
that depth of cut and feed rate are the significant factors affecting MRR.

Table 5.10: Analysis of variance (ANOVA) for material removal rate

Source DOF SS MS F-value p-value C (%)

Spindle Speed 3 1843.1 614.4 4.62 0.120 6.43

Feed Rate 3 3477.9 1159.3 8.73 0.054 12.13

Depth of Cut 3 22454.8 7484.9 56.35 0.004 78.31

Material Type 3 498.6 166.2 1.25 0.429 1.74

Error 3 398.5 132.8 1.39

Total 15 28672.9 100

(Significance level= 0.05)

Where, DOF- Degree of Freedom, SS- Sum of Squares, MS- Mean of Squares, F- A Statistical Parameter, P-
Significance Value and C- Percentage Contribution.

66
5.3.4 Normal probability plot

If at least one of the p-value in ANOVA analysis is below 0.05, it is necessary to check the
assumptions of ANOVA before we draw conclusions. Assumptions of this technique include
that the sampled populations are normally distributed and have equal variances. ANOVA
requires the population in each treatment from which you draw your sample be normally
distributed. The population normality can be checked with a normal probability plot of
residuals. If the distribution of residuals is normal, the plot will resemble a straight line. The
constant variance assumption is checked by the plot of residuals versus fitted values. If the plot
of residual vs. fitted values (treatment) does not show any pattern, the constant variance
assumption is satisfied. Figure 5.7 shows the normality plot of the residuals for material
removal rate. It is observed that the residuals follow a normal distribution. Figure 5.8, i.e. plot
of residuals versus fitted values for material removal rate, does not show any pattern. Thus,
assumptions of normality and constant variance are satisfied.

Figure 5.7: Normality plot of residuals for material removal rate

67
 Figure 5.8: Residuals versus fitted values plot for material removal rate

5.4 Confirmation experiment

Based on the S/N ratios and ANOVA analyses, the optimal levels of all the control factors’
combination are identified. As mentioned before the optimum setting of parameters for surface
roughness is A4B1C4D4 and for material removal rate is A4B4C4D1. A confirmation
experiment is the final step of a design of experiment. Its purpose is to verify that the optimum
conditions suggested by the matrix experiment do indeed give the projected improvement. The
confirmation experiment is performed by conducting a test with optimal settings of the factors
and levels previously evaluated. The predicted value of S/N ratio at optimum level (𝜂0 ) is
calculated by formula (5.1).
𝑗
𝜂0 = 𝜂𝑚 +) ∑𝑖=1( 𝜂𝑖 − 𝜂𝑚 ) (5.1)

Where, j is the number of factors and 𝜂𝑚 is the mean value of S/N ratios in all experimental
runs, 𝜂𝑖 are the S/N ratios corresponding to optimum factor levels (Ross 1996, Dubey et al
2007).

68
5.4.1 S/N ratio calculation at optimum level

For surface roughness:

𝜂0 = 𝜂𝑚 + (𝜂𝐴4 -𝜂𝑚 ) + (𝜂𝐵1 -𝜂𝑚 ) + (𝜂𝐶4 -𝜂𝑚 ) + (𝜂𝐷4 -𝜂𝑚 ) (5.2)

Where,
𝜂0 is optimum S/N ratio,

𝜂𝑚 is the overall mean of S/N values,

𝜂𝐴4 is the average value of S/N at fourth level of spindle speed (1500 rpm).

𝜂𝐵1 is the average value of S/N at the first level of feed rate (0.1 mm/rev.).

𝜂𝐶4 is the average value of S/N at fourth level of depth of cut (1 mm).

𝜂𝐷4 is the average value of S/N at fourth level of material type (EN47).

From table 5.3, we have

𝜂𝑚 = -0.54427 𝜂𝐴4 = 0.89351 𝜂𝐵1 = 3.82248 𝜂𝐶4 = 0.30671

𝜂𝐷4 = 0.36406

𝜂0 = -0.54427 + (0.89351+0.54427) + (3.82248+0.54427) + (0.30671+0.54427) +

(0.36406+0.54427)

𝜂0 = 7.01957 (5.3)

If the optimum S/N ratio is known the value of surface roughness can be determined by
equation 3.3. The procedure is to back-transform S/N ratio to find expected performance value
(Roy 2001, Savaşkan 2003).

When the optimum S/N ratio value obtained in equation (5.3) is put into equation (3.3), the
expected performance value for surface roughness comes out to be

𝑆⁄ = −10. log( 1 ∑𝑛 𝑦 2 )
𝑁𝑠 𝑛 𝑖=1 𝑖

7.01957 = -10 log y2

7.01957 = -20 log y
Log y = -0.3509785
y = 10-0.3509785
y = 0.4456

69
For material removal rate the same procedure is followed as that of surface roughness for
calculating the optimum S/N ratio and then the expected performance value. The results for
both the response parameters are tabulated in table 5.11.

Table 5.11: Results of confirmation experiment

Optimal cutting parameter

Prediction Experimental
Level A4B1C4D4 A4B1C4D4
Surface Roughness (µm) 0.4456 0.4857
S/N ratio (dB) 7.01957 6.27263
Level A4B4C4D1 A4B4C4D1
Material Removal Rate
246.959 259.250
(𝑚𝑚3 /sec)
S/N ratio (dB) 47.8525 48.27437
A4 (Spindle Speed=1500 rpm); B1 (Feed rate=0.1mm/rev.); C4 (Depth of cut= 1mm);
D4 (Material Type= EN47); B4 (Feed rate= 0.19mm/rev.); D1 (Material Type=EN8)

The confirmation test is done to check whether the predicted results are in acceptable zone with
respect to the experimental results or not based on the optimised process parameters. Thus,
analysing the results of confirmation test shown in table 5.11, it can be concluded that the
predicted values of surface roughness and material removal rate seems to have been in good
agreement with the experimental values.

5.5 Conclusion

In this chapter, an optimal parameter combination of input parameters have been obtained using
main effects and S/N ratio plots for surface roughness and material removal rate. The results
show that optimum parameter for surface roughness is speed 1500 rpm (level 4), feed rate 0.1
mm/rev (level 1), depth of cut 1.0 mm (level 4) and material type EN47 (level 4). Whereas for
material removal rate the optimum parameter is speed 1500 rpm (level 4), feed rate 0.19
mm/rev (level 4), depth of cut 1.0 mm (level 4) and material type EN8 (level 1). An analysis
of variance (ANOVA) is performed to find out which process parameter has statistically
significant effect on surface roughness and material removal rate. The ANOVA results show
that spindle speed and feed rate have statistically significant effect on surface roughness and in

70
case of material removal rate depth of cut has statistically significant effect. A confirmation
experiment is carried out to verify the optimal process parameter settings obtained during this
study. The confirmation test results shows that the predicted values of surface roughness and
material removal rate are in the acceptable zone with respect to the experimental values based
on the optimized process parameters.

71
 CHAPTER 6
CONCLUSIONS AND SCOPE FOR FUTURE WORK
6.1 Conclusions
In this study, an attempt has been made to apply the parameter design of the Taguchi method
in the optimization of turning operations. The following conclusions can be drawn based on
the results of this study:

 Taguchi’s robust orthogonal array design method is suitable to analyse the surface
roughness and material removal rate during turning operation.
 It is found that the parameter design of the Taguchi method provides a simple,
systematic and efficient methodology for the optimization of the machining parameters.
 In turning for minimum surface roughness, use of higher spindle speed (1500 rpm),
lower feed rate (0.1 mm/rev), higher depth of cut (1.0 mm) and EN grade material
(EN47) i.e. A4B1C4D4, are recommended to obtain lower surface roughness.
 The experimental results show that the effect of spindle speed on surface roughness is
about (48.17%) and feed rate is (42.54%) respectively. These are the main parameters
among the four controllable factors (spindle speed, feed rate, depth of cut and material
type) that influence the surface roughness.
 In turning for maximum material removal rate, use of higher spindle speed (1500 rpm),
higher feed rate (0.19 mm/rev), higher depth of cut (1.0 mm) and EN grade material
(EN8) i.e. A4B4C4D1, are recommended to obtain a higher material removal rate for
the specific test range.
 The experimental results show that the depth of cut (78.31%) and feed rate (12.13%)
are the main parameters among the four controllable factors (spindle speed, feed rate,
depth of cut and material type) that influence the material removal rate as a response
parameter.
 The confirmation test results shown in table 5.11 shows that the predicted values of
surface roughness and material removal rate are in the acceptable zone with respect to
the experimental values based on the optimised process parameters.

72
6.2 Scope for future work

Turning process provides a wide spread area for research and study. Future works may include:

 Performing the experiments with same input and output parameters in dry
environment.
 Performing the simultaneous optimization of surface roughness and material
removal rate under various working environment.
 More study is essential to know the effect of other parameters such as tool geometry,
tool material, machine vibration etc. on cutting performance in turning
environment.
 The effect of cutting parameters on tool life, residual stress and temperature rise in
turning method can be explored.
 Further investigation is necessary to assess the impact of cutting tool edge
condition, effect of rake angle and effect of the process on other materials.
 There is also a possibility of evaluating the tool wear under various working
environments.

Attempts can be made to make the process more effective and productive by removing the
inherent difficulties of the process.

73
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