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Optimization of Machining Parameters of 20MnCr5 Steel in

Turning Operation using Taguchi technique
Narayana Reddy. A R1, Ganti satya prakash2
1
2

M.Tech student, Dept of Mech. Engg, CMR Institute of Technology, Hyderabad, India
Associate. prof, Dept of Mech. Engg, CMR Institute of Technology, Hyderabad, India

Abstract: Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchis L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis.
Keywords: orthogonal array, surface roughness, MINITAB, regression model, turning, coolant

I. INTRODUCTION
In this work, the Taguchi methods, a powerful statistical tool to design of experiments for quality, is
used to find the optimal cutting parameters for turning operations. Even though the present not only optimize
cutting parameters for turning operations but also the main cutting parameters and its interaction that affect
the cutting performance is the highlight of the work. Experimental results are provided to confirm the
effectiveness of Taguchis approach. Every manufacturing industry aims at producing a large number of
products within relatively lesser time. But it is felt that reduction in manufacturing time may cause severe
quality loss. In order to embrace these two conflicting criteria it is necessary to check quality level of the item
either on-line or off-line. The purpose is to check whether quality lies within desired tolerance level which can
be accepted by the customers. Quality of a product can be described by various quality attributes. The attributes
may be quantitative or qualitative. If quality falls down the expected level the controller supplies a feed back in
order to reset the process environment. In off-line quality control the method is either to check the quality of
few products from a batch or lot (acceptance sampling) or to evaluate the best process environment capable of
producing desired quality product. This invites a optimization problem which seeks identification of the best
process condition or parametric combination for the said manufacturing process. If the problem is related to a
single quality attribute then it is called single objective or single response optimization.

II. LITERATURE REVIEW

Machining parameters in metal turning are cutting speed, feed and depth of cut. The setting of these
parameters determines the quality characteristics of turned parts. Consideration of machining parameter
optimization started out as early as 1907 when (Taylor, 1907) [1] acknowledged the existence of an optimum
cutting speed for maximizing material removal rate in single pass turning operations. Research on machining
parameter optimization has increased since the 1950s.
In 1950 (Gilbert, 1950) [2] presented a theoretical analysis of optimization of machining process and
proposed an analytical procedure to determine the cutting speed for a single pass turning operation with fixed
feed rate and depth of cut by using two different objectives maximum production rate and minimum machining
cost.

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

P. G. Benardos and G. C. Vosniakos, [3] this paper presents the set of parameters that are influence
the surface Roughness and also they diagrammatically displayed in Fishbone Diagram.
Aman Aggarwal and Hari Singh, [4] this paper presents that Fuzzy Logic, Genetic Algorithm, scatter
search and Taguchi technique are the latest optimization Techniques.
Mahendra Korat and Neeraj Agarwal (2012) [5] investigated the effects of the process parameters
viz., coolant condition, cutting speed, feed, depth of cut, nose radius, on response characteristics viz., material
removal rate, surface roughness, on EN24 material in CNC turning. ANOVA results shows that nose radius,
feed rate, depth of cut, cutting speed and coolant condition affects the surface roughness by 65.38%, 25.15%,
3.06%, 1.41% and 0.09% respectively.
Sahoo et al. (2008) [9] studied for optimization of machining parameters combinations emphasizing
on fractal characteristics of surface profile generated in CNC turning operation. The authors used L27 Taguchi
Orthogonal Array design with machining parameters: speed, feed and depth of cut on three different work
piece materials viz., aluminum, mild steel and brass. It was concluded that feed rate was more significant
influencing surface finish in all three materials.

III. TAGUCHI TECHNIQUE

The Taguchi experimental design method, by Genichi Taguchi is a well-known, unique and powerful
technique for product or process quality improvement. It is widely used for analysis of experiment and product
or process optimization. Genichi Taguchi is a Japanese engineer who has been active in the improvement of
Japans industrial products and processes since the late 1940s.
Taguchi introduces his concepts to:
Quality should be designed into a product and not inspected into it.
Quality is best achieved by minimizing the deviation from a target.
Cost of quality should be measured as a function of deviation from the standard and the losses should be
measured system wide.

IV. EXPERIMENTAL DETAILS

4. 1: Material
20MnCr5 is categorized as case hardened steel produced by casting, it is easily machinable and can
have a wide variety of surface finishes. It also has high strength and stiffness. It is used in the field of high
stressed components in automobile industry like small gear, shafts, crankshafts, connecting rods, cam shafts,
piston bolts, spindles and other mechanical controlling parts.
Carbon

0.220%

Manganese

1.112%

Silicon

0.244%

Sulphur

0.026%

Phosphorus

0.028%

Chromium

1.154%

Table 1: Chemical compositon of 20MnCr5

4. 2: Cutting tool inserts
Inserts are individual cutting tools with several cutting points. Inserts are usually clamped on the tool
shank with various locking mechanisms. Most of high performance cutting tools use the insert method. Here
there are three type cutting insrets are using they are
1. SUMITOMO AC700G CARBIDE COATED
2. KORLOY PC9030 PVD COATED STEEL GRADE
3. TAGUETEC CT3000 CERAMIC UNCOATED

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

4. 3: Machine tool

Fig1: CNC Horizontal turning lathe LL 15T L3

4.4: Cutting parameters and their levels
Symbol

Cutting
Paramete
r

Unit

Level 1

Level
2

Level 3

Cutting
Speed

rpm

1000

2000

3000

Feed

mm/rev

0.05

0.1

0.15

Depth of
Cut

mm

0.2

0.4

0.6

Hardness
of
Cutting
Tool

HRC

65
(Ceramic
Uncoated
)

71
(PVD
Coate
d Steel
Grade)

76
(Carbid
e
Coated)

Table 2 : Cutting parameters and their levels

4. 5: To find Minimum number of Experiments to be conducted
Parameter

Number of Levels

Degree of Freedom

Cutting Speed

Feed

Depth of Cut

Hardness of Cutting
Tool

Total Degrees of
Freedom

Minimum no. of
Experiments

Table 3: Factors, levels and Degree of freedom

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

4. 6: Orthogonal array
Trial
no.

Cutting
Speed
(m/min)

Feed
(mm/rev)

Depth of Cut
(mm)

Hardness of Cutting tool

(HRC)

Table 4: standard L9 orthogonal array

V. FORMULAS USED
1) MRR (a) represents Actual Material Removal Rate in mm3/min
MRR (a) =

mm3/min

2) MRR (t) represents Theoretical Material Removal Rate in mm3/min

MRR (t) = f * d * v * 1000 mm3/min
Here f denotes feed in mm/rev,d denotes depth of cut in mm and v denotes cutting speed in m/min
3) To calucalate Machining time (t) (theoretical) fallowing formula is used
t=

in min
L = Distance travelled by the tool in the direction of feed in single cut.
F = Feed in mm/rev
N = speed in rpm

VI. RESULTS AND DISCUSSION

In the first run experiment is performed using coolant APPRO SOL XL. Readings are tabulated in
table5. Surface roughness is measured and MRR values are calculated using formulae.
Surface
Roughness
In m

Initial
Weight
gms

Final
Weight
gms

1.61

907.00

1.56

2.23

Tria
l no
1

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Machining
Time
(theoretical)
in sec
150.00

MRR (a)
mm3/min

MRR (t)
mm3/min

885.90

Machining
Time
(actual) in
sec
148.00

1089.69

984.38

907.00

883.60

74.00

75.00

2416.94

3937.50

907.00

867.10

50.00

50.00

6099.36

8859.38

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

4

1.62

907.00

876.50

76.00

75.00

3067.38

3937.50

0.70

907.00

866.70

37.00

37.50

8325.01

11812.50

0.79

907.00

893.40

24.00

25.00

4331.21

5906.25

0.22

907.00

873.90

50.00

50.00

5059.87

8859.38

0.43

907.00

889.30

25.00

25.00

5411.46

5906.25

1.15

907.00

878.30

17.00

16.67

12903.71

17718.75

Table 5: Experiment results when coolant is ON

Surface
Roughness
In m

Initial
Weigh
t gms

Final
Weigh
t
gms

Machinin
g Time
(actual)
In sec

MRR (a)
mm3/mi
n

mrr(t)
mm3/mi
n

148.00

Machining
Time
(theoretical
)
In sec
150.00

1.64

907.00

887.00

1032.88

984.38

1.59

907.00

876.50

74.00

75.00

3150.28

3937.50

2.26

907.00

865.80

50.00

50.00

6298.09

8859.38

1.62

907.00

877.10

76.00

75.00

3007.04

3937.50

0.74

907.00

869.20

37.00

37.50

7808.57

11812.50

0.83

907.00

887.10

24.00

25.00

6337.58

5906.25

0.25

907.00

867.40

50.00

50.00

6053.50

8859.38

0.47

907.00

884.60

25.00

25.00

6848.41

5906.25

1.18

907.00

879.10

17.00

16.67

12544.02

17718.75

Tria
l no

Table 6: Experiment results when coolant is OFF

In the Second run experiment is performed in dry condition. Readings are tabulated in table6 Surface
roughness is measured and MRR values are calculated using formulae.
REGRESSION MODELS
The regression equation for surface roughness when coolant is ON given by:
Surface Roughness (m) = 0.42 - 0.00610 Cutting Speed A (m/min) + 2.40 Feed B (mm/rev) + 0.27
Depth of Cut C (mm) + 0.0224 Tool Hardness D
The regression equation for MRR when coolant is ON given by:
MRR (a) mm3/min = 10621 + 23.31 cutting speed A ( m/min) +47058 feed B (mm/rev) + 7210 depth
of cut C (mm) 246 tool hardness D
The regression equation for surface roughness when coolant is OFF given by:
Surface Roughness = 0.49 - 0.00608 cutting speed A (m/min) + 2.53 feed B (mm/rev) + 0.26 depth of
cut C (mm) + 0.0215 tool hardness D
The regression equation for MRR when coolant is OFF given by:
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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

MRR (a) mm3/min = 5491 + 25.3 cutting speed A ( m/min) + 50288 feed B( mm/rev) + 4951 depth of
cut C (mm) - 164 tool hardness D
Source
DF
Seq SS
Adj SS
Adj MS
%p
Cutting speed(A)
2
2.2134
2.2134
1.1067
63.56
Feed(B)
2
0.3652
0.3652
0.1826
10.48
Depth of cut(C)
2
0.4161
0.4161
0.2080
11.94
Tool ardness(D)
2
0.4876
0.4876
0.2438
14.00
Total
8
3.4822
Table 7: Analysis of Variance for surface roughness

Rank
1
4
3
2

Fig.2: Effect of process parameters on surface roughness

Level

1
2
3
Delta
Rank

Source
Cutting
speed(A)
Feed
(B)
Depth of
cut(C)
Tool
Hardness(D)
Total

Cutting
Feed
Depth of Cut
Speed
(mm/rev)
(mm)
(m/min) A
B
C
-4.9884
1.6082
1.7472
0.3184
2.1887
-3.0889
6.4227
-2.0442
3.0495
11.4111
4.2329
6.1834
1
4
2
Table 8: Response table for surface roughness

Hardness of
Cutting tool
(HRC) D
-0.7508
3.7788
-1.2753
5.0541
3

DF
2

Seq SS
31728492

Adj SS
31728492

Adj MS
15864246

%p
31.87

Rank
2

33219867

33219867

16609933

33.37

14793873

14793873

7396936

14.86

19783672

19783672

9891836

19.87

99525902

99525902

Table 9: Analysis of Variance for MRR

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

Level

1
2
3
Delta
Rank

Cutting
Feed
Depth of Cut
Speed
(mm/rev)
(mm)
(m/min) A
B
C
68.04
68.19
69.38
73.63
73.58
73.20
76.99
76.88
76.07
8.95
8.70
6.68
1
2
3
Table 10:Response table for MRR

Hardness of
Cutting tool
(HRC) D
73.79
71.49
73.27
2.30
4

Figure3: Effect of process parameters on MRR

Source
DF
Seq SS
Adj SS Adj MS
%p
Cutting
2
2.20469 2.20469 1.10234 64.37
speed(A)
Feed
2
0.36029 0.36029 0.18014 10.52
(B)
Depth of
2
0.38869 0.38869 0.19434 11.34
cut(C)
Tool
2
0.47096 0.47096 0.23548 13.75
Hardness(D)
Total
8
3.42462
Table 11: Analysis of Variance for surface roughness

Level

Rank
1
4
3
2

Cutting
Speed
(m/min) A
-5.13566

Feed
(mm/rev)
B
1.18467

Depth of
Cut (mm)
C
1.29320

Hardness of
Cutting tool
(HRC) D
-1.03972

0.01450

1.71516

-3.21863

3.21057

5.72053

-2.30046

2.52480

-1.57148

Delta

10.85620

4.01561

5.74343

4.78204

Rank

Table 12: Response table for surface roughness

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

Fig.4: Effect of process parameters on surface roughness

Source
Cutting speed(A)
Feed(B)
Depth of cut(C)
Tool Hardness(D)
Total

Level

1
2
3
Delta
Rank

DF
Seq SS
Adj SS
Adj MS
2
37469560 37469560 18734780
2
37939065 37939065 18969532
2
6391089
6391089
3195545
2
6877952
6877952
3438976
8
88677667
Table 13: Analysis of Variance for MRR
Cutting
Feed
Depth of Cut
Speed
(mm/rev)
(mm)
(m/min) A
B
C
-5.13566
1.18467
1.29320
0.01450
1.71516
-3.21863
5.72053
-2.30046
2.52480
10.85620
4.01561
5.74343
1
4
2
Table 14: Response table for MRR

%p
42.25
42.78
7.20
7.756

Rank
2
1
4
3

Hardness of
Cutting tool
(HRC) D
-1.03972
3.21057
-1.57148
4.78204
3

Fig 5: Effect of process parameters on MRR

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

Trial
no
1

Surface
roughness Ra
(m) Coolant
ON
1.612

Surface
roughness Ra
(m) Coolant
OFF
1.64

1.56

1.59

1.89

2.23

2.26

1.33

1.62

1.62

0.00

0.7

0.74

5.41

0.79

0.83

4.82

0.22

0.25

12.00

0.43

0.47

8.51

%age improvement in
Ra when coolant is used
1.71

1.15
1.18
2.54
Table 15: shows the effect of coolant on Surface roughness

Fig 6: Effect of coolant on MRR

Trial no
1
2
3
4
5
6
7

MRR (a)
(mm3/min)
Coolant ON
1089.69

MRR (a)
(mm3/min)
Coolant OFF
1032.88

2416.94
6099.36
3067.38
8325.01
4331.21
5059.87

3150.28
6298.09
3007.04
7808.57
6337.58
6053.50

8
5411.46
6848.41
9
12903.71
12544.02
Table 16: shows the effect of coolant on MRR

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

Fig 7: Effect of coolant on MRR

VII. CONCLUSION
The effect of process parameters cutting speed, Feed, Depth of cut and Tool Hardness on response
Characteristics MRR and Surface roughness were studied on 20MnCr5 steel alloy in CNC Turning. Based on
results obtained, the fallowing conclusions can be drawn:
The experimental results showed that the Taguchi parameter design is an effective way of determining
the optimal cutting parameters for achieving low surface roughness and maximum material removal
rate.
The relationship between cutting parameters (cutting speed, feed, depth of cut and hardness of cutting
tool) and the performance measures (surface roughness and material removal rate) are expressed by
multiple regression equation which can be used to estimate the expressed values of the performance
level for any parameters levels.
ANOVA suggests that cutting speed is the most significant factor and feed is most insignificant factor
for surface roughness and cutting speed is the most significant factor and tool hardness is the most
insignificant factor for MRR when the coolant is ON.
ANOVA suggests that cutting speed is the most significant factor and feed is most insignificant factor
for surface roughness and cutting speed is the most significant factor and feed is the most insignificant
factor for MRR when the coolant is OFF.
ANOVA (S/N Data) results shows that cutting speed, feed, depth of cut and tool hardness affects the
surface roughness by 63.56%, 10.48%, 11.94% and 14% respectively when the coolant is ON.
ANOVA (S/N Data) results shows that cutting speed, feed, depth of cut and tool hardness affects the
MRR by 31.87%, 33.37%, 14.86% and 19.87% respectively when the coolant is ON.
ANOVA (S/N Data) results shows that cutting speed, feed, depth of cut and tool hardness affects the
surface roughness by 64.37%, 10.52%, 11.34% and 13.75% respectively when the coolant is OFF.
ANOVA (S/N Data) results shows that cutting speed, feed, depth of cut and tool hardness affects the
MRR by 42.25%, 42.78%, 7.20% and 7.756% respectively when the coolant is OFF.
The result shows that surface roughness is good when coolant is used. An average improvement of
4.24% in surface roughness was found when coolant is used.
The result shows that MRR is almost same when coolant is ON and coolant is OFF. Therefore it can be
concluded that MRR does not depend much on coolant.

Acknowledgements
The support extended by the guide (Mr.Ganti satya prakash) and college authorities is highly
appreciated and acknowledged with due respect.

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Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation using Taguchi

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