Tefera et al.

Journal of Engineering
Journal of Engineering and Applied Science (2023) 70:145
https://doi.org/10.1186/s44147-023-00314-5 and Applied Science

RESEARCH Open Access

Experimental investigation and optimization

of cutting parameters during dry turning
process of copper alloy
Aklilu Getachew Tefera1, Devendra Kumar Sinha1* and Gaurav Gupta2

*Correspondence:
ds3621781@gmail.com Abstract
1
Department of Mechanical Increasing the quality and productivity of machined components are the main
Engineering, School issues of machining operations in metalworking industries. The copper alloys CuZr
of Mechanical, Chemical and CuCrZr generally find applications for current-carrying structural components,
and Materials Engineering,
Centre of Advanced seam welder wheels, shafts, and bearings flash. The manufacturing of these compo-
Manufacturing Engineering, nents is still facing challenges in the form of machining process characteristics. One
Adama Science and Technology of the most common machining operations for removing material is turning that pro-
University, Adama, Ethiopia
2
Mechanical Engineering duces reasonably good surface finish quality, which is influenced by different factors
Department, Amity School (speed of cut, rate of feed, tool geometry, cutting fluid, cutting tool, etc.). This research
of Engineering, Noida, India has focused on experimental study and optimization of the cutting parameters viz.
cutting speed, depth of cut, and feed, for best surface finish, material removal rate,
tool tip temperature as well as surface morphology during dry turning of C15000
and C18150 copper alloy using High-Speed Steel (HSS) tool The plan and design
of experiment has been performed through orthogonal Taguchi L9. array. The opti-
mum cutting settings were discovered by using the Taguchi technique and using
the performance index by applying a Grey Relational Grade (GRG). The best cutting
parameters for both materials were a cutting speed 1200 rpm, feed rate 0.06 mm/rev,
and depth of cut 1.25 mm. The optimum factors obtained from GRA for all responses
(surface roughness, MRR, and tool temperature) at the best level of cutting parameters
are the same for both materials. These cutting parameters values yielded the experi-
mental result for each response like surface roughness, MRR, and tool tip temperature
(2.5 µm,12,475 ­mm3/min, and 74 °C) for grade C15000 whereas (2.39 µm, ­2590mm3/
min and 68 °C) for grade C18150. The optimization of cutting parameters plays a vital
role in the improvement of surface finish which minimizes mechanical failures caused
by wear, corrosion, and thereby increasing the productivity of the products. This inves-
tigation is expected to help all researchers working in this area of applications.
Keywords: C15000, C18150, Taguchi orthogonal array, High speed steel, Surface
roughness, Metal removal rate, Tool temperature, Grey relational analysis

Introduction
The excellent mechanical, thermal, and electrical conductivities of copper and its alloys
lead to them being more popular materials. Other important properties of copper and
its alloys include exceptional corrosion resistance, machinability, high heat conductivity,

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Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 2 of 26

and excellent electrical conductivity. With extraordinarily high softening temperatures,

copper zirconium is a great resistance welding material. A small addition of zirconium
to copper enhances resistance to softening and resists deformation at high tempera-
tures when normal copper would rapidly melt. Due to its excellent thermal conductivity,
which minimizes sticking, it is especially helpful during the welding of galvanized mate-
rials. The two copper alloys (CuZr and CuCrZr) are more frequently used in mechanical
joining techniques like rivets and screws as well as applicable in electrical applications
such as switching contact bridges and separation rings [1]. Additionally, it is useful for
current-carrying structural components, seam welder wheels, shafts, and bearings flash
and butt-welding dies, and projection welding dies. The turning is the most widely used
operation due to its advantages of high-speed removal of material and acceptable surface
quality. By removing excess metal from a workpiece through the relative motion of a
single-point cutting tool that is either parallel to or perpendicular to the rotating cylin-
drical workpiece, a workpiece is machined to the desired size and shape in the turning
process [2]. The most crucial step in every turning operation is choosing the best cutting
parameters to produce suitable surface quality, excessive material removal rate, and a
minimum tool wear rate. The surface quality, size, and texture of the workpiece reflect
the impact of the cutting parameters.
The most commonly used materials CuZr and CuCrZr find vast applications in pre-
cision components owing to their special properties like ductility, thermal conduc-
tivity, hardness, and strength. The machinability and surface characteristics of the
component over its useful working life play a major role during the selection of mate-
rial for machine components. To avoid the occurrence of defects such as dimensional
inaccuracy, wear, corrosion, valley formation, and crack formation, there is a need to
explore the machining characteristics of CuZr and CuCrZr alloys as there is a lack of
sufficient investigation about machining performance and machinability data related
to this material. The optimization of controllable parameters needs to be explored to
achieve the best machinability and surface characteristics during the machining of
CuZr and CuCrZr to make it suitable for various applications. The most important
engineering problem is to maintain the optimum balance between manufacturing cost
and product quality without negatively damaging the environment. The surface finish
of an item is crucial in this machining process for estimating its quality [3]. Surface
roughness, which has an influence on tribological characteristics, corrosion resistance,
and fatigue life, is a crucial factor. It indicates the condition of tool wear and provides
an indication of the quality of machined products. The type of tool, cutting param-
eters, tool condition (wear, built-up edge), work material machinability, vibration, etc.
all have an impact on the surface [4]. Surface integrity refers to the topographical (geo-
metric) characteristics of surfaces as well as their physical, chemical, mechanical, and
metallurgical characteristics. The ongoing requirement for greater surface integrity
and higher functional performance of manufactured components due to modern tech-
nological improvements in high precision and new machining capabilities has made it
possible to make smaller components [5].
The function that various machining fluids, including vegetable oil, mineral oil, syn-
thetic oil, and nanofluid-based machining fluid, play a vital role in improving MQL
(minimum quantity lubrication) machinability during turning, milling, and grinding
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 3 of 26

operations. Today, minimum quantity lubrication technology is the talk of many

industry sectors in terms of machining temperature, surface quality, tool wear, and
tool life. It was determined that nano-particle-based machining fluid performed bet-
ter than traditional machining fluid. Reduced tool wear, improved surface polish, and
decreased machining oil consumption were the results of using machining fluid based
on nanoparticles. Surface roughness measurements under MQL conditions were
found to be lower than those under dry and wet machining environments, particu-
larly at the greatest cutting speed [6].
Hard turning of AISI D2 steel (53 HRC) uses a multilayer coated carbide insert in
a wet cutting environment and the Taguchi design of the experiment for improving
the process parameters. The regression model has also been created and evaluated
for suitability. The study’s goal is to evaluate, using the Taguchi design of experiments
how well multilayer coated carbide inserts perform during machining of hardened
AISI D2 steel (53 HRC). To predict surface roughness, the experiment was created
using the Taguchi L27 orthogonal array. The most effective parametric condition
and S/N ratio were examined. An analysis of variance was also done to identify the
key elements influencing surface roughness. According to the Taguchi S/N ratio and
ANOVA, cutting speed was the second most important factor for surface roughness,
while feed had the least significant effect in the studies [7].
In order to optimize, the Grey Relational technique was used to determine the ideal
number of factors on multi-response characteristics. The percentage contributions of
significant factors were calculated with ANOVA (surface roughness) [8]. The machin-
ing of nickel-silicon-chromium-copper (C18000) performs when it was assessed
for surface roughness and peak-to-valley profile (accuracy) under optimum process
parameters [9]. The goal of the study on this material was to provide a mirror finish
and eliminate profile inaccuracies. Surface roughness and profile accuracy are greatly
affected by the tool nose radius, feed rate, depth of cut, and spindle speed.
By determining flank wear, surface quality, and chip morphology while finishing
turning AISI 52100 bearing steel (55 ± 1 HRC) in a dry environment using a car-
bide insert coated with various layers (TiN/TiCN/Al2O3), the researcher looks into
the characteristics of machinability. ANOVA was used to analyze the effects of the
machining factors, cutting speed, feed rate, and depth of cut, on the responses.
Quadratic regression and an Artificial Neural Network were used to model the data.
Using Taguchi-based GRA, multi-parametric optimization of cutting conditions was
achieved. According to an analysis of chip morphology, a multilayer-coated carbide
insert produces a lower temperature, preserves the sharpness of the cutting edge, and
slows the development of tool wear [10].
The turning operations with different performance criteria were solved using a grey
relational grade generated from the grey relational analysis. The Taguchi approach,
which uses the grey relational grade as the performance index was able to be utilized
to identify the ideal cutting parameters. The study optimizes the cutting parameters,
such as cutting speed, feed rate, and depth of cut, using these features. Therefore, by
using this method, complex multiple performance characteristic optimizations may
be significantly optimized. It has been shown that the approach suggested by this
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 4 of 26

study improves the turning operations’ performance characteristics, such as tool life,
cutting force, and surface roughness, collectively [11].
Multi-objective grey analysis to define hole features in abrasive water jet drilling was
carried out. To determine the pattern in which each parameter influences the process
performance, the analysis of the variance of the individual responses was used. Impor-
tant turning features include tool life, cutting force, and surface roughness. This strat-
egy improved the outcomes of experiments. Therefore, by using this method, complex
multiple-performance characteristic optimization can be significantly optimized. It is
shown that the method recommended by this study enhances the turning operations’
performance characteristics, such as tool life, cutting force, and surface roughness [12].
The L9 orthogonal array was successfully tested using the Taguchi method. Three
levels of input parameters, such as cutting speed, depth of cut, and feed rate, were
used in the trials, which were carried out on an all-geared lathe using carbide tools.
For surface roughness, it was discovered that the feed rate was the most significant
parameter, followed by the depth of cut. The reduction in surface roughness from the
initial cutting settings to the optimum cutting parameters was approximately 300%
and 252%, respectively [13].
The effects of temperature in tooltip on the wear of ceramic cutting insets used to
machine Inconel 718 at varied hardness levels between 26 and 45 HRC. The temperature
of the tooltip and the wear on the crater were examined in relation to cutting speed [14].
During the turning process, a sequence of tests was executed to monitor the tempera-
ture of the tooltip under controlled process conditions. Under dry machining circum-
stances, triangular cutting inserts made of silicon nitride ceramic (6190), mixed oxide
ceramic (6050), and aluminum oxide ceramic (620) were employed. It was found that
when cutting speed increases, cutting temperature grows monotonically. Additionally,
crater wear caused by heating that builds up on the surface was close to the tooltip. In
the development of temperature at the cutting tool’s tip and wear, the hardness of the
workpiece is a major factor, and cutting speed is second. With increased cutting speed
and all cutting inserts, the temperature at the tooltip rises. All three of these ceramic
inserts had an average temperature increase of 22%, for a 40% improvement in cutting
speed.
The experiment’s workpiece was OHNS (Oil Hardened Non-Shrinkage Steel). L9 OA
was used in the studies to examine how the machining parameters affect the tempera-
ture of the tooltip [15]. The cut depth has shown the highest impact on tool tip tem-
perature, followed by feed and spindle speed. The use of low values of depth of cut and
spindle speed to achieve a minimal temperature in the case of OHNS during the work
time was taken into consideration in this study. It was found that tungsten carbide tool
machining produces the greatest results at medium speed and medium depth of cut,
whereas polycrystalline diamond tool machining produces the best results at high speed
and low depth of cut.
The experimental runs, which were carried out at cooled and ambient temperatures,
were planned using the Taguchi L18. Cutting speeds, feed rates, and depth of cut were
the machining parameters, and the temperature at the tool to workpiece interface
was measured using a digital thermometer. Surface roughness and material removal
rate were chosen as the control variables. With a 58.6% temperature drop during wet
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 5 of 26

machining and an 86.9% decrease during cool machining, the use of coolant allowed
a drop in temperature between the interface of the tool and the workpiece. The major
objective of this study will be a comparison of the contributions of liquid coolant to
lower the cutting temperature [16]. Here, three variables speed, depth of cut, and feed
rate were taken into consideration as indicators of cutting temperature and surface
roughness when coolant-free and coolant-operated operations were performed with
metal C45. On a CNC machine, during turning operation, the depth of cut and rota-
tional speed were often the most significant variables affecting the cutting tool tem-
perature and the surface in dry operation as well as in coolant operation.
In order to change a material’s physical and chemical properties, heat treatment is
a combination of industrial and metalworking operations. In order to give a material
the desired properties, such as hardening or softening, heat treatment entails heat-
ing it to a specific temperature. The main methods for heat treatment are thermo-
chemical treatment, surface treatment, annealing, and solution treatment. Titanium
and its alloys had enhanced mechanical strength, fracture toughness, creep strength,
and fatigue strength using solution treatment and age. Medical implants’ surfaces can
be treated to inhibit bacterial growth without affecting cell metabolism. Addition-
ally, it improved the coefficient of friction and wear resistance of titanium alloys. The
ductility, fracture toughness, thermal and dimensional stability, and creep resistance
of titanium alloys were improved by annealing. The yield strength of materials was
enhanced by aging [17].
The impact of the tool coating, radius of the cutting-edge, angle of chamfer, corner
radius, and cutting-edge radius on the thermo-mechanical stress during cryogenic
turning was investigated. The resultant surface morphology was assessed and ana-
lyzed to enhance the surface morphology, and recommendations for tool design were
investigated [18].
Increasing cutting-edge radii and chamfer angles increases the subsurface qualities
while decreasing the topography on the surface. Here, based on the qualities needed
for the application of the manufactured component, an adjustment of the original
geometry was required [19]. Examined through scanning electron microscopy (SEM),
how the surface influences Abrasive Water Jet Machining (AWJM) parameters on
composite material throughout the machining process. The presence of reinforcing
particles contributed to the production of grooved lines, surface erosion, and plough-
ing materials Similarly, a high weight percentage of TiC makes the composite mate-
rial tougher, which leads to poor machinability and poor surface quality. The garnet
particles interact with the reinforcement particles at the same augmented weight per-
centage, causing the aluminum matrix to dissolve and increasing surface roughness.
To achieve the required precision and concision, the surface morphology was evalu-
ated using a novel evaluation technique that incorporates a wavelet filter and fractal
theory [20].
The machining characteristics of the accelerated cooling environment (ACE)
spray jet cooling technology that was used in the hard turning of D2 steel employ-
ing ceramic inserts and a minimum quantity of lubricant. It was observed that
chipping and abrasion were the primary wear mechanisms. Cutting temperature
and flank wear are significantly influenced by cutting speed and depth of cut, but
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 6 of 26

average surface roughness was significantly influenced by feed. At faster cutting

rates and higher feeds, serrated chips were seen. The results of the investigation
support the adoption of ACE in environmentally and economically challenging
industrial sectors [21].
Rapid tool wear took place while cutting resulting in surface degradation and rising
manufacturing costs. Chippings and distortion at the cutting edge degraded cutting tool
strength and structure. Secondly, surface roughness and defects looked into the effect of
tool wear on the related surface topography [22]. The mechanical characteristics like work
hardening and residual stress as well as metallurgical aspects like dynamic recrystallization
and grain structure, as well as surface roughness, defects (metal debris, surface cavities,
smeared material, plucking, cracked carbide particles, redeposited material, feed marks,
laps, and grooves) were listed [23]. Because of the enhanced non-homogeneities of the met-
allurgical phases inside the recast layer, micro-cracks may develop in this extremely hard,
brittle layer. The main cause of cracks is thermal stress on the workpiece was brought on
by large temperature swings over a short period of time as well as an unequal distribution
of temperature throughout the surface area [24]. The feed mark, debris, tearing, and micro-
voids were the surface defects of the machined HIP workpiece. The feed mark, debris, and
ripping flaws occur in the same ways as the surface of a machined forging workpiece [25].
From the literature review, it is clear that very few works have been done on C15000 and
C18150 related to their behavior during dry turning operations at various boundary condi-
tions. Also, the optimization of process parameters through GRA has been not explored
much in the recent past. Therefore, in the present paper, an attempt has been made to
explore the machining characteristics of widely used copper alloys C15000 and C18150.
Also, optimization of controllable parameters to achieve the best machinability and surface
characteristics during machining of CuZr and CuCrZr has been done.

Materials and methods

Materials and its compositions
Copper grades used in this study are C18150 and C15000, which have a high ductility but
both materials have lower ductility than pure copper. The composition has been identified
using a portable Optical Emission Spectrometer (OES). Table 1 below shows the composi-
tion of CuZr (C15000). Table 2 depicts the mechanical and physical properties of C15000.
Tables 3 and 4 below depict the composition of C18150 and the Mechanical and Physical
properties of C18150 respectively.
Table 5 below shows the mechanical properties of HSS.
The most critical task in the turning process is to choose cutting parameters that will
result in significant cutting quality and a good surface finish. Cutting parameters for
C18150 and C15000 copper were selected for testing based on the knowledge available on
the standard cutting parameters of copper according to tool manufacturer recommenda-
tions, manufacturer’s handbook guidelines for the test sample, existing industry practice,

Table 1 Composition of CuZr (C15000) [26]

Composition Cu Zr Ni Pb Zn Bi

Wt% 98.94 0.565 0.0416 0.0250 0.0152 0.0250

Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 7 of 26

Table 2 Mechanical and physical properties of CuZr (C15000) [26]

Properties Metric Imperial

Hardness (HV) 75 75
Tensile strength 415 MPa 60000psi
Poisson’s ratio 0.15 0.15
Modulus of Elasticity 129GPa 18700ksi
Machinability of elasticity 20% 20%
Melting point 980°c 1796°f
Density 8.89 g/cm3 0.321 lb/in3

Table 3 Composition of CuCrZr (C18150) [27]

Composition Cu Cr Zr Al Fe Si

Wt% 98.92 1.01 0.595 0.0298 0.0567 0.0511

Table 4 Mechanical and physical properties of [27]

Properties Metric Imperial

Hardness (HV) 95 95
Tensile strength 379 MPa 55000 psi
Modulus of elasticity 117 GPa 17000 ksi
Poisson’s ratio 0.18 0.18
Shear modulus 49.6 GPa 7200 ksi
Machinability of elasticity 20% 20%
Melting point 980 °C 1796°f
Density 8.89 g/cm3 0.321 lb/in3

Table 5 Mechanical properties of HSS [28]

Properties Hardness Young’s modulus Tensile strength Density Thermal expansion

Metric 750 HV 233 GPa 1280 MPa 7600 kg/m3 12.6 × ­10−6 ­k−1

Table 6 Cutting parameters for both C15000 and C18150 [29]

Cutting parameters Standard unit Levels

Cutting speed rpm 800(N1) 1000(N2) 1200(N3)

Feed rate mm/rev 0.05(f1) 0.055(f2) 0.06(f3)
Depth of cut mm 1.05(p1) 1.15(p2) 1.25(p3)

and experience. Recommended machining parameters for copper and copper alloys” con-
tinue a long tradition established by the German Copper Institute selected parameters.
Table 6 below depicts the cutting parameters for both workpieces made of C15000 and
C18150.
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 8 of 26

Fig. 1 Experimental procedure flow chart for determination of optimal parameters

Table 7 L9 design matrix

Exp No Cutting parameters
Cutting speed (rpm) Feed rate (mm/rev) Depth of
cut (mm)

1 800 0.050 1.05

2 800 0.055 1.15
3 800 0.060 1.25
4 1000 0.050 1.15
5 1000 0.055 1.25
6 1000 0.060 1.05
7 1200 0.050 1.25
8 1200 0.055 1.05
9 1200 0.060 1.15

Methodology
The flow chart’s schematic description of the framework. The flow chart of work meth-
odology has been depicted through Fig. 1.

Design matrix
In the present work, three factors with three levels for each have been selected and
Taguchi L9 orthogonal array has been chosen.. The design matrix of variables has been
shown in Table 7.
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 9 of 26

Grey relational analysis

The gray relational analysis begins by normalizing experimental data, commonly referred
to as measurable aspects of the item’s overall characteristics, to a range of zero to one.
The correlation between the desired and actual experimental data is symbolized by the
gray relational coefficient, which was determined using normalized experimental data.
The total gray relational grade is then calculated by averaging the gray relational coef-
ficients corresponding to the chosen responses [30]. The overall performance character-
istic of the multiple response processes is determined by the computed gray relational
grade. This strategy converts the multiple-response process optimization issue into a
single-response optimization scenario because the objective function is an overall gray
relational grade. The ideal parameter arrangement was subsequently selected by maxi-
mizing the total gray relational grade. Figure 2 shows the flow chart related to estimation
of Grey Relational Grade.

Results and discussion

The experimentations have led to the determination of the effects of cutting parameters
on surface roughness (Ra), MRR, and tool temperature during dry turning of the copper
grades C15000 and C18150. These factors include the speed of the spindle, feed rate,
and depth of cut. The outcomes of the experiments have been discussed in this section.
In order to determine the most important cutting parameters for both materials and

Fig. 2 Grey relational approach flowchart

Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 10 of 26

determine the impact of adding chromium (Cr) to copper zirconium (CuZr), the Tagu-
chi design was used to evaluate how cutting parameters affected response. The Grey
relational technique also used to find the ideal number of variables on multi-response
characteristics and to obtain the global factor.
Figure 3 demonstrates that after turning copper grades C15000 and C18150, all
nine tests, each with a different combination of cutting parameters, had a cut length
of 25 mm. The experimental workpiece has a 20-mm diameter. The standard copper
machining feed rates are 0.05, 0.055, and 0.06 mm/rev respectively, with depth of cut
of 1.25, 1.15, and 1.05 mm, cutting speed (800, 1000, and 1200 rpm), and the machin-
ing rate set at 20% for both grades of copper are the experimental conditions that were
chosen for both materials. C151, C152, and C153 were made of C15000 specimens with
first-level cutting speed (800 rpm), C154, C155, and C156 were made of C15000 speci-
mens with second-level cutting speed (1000 rpm), and C157, C158, and C159 were made
of specimens with third level spindle speed (1200 rpm).
Similar to the first piece with C181, C182, and C183, the second piece with C184, C185,
and C186 contained C18150 specimens with second-level cutting speed(1000 rpm), and
the third piece with C187, C188, and C189 contained C181500 specimens with third
level spindle speed (1200 rpm) with a wide range of feed rates and depths of cut.

Surface roughness comparison for CuZr and CuCrZr

Tables 8 and 9 show the surface roughness experimental results for CuZr and CuCrZr.
This demonstrates the experimental results for the levels of surface roughness (Ra) for
the particular CuZr and CuCrZr turned specimens. The SN ratio for each specimen is
listed in the table’s final columns, and each trial value of surface roughness (Ra) in this
study is the average value of two readings.
It has been observed from Fig. 4 that the surface roughness of C18150 is less as com-
pared to C15000 at various cutting conditions. The most important characteristic com-
mon to all chromium-containing copper alloys (C18150) is that they contain sufficient
chromium to make them corrosion-resistant, oxidation-resistant, and heat-resistant.
As the feed rate increases at constant cutting speed, the surface roughness is increased
both for CuZr and CuCrZr turned specimens. The higher feed rates signify more mate-
rial in contact with the cutting tool, hence higher cutting force evolution which causes
the vibration leading to high surface roughness. The increase in cutting force with an
increase in feed rate may be attributed to the higher friction between the tool and the

Fig. 3 Experimental sample after turning CuZr and CuCrZr

Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 11 of 26

Table 8 Experimental results of surface roughness (Ra) and S/N ratio for C15000 (CuZr)
Exp No Cutting parameters
Cutting speed Feed rate (mm/ Depth of cut I II Surface
(rpm) min) (mm) roughness,
Average (µm)

1 800 0.050 1.05 2.63 2.67 2.65

2 800 0.055 1.15 3.38 3.36 3.37
3 800 0.060 1.25 3.43 3.39 3.41
4 1000 0.050 1.15 2.11 2.17 2.14
5 1000 0.055 1.25 2.47 2.56 2.52
6 1000 0.060 1.05 2.64 2.58 2.61
7 1200 0.050 1.25 1.97 1.91 1.94
8 1200 0.055 1.05 2.31 2.23 2.27
9 1200 0.060 1.15 1.95 1.87 2.38

Table 9 Experimental results of surface roughness (Ra) C18150 (CuCrZr)

Exp No Cutting parameters
Cutting speed Feed rate Depth cut (mm) I II Average
(rpm) (mm/min) roughness of
surface, (µm)

1 800 0.050 1.05 2.48 2.56 2.52

2 800 0.055 1.15 3.15 3.21 3.18
3 800 0.060 1.25 3.36 3.42 3.39
4 1000 0.050 1.15 1.96 1.98 1.97
5 1000 0.055 1.25 2.41 2.37 2.39
6 1000 0.060 1.05 2.49 2.45 2.47
7 1200 0.050 1.25 1.67 1.65 1.64
8 1200 0.055 1.05 2.13 2.05 2.09
9 1200 0.060 1.15 2.33 2.25 2.29

Fig. 4 Surface roughness for each experimental run

Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 12 of 26

workpiece. Feed, on the other hand, negatively influences the surface roughness, where
the surface finish deteriorates with an increase in feed. Higher feed rates also cause an
increase in the cutting temperature, which leads to more tool wear hence undesired
surface roughness. Also, the SR tends to decrease with the increase in speed with the
minimum SR occurring at maximum speed. When feed increases, the SR increases.
Therefore, the minimum SR prevails with the combination of maximum speed and max-
imum depth of cut.
The additional alloying with Cr increases the formation of the Cu oxide scale on the
surface up to such a level that the Cu content in bulk can be kept within the standard
limits for achieving better mechanical properties of the alloy. In most cases, heat treat-
ment improves the strength and reduces the ductility and toughness of alloy material.

Cutting parameter effects on roughness of the surface

Feed rate influence on roughness
Figures 5, 6, and 7 demonstrate the influence of feed rate on ‘Ra’ at cutting speeds of 800,
1000, and 1200 rpm, respectively. The polynomial curve fitted equation shows the feed
rate (x) and the average surface roughness (y). The term “coefficient of determination”
refers to R2. It determines how well the data points fit the curve. The experimental and
mathematical curve fitting values are said to be in good agreement when the R2-value is
close to 1. As observed from the Figs. 5, 6, and 7, the fitted curve is approximated to R2-
value of 1.
The surface roughness of turned CuZr and CuCrZr specimens both increases as the
feed rate improves at the same cutting speed, as depicted in Fig. 5. As more material
comes into contact with the cutting tool at higher feed rates, cutting force evolution
increases, resulting in vibration and a rougher surface. Because there is more friction
between the tool and the workpiece, cutting force increases as the feed rate increases.

(a) (b)

(c)

Fig. 5 Feed rate effect on surface roughness at N = 800, 1000, and 1200 rpm
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 13 of 26

(a) (b)

(c)

Fig. 6 Effect of depth of cut on surface roughness at N = 800, 1000, and 1200 rpm

(a) (b)

(c)

Fig. 7 Surface roughness at various feed rates at f = 0.05, 0.055, and 0.06 mm/rev

On the other hand, feed has a negative impact on surface roughness; as feed increases,
surface finish deteriorates. Additionally, a rise in cutting temperature at higher feed
rates results in increased tool wear and undesirable surface roughness. The maximum
surface roughness value at a feed rate of 0.06 mm/rev and a cutting speed of 800 rpm
was 3.41 µm for CuZr and 3.39 µm for CuCrZr, respectively, as cutting speed increased.
When the speed of cutting was raised to 1200 rpm, it decreased to 2.29 µm for CuCrZr
and 2.38 µm for CuZr, respectively.
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 14 of 26

Depth of cut effect on roughness of surface

During dry turning, the relationship between the cut depth and roughness of the surface
for CuZr and CuCrZr at a constant spindle speed is depicted in Fig. 6. Surface roughness
increased at constant cutting speed as the depth of cut increased because of more mate-
rial removal with greater cutting forces at a deeper depth of cut.
The maximum roughness of the surface at 1.25 mm depth cut and 800 rpm cutting speed
was 3.41 µm for CuZr and 3.39 µm for CuCrZr, respectively, as spindle speed increased.
When the speed of the spindle was raised to 1200 rpm, it decreased to 1.94 µm for CuZr
and 1.66 µm for CuCrZr, respectively. Figure 6 illustrates the influence of cut speed and
depth over Ra. With increasing speed, the Ra tends to decline, with the lowest Ra occur-
ring at the highest speed. The Ra rises as feed does in addition. With the combination of
the highest speed and maximum depth of cut, the smallest Ra therefore obtained.

Effect of feed rate on surface roughness

The roughness of the turned surface decreased as the feed was increased, as can be seen.
The surface roughness was increased by spinning at a faster feed rate. CuZr and
CuCrZr showed the lowest surface roughness of 1.94 m and 1.66 m, respectively, at
0.05 mm/min and 1200 rpm of feed rate.

Optimizing cutting parameters on roughness of surface (CuCrZr)

The fractional orthogonal designs of Taguchi’s orthogonal arrays where the main effects
are the primary focus of orthogonal array designs. Using a small number of experimental
runs, these designs are used to estimate the main effects. Taguchi S/N ratios, which are
log functions of the desired output, are useful as objective functions for optimization,
aid in data analysis, and aid in predicting the best outcomes. The Taguchi method stud-
ies response variation using the S/N ratio.

Analysis of S/N ratios on roughness surface (CuCrZr)

By minimizing the effects of noise factors, the Taguchi design is applied to detect control
factors that minimize product or process variability. Control factors are the parameters
of the design and the process that can be controlled. In experimental design, the Taguchi
method measures the variations in the surface roughness value using the S/N ratio. Find
control factor settings that minimize the effects of the noise factors by increasing the S/N
ratio. The response table for this study’s SN ratios is shown in Table 10, for smaller is better.
Table 10 presents that the best combination of parameters for smaller is the better
characteristic. The spindle speed is highly affected, the second one is feed rate and
depth of cut have lower effects on surface roughness, which can be observed from

Table 10 S/N ratios response (CuCrZr)

Level Cutting speed (rpm) Feed rate (mm/rev) Depth cut (mm)

1 − 9.560 − 6.071 − 7.428

2 − 7.104 − 8.006 − 7.712
3 − 5.966 − 8.552 − 7.490
Delta 3.595 2.480 0.283
Rank 1 2 3
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 15 of 26

Fig. 8 Main effect plots for S/N ratio (CuCrZr)

Table 11 Optimum setting levels for parameters

Control factors Level selected Level value Rank of
response
affected

Cutting speed 3 1200 rpm 1

Feed rate 1 0.05 mm/rev 2
Depth of cut 1 1.05 mm 3

rank table row and it is the probable combinations of parameters for enhancing the
property of specimen’s surface. Figure 8 shows a plot of the main effect of the con-
trol factor for the roughness of the surface S/N ratio.
The effect of a steeper slope in the S/N ratio implies that the cutting parameter
has a greater impact on the surface roughness (Ra) (Fig. 8). The surface roughness is
diminishing with cutting speed up from 800 to 1200 rpm. In this way, the ideal cut-
ting velocity level is 1200 rpm. The effect of the parameter feed rate on the surface
roughness values is shown above in terms of the S/N ratio. As feed increases, the
surface roughness decreases. Therefore, the ideal feed rate is 0.05 mm/rev. The S/N
ratio above illustrates the impact of cut depth on surface roughness values. As the
depth cut increases, the surface roughness decreases. Therefore, the ideal depth cut
is 1.05 mm.

Determining the optimum factor on surface roughness for CuCrZr

High cutting speed, lower feed rate, and depth cut were found to be the best param-
eters for determining the surface roughness value from S/N ratio analysis. The
cutting speed of 1200 rpm, the feed rate of 0.05 mm/rev, and the depth of cut of
1.05 mm are the cutting parameters that correspond to these values. The optimal
parameter settings for the roughness of the surface based on the results of the design
of the experiment are depicted in Table 11. The roughness of the surface is predicted
to have a mean value of 1.5344 µm and a S/N ratio of − 4.37892.
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 16 of 26

Table 12 Experimental results of MRR for CuZr and CuCrZr

Exp No Cutting parameters
Cutting Feed rate Depth of Cutting time MRR for Cutting time MRR for
speed (mm/rev) cut (mm) for CuZr (min) CuZr (­ mm3/ for CuCrZr CuCrZr
(rpm) min) (min) ­(mm3/min)

1 800 0.050 1.05 0.70 1147 0.67 1172

2 800 0.055 1.15 0.62 1415 0.58 1507
3 800 0.060 1.25 0.55 1729 0.53 1789
4 1000 0.050 1.15 0.52 1687 0.51 1705
5 1000 0.055 1.25 0.50 1881 0.49 1929
6 1000 0.060 1.05 0.52 1534 0.50 1611
7 1200 0.050 1.25 0.45 2113 0.44 2179
8 1200 0.055 1.05 0.40 2059 0.38 2110
9 1200 0.060 1.15 0.36 2437 0.35 2522

Fig. 9 Material removal rate for each experimental run

Comparison of material removal rate (MRR) for C15000 and C18150

MRR analysis
The optimal parameter combination yielded a material removal rate of 2437 and
2522 ­mm3/min, as shown in Table 12. Figure 9 shows the material removal rate for every
experimental run. It is observed that MRR for C18150 alloy is greater than C15000 for
the defined cutting conditions.

Comparison of tool temperature for C15000 and C18150

Analysis of tool tip temperature for CuZr and CuCrZr
Heat is developed while machining any type of material due to friction, which occurs
between the cutting tool and workpiece. This heat generated while machining is best if it
is too low since it affects the cutting tool as well as the workpiece and disturbs the opera-
tion. The tooltip becomes softer as a result of the cutting tool’s undesirable temperature,
causing rapid wear on the cutting tool’s materials. Many researches have contributed to
ways of minimizing the temperature produced during machining. One method of mini-
mizing this temperature is a selection of suitable cutting tools and cutting parameters for
the selected workpiece. In this experimental work, the tool tip temperature generated at
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 17 of 26

Table 13 Experimental results of cutting tool temperature for CuZr and CuCrZr
Exp No Cutting parameters
Spindle speed Feed rate (mm/ Depth of cut Temp. for CuZr Temp. for
(rpm) rev) (mm) (̊C) CuCrZr (̊C)

1 800 0.050 1.05 40.5 37.8

2 800 0.055 1.15 44.2 40.6
3 800 0.060 1.25 50.1 47.2
4 1000 0.050 1.15 52.3 50.1
5 1000 0.055 1.25 56.1 53.4
6 1000 0.060 1.05 49.5 46.7
7 1200 0.050 1.25 72.2 64.9
8 1200 0.055 1.05 62.5 58.6
9 1200 0.060 1.15 67.8 61.7

Fig. 10 Temperature for CuZr and CuCrZr on each experimental run

each run of the experiment was measured and the average temperature was acquired
and displayed in Table 13. The average temperature generated during the turning of
CuZr and CuCrZr varies with varying cutting parameters as shown in Table 13. As the
cutting spindle speed increased, so did the cutting temperature. The morphology of the
workpiece is negatively impacted by the rise in temperature. Additionally, increased heat
results in dimensional changes in the machined part, making it challenging to control
dimensional accuracy. It is observed from Fig. 10 that cutting tool temperature genera-
tion is higher in C15000 than in C18150 at defined cutting conditions.

Multi‑objective response optimization of process parameters for CuZr and CuCrZr using
TGRA​
This study presents multi-objective response optimization in order to achieve the best
possible surface quality, MRR, and tool temperature for both material grades. The Tagu-
chi technique combined with Grey relational analysis was utilized to get the ideal set
of three input process parameters with a focus on the quality of the machined surface,
MRR, and tool temperature. Grey relational analysis may be used to evaluate even the
performance of large tasks with little information. GRA is used to calculate the optimal
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 18 of 26

Table 14 Signal-to-noise ratios for CuZr on each response

Exp No Cutting parameters Signal to Noise ratios

Cutting speed Feed rate Depth of cut MRR SR Tool Temp

(rpm) (mm/rev) (mm)

1 800 0.05 1.05 − 58.181 − 8.4652 − 32.1491

2 800 0.055 1.15 66.0254 − 10.552 − 32.9084
3 800 0.06 1.25 67.7662 − 10.655 − 33.9968
4 1000 0.05 1.15 67.5526 − 6.6091 − 34.3700
5 1000 0.055 1.25 68.4981 − 8.0121 − 34.9793
6 1000 0.06 1.05 66.7268 − 8.3334 − 33.8921
7 1200 0.05 1.25 69.5083 − 5.7571 − 37.1707
8 1200 0.055 1.05 69.2834 − 7.1219 − 35.9176
9 1200 0.06 1.15 70.7474 − 5.6226 − 36.6246

Table 15 Signal-to-noise ratios for CuCrZr on each response

Exp No Cutting parameters Signal-to-noise ratios

Cutting speed Feed rate Depth of cut MRR SR Tool Temp

(rpm) (mm/rev) (mm)

1 800 0.05 1.05 − 58.3683 − 8.0291 − 31.549

2 800 0.055 1.15 66.5726 − 10.0489 − 32.170
3 800 0.06 1.25 68.0625 − 10.6043 − 33.478
4 1000 0.05 1.15 67.6448 − 5.8894 − 33.996
5 1000 0.055 1.25 68.7169 − 7.5683 − 34.550
6 1000 0.06 1.05 67.1522 − 7.8542 − 33.386
7 1200 0.05 1.25 69.7754 − 4.4023 − 36.244
8 1200 0.055 1.05 69.4959 − 6.4045 − 35.358
9 1200 0.06 1.15 71.0452 − 7.1980 − 35.805

desirable properties for a wide series of input parameters. Tables 14 and 15 show the
signal-to-noise ratio of all responses to C15000 and C18150 respectively.
As part of a grey relational generation to obtain precise solutions within the range of
sequences through data pre-processing, the normalization procedure is used. Data pre-
processing is the process of normalizing each response between 0 and 1 in order to gen-
erate a sequence that is comparable to the original sequence. “Higher-the-better” (HB)
is the form we obtained as the original sequence, then the original sequence can be nor-
malized, and “smaller-the-better” (LB) is the form we obtained as the original sequence,
then the original sequence can be normalized. Table 16 below shows the normalized
value of responses. Table 17 depicts the quality loss of all responses.
Tables 18 and 19 show the grey relational coefficient which is calculated to express the
relationship between the ideal and actual normalized experimental results and optimiza-
tion of the complicated multiple process responses can be converted into the optimiza-
tion of a single grey relational grade. The mean of the grey relational grade for each level
of cutting parameters and the total mean of the grey relational grade are summarized.
The levels where the greatest normal response was attained were chosen since a larger
GRG demonstrates superior diverse execution qualities. The turning operations with
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 19 of 26

Table 16 Normalized values and deviational sequences for MRR, SR, and tool temperature (CuZr)
Exp No Normalization of S/N ratios Quality loss (Delta)
MRR SR Tool Temp MRR SR Tool Temp

1 0.0000 0.5648 0.0000 1.0000 0.4352 1.0000

2 0.9634 0.9796 0.1512 0.0366 0.0204 0.8488
3 0.9769 1.0000 0.3679 0.0231 0.0000 0.6321
4 0.9752 0.196 0.4423 0.0248 0.804 0.5577
5 0.9826 0.4748 0.5636 0.0174 0.5252 0.4364
6 0.9688 0.5386 0.3471 0.0312 0.4614 0.6529
7 0.9904 0.0267 1.0000 0.0096 0.9733 0.0000
8 0.9886 0.2979 0.7505 0.0114 0.7021 0.2495
9 1.0000 0.0000 0.8912 0.0000 1.0000 0.1088

Table 17 Normalized values and deviational sequences for MRR, SR, and tool temperature (CuCrZr)
Exp No Normalization of S/N ratios Quality loss (Delta)
MRR SR Tool Temp MRR SR Tool Temp

1 0.0000 0.5848 0.0000 1.0000 0.4152 1.0000

2 0.9654 0.9104 0.1322 0.0346 0.0896 0.8678
3 0.9770 1.0000 0.4109 0.0230 0.0000 0.5891
4 0.9737 0.2398 0.5212 0.0263 0.7602 0.4788
5 0.9820 0.5105 0.6392 0.0180 0.4895 0.3608
6 0.9699 0.5566 0.3912 0.0301 0.4434 0.6088
7 0.9902 0.0000 1.0000 0.0098 1.0000 0.0000
8 0.9880 0.3228 0.8111 0.0120 0.6772 0.1889
9 1.0000 0.4508 0.9065 0.0000 0.5492 0.0935

Table 18 Grey relational coefficient (GRC) and grey relational grade (GRG) for CuZr
Exp No Grey relational coefficient (GRC) Grey
relational
MRR SR Tool Tem grade (GRG)

1 0.5000 0.6968 0.5000 0.5656

2 0.9647 0.9800 0.5409 0.8285
3 0.9774 1.0000 0.6127 0.8634
4 0.9758 0.5543 0.6420 0.724
5 0.9829 0.6557 0.6962 0.7782
6 0.9698 0.6843 0.6050 0.753
7 0.9905 0.5068 1.0000 0.8324
8 0.9888 0.5875 0.8003 0.7922
9 1.0000 0.5000 0.9019 0.8006

different performance criteria were solved using a grey relational grade generated from
the grey relational analysis. The optimum cutting settings were discovered by using the
Taguchi technique and the grey relational grade as the performance index. The best cut-
ting parameters for both materials: cutting speed 1200 rpm, feed rate 0.06 mm/rev, and
depth cut 1.25 mm. The optimum factors obtained from GRA for all responses (surface
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 20 of 26

Table 19 Grey relational coefficient (GRC) and grey relational grade (GRG) for CuCrZr
Exp No Grey relational coefficient (GRC) Grey
relational
MRR SR Tool Tem grade (GRG)

1 0.5000 0.7066 0.5000 0.5689

2 0.9666 0.9178 0.5354 0.8066
3 0.9775 1.0000 0.6293 0.8689
4 0.9744 0.5681 0.6762 0.7396
5 0.9823 0.6714 0.7349 0.7962
6 0.9708 0.6928 0.6216 0.7617
7 0.9903 0.5000 1.0000 0.8301
8 0.9882 0.5962 0.8411 0.8085
9 1.0000 0.6455 0.9145 0.8533

roughness, MRR, and tool temperature) at the best level of cutting parameters are the
same for both the grades of material (N3 f3 p3) (Tables 20 and 21).

Confirmation of the optimum results for CuZr and CuCrZr on three responses
In this study, the confirmation experiment was conducted to verify the ideal cutting
conditions. In accordance with the DOE analysis and the Taguchi approach’s improve-
ment steps, a confirmation experiment was carried out to assess the predictability of the
outcome. The best parameter is used to carry out the confirmation test taking this into
account. Taguchi analysis with Minitab 21 Table 22 yielded the predicted surface rough-
ness MRR and tool temperature at optimal machining conditions.
Experimental values for three responses were also measured using these machining
conditions. Both for CuZr and for CuCrZr, confirmation experiments were carried out
with the GRA optimum cutting parameters derived from Taguchi analysis. The optimal
level of the cutting parameter results in the same for both materials, i.e., cutting speed
1200 rpm feed rate 0.06 mm/rev and depth of cut 1.25 mm (N3 f3 p3), and the result is
displayed in Table 23.

Table 20 Response signal-to-noise ratios for CuZr

Level Cutting speed (rpm) Feed rate (mm/rev) Depth cut (mm)

1 − 2.620 − 3.116 − 3.146

2 − 2.483 − 1.945 − 2.124
3 − 1.849 − 1.891 − 1.682
Delta 0.770 1.226 1.463
Rank 3 2 1

Table 21 Response signal-to-noise ratios for CuCrZr

Level Cutting speed (rpm) Feed rate (mm/rev) Depth cut (mm)

1 − 2.662 − 3.046 − 3.037

2 − 2.321 − 1.898 − 1.955
3 − 1.614 − 1.654 − 1.606
Delta 1.048 1.391 1.431
Rank 3 2 1
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 21 of 26

Table 22 Predicted value for responses

Material Surface roughness (µm) MRR ­(mm3/min) Tool
temperature
(°C)

C15000 2.44444 2454 72.7222

C18150 2.32111 2538 66.3222

Table 23 Result of confirmation experiments for responses

Material Surface roughness (µm) MRR ­(mm3/min) Tool
temperature
(°C)

C15000 2.51 2475 74

C18150 2.39 2590 68

Table 24 Comparison between predicted and experimental value

Material Predicted value of Ra (µm) Experimental value of Ra (µm) Error %

C15000 2.44444 2.51 2.62

C18150 2.32111 2.39 2.88

Table 25 Comparison between predicted and experimental value

Material Predicted value of MRR ­(mm3/ Experimental value of MRR ­(mm3/ Error %
min) min)

C15000 2454 2475 0.84

C18150 2538 2590 2.007

Table 26 Comparison between predicted and experimental value

Material Predicted value of temperature Experimental value of Error %
(°C) Temperature (°C)

C15000 72.7222 74 1.72

C18150 66.3222 68 2.47

Tables 24, 25, and 26 show the predicted and actual response of surface roughness
MRR and tool temperature using TGRA optimal cutting parameters. The relative
percentage error between the fitted values predicted and the experimental values of
response are computed.
The values that were predicted using the Taguchi method are pretty close to the
actual value that was found through experiments. This demonstrates that responses’
experimental and predicted outcomes are strongly correlated.
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 22 of 26

Fig. 11 Surface morphology of CuZr at surface roughness value of 3.41 µm (a) and 1.94 µm (b)

Fig. 12 Surface morphology of CuCrZr at surface roughness value of 3.39 µm (c) and 1.66 µm (d)

Analysis of surface morphology defects

These surface morphological characteristics of a machined surface are behavioral indi-
cators of defects. They include surface texture composed of roughness, waviness, and
layness. Surface irregularities with a high frequency of occurring are induced by the
interaction of the material microstructure and cutting tool action. The repeated form of
surface defects is referred to as surface roughness. The images of the surface machined
during the turning operation process are shown in Figs. 11 and 12.
The detailed microstructural investigation of the surface morphology of CuZr and
CuCrZr after machining was carried out using a scanning electron microscope (SEM)
and analyzed using measuring 20 × 20 microns and at a magnification of × 1500. To
obtain a good surface quality free of microvoids, abrasions, craters, grooved lines, and
other surface defects, a large variety of process factors was managed during the turn-
ing process. The SEM images of the workpiece for the parameters were performed at
800 rev/min, 0.060 mm/rev, and 1.2 mm depth of cut for a higher surface roughness
value, and at 1200 rev/min, 0.05 mm/rev, and 1.25 mm depth cut for a lower surface
roughness value for both the grades of materials.
The SEM micrograph of the machined surface at high average roughness of surface
(3.41 µm, 3.39 µm) and (1.94 µm, 1.66 µm) lower average surface roughness (Ra) value
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 23 of 26

of CuZr and CuCrZr respectively. During the machining operation, minimum particles
were pulled away from the workpiece surface due to the high speed of the process, and
thus microvoids and craters were formed as shown in Fig. 11b, d which was found dur-
ing the casting of the material which indicates that the material does not have uniform
distribution (homogeneity) of material particles.

Effect of Cr on the machining process characteristics of C15000 and C18150 during turning
operation
It is observed from experimental results that spindle speed has a great effect on surface
roughness and MRR on both material grades C15000 and C18150. During machining
CuCrZr, it was observed that it had better deformation resistance than CuZr due to the
content of chromium. In CuZr the ductility of material was reduced. The presence of
chromium in CuCrZr yielded a relatively higher material removal rate in the operation
as well as temperature resistance during machining which led to enhanced life of the
component and tool.
The presence of Cr in C18150 strongly increases the hardenability of copper and mark-
edly improves the resistance to corrosion and high-temperature strength or creep resist-
ance of alloys. This reduces the defect of microstructure in CuCrZr thereby making it
highly suitable in welding applications (seam welding wheel) than CuZr.
The presence of Cr in C18150 increased the deformative temperature resistance lead-
ing to less cutting tool tip generation than that in C15000.

Conclusion
This research was focused on investigating the influence of cutting parameters on the
roughness of the surface, MRR, tool tip temperature, and morphology of the surface
with optimization of the process parameters to get optimal end response and find the
optimal global factor through GRA based approach during dry turning of C15000 and
C18150 copper alloys with HSS cutting tool. The three main cutting parameters (spin-
dle speed, depth of cut, and feed rate) with three levels for each were selected and their
effects on end responses were studied. Based on the results presented in the thesis, the
conclusions drawn are as follows:

1. At a depth of cut 1.25 mm, a feed rate of 0.05 mm/min, and a cutting speed of
1200 rpm, the orthogonal array yielded a minimum surface roughness of 1.94 µm for
CuZr and 1.64 µm for CuCrZr.
2. Cutting speed was seen to be the important parameter for the roughness of the sur-
face using analysis of variance (ANOVA), followed by feed rate and depth of cut hav-
ing contributions of 70.20%, 29.82%, and 0.478% respectively for CuZr and 66.02%,
33.23%, and 0.434% for CuCrZr.
3. Cutting speed had the greatest impact on the material removal rate, followed by
depth cut and feed rate. A higher material removal rate was observed at the high-
est levels of all factors for both materials were the same. The value of material
removal rate at optimum cutting parameters that leads to minimum surface rough-
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 24 of 26

ness (cutting speed 1200 rpm, depth of cut 1.15 mm, and feed rate 0.06 mm/rev) was
2437 ­mm3/min for CuZr and 2538 ­mm3/min CuCrZr.
4. Cutting speed, followed by depth of cut and feed rate, had a significant impact on
the average tool tip temperature. The temperature of the tooltip increases as the cut-
ting speed and depth of the cut increase. At a cutting speed of 800 rpm, a depth of
cut 1.05 mm, and a feed rate of 0.05 mm/rev, the lowest average temperature was
achieved. CuZr and CuCrZr alloy obtained average tool tip temperatures of 40.5 °C
and 37.8 °C, respectively, when cutting parameters were optimal and surface rough-
ness was minimal.
5. The optimum cutting settings were discovered by using the Taguchi technique and
the grey relational grade as the performance index. The best cutting parameters
for both materials were a cutting speed of 1200 rpm, feed rate of 0.06 mm/rev, and
depth of cut of 1.25 mm. The optimum factors obtained from GRA for all responses
(surface roughness, MRR, and tool temperature) at the best level of cutting param-
eters are the same for both materials. These cutting parameters values yielded the
experimental result for each response like surface roughness, MRR, and tool tip
temperature (2.5 µm, 12,475 ­mm3/min, and 74 °C) for grade C15000 also (2.39 µm,
­2590mm3/min, and 68 °C) for grade C18150.
6. The detailed microstructural investigation of the surface morphology of CuZr and
CuCrZr after machining was carried out using a scanning electron microscope
(SEM) and was analyzed at 20 × 20 microns and a magnification of × 1500. The SEM
images of the workpiece were performed at 800 rev/min, 0.060 mm/rev, and 1.2 mm
depth cut for a higher surface roughness value, and at 1200 rev/min, 0.05 mm/rev,
and 1.25 mm depth of cut for a lower surface roughness value for both the grades of
materials.
7. The SEM micrograph of the machined surface had high average roughness of sur-
face (3.41 µm, 3.39 µm) and lower average surface roughness (Ra) of 1.94 µm and
1.66 µm for CuZr and CuCrZr respectively. When the cutting speed was lower and
the feed rate and depth of cut were high, the surface had more defects like the micro
void, abrasions, and crater grooves. During the machining process, the particles were
pulled away from the workpiece surface due to the high speed of the process, and
thus microvoids and craters were formed.

Scope for future work

The scope of future work is as follows:

1. Analysis of the effect of cutting parameters on force and tool wear rate.
2. Study the effects of tool geometry like rake angle and nose radius on the surface
roughness and other process characteristics.
3. Study the effect of different cutting tools and materials with similar cutting param-
eters.
Tefera et al. Journal of Engineering and Applied Science (2023) 70:145 Page 25 of 26

4. Future research work may also be directed towards applying the minimum quantity
lubrication technique for further investigation of the effect of cutting parameters and
to compare it with dry and wet turning.

Abbreviations
CuZr Copper Zirconium
CuCrZr Copper chromium zirconium
MRR Material removal rate
S/N Signal-to-noise ratio
ANOVA Analysis of variance
SR Surface roughness
SEM Scanning electron microscope
OA Orthogonal array
HSS High-speed steel
GRA​ Grey relational analysis

Acknowledgements
Not applicable.

Authors’ contributions
Conceptualization: Akhlilu, D.K.S and G.G; methodology, Akhlilu, D.K.S and G.G; formal analysis Akhlilu, D.K.S and G.G.;
investigation D.K.S.; writing—original draft preparation, and D.K.S.; writing—review and editing, D.K.S, G.G. All authors
have read and agreed to the published version of the manuscript.

Funding
No funding has been given for this research work.

Availability of data and materials

The datasets used and/or analysed during the current study are available from the corresponding author on reasonable
request.

Declarations
Competing interests
The authors declare that they have no competing interests.

Received: 26 July 2023 Accepted: 5 November 2023

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