ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print) IJRMET Vol.

5, Issue 2, May - Oct 2015

Effect of Spindle Speed and Feed Rate on Surface

Roughness and Material Removal Rate of AA6063A
in CNC Turning Using Response Surface Methodology
1
C.JohnJoshua, 2N.Rajakumar
1,2
Dept. of Mechanical Engg., Chendhuran College of Engg & Tech., Anna University, Chennai, INDIA

Abstract Predictive Modelling of Surface roughness and Material removal

The purpose of the paper aims at the analysis of cutting parameters rate in Turning using Grey relational and Regression Analysis.
in CNC machine of AA6063A. This paper explains the effective U.D.Gulhane, B.D. Sawant, P.M.Pawar [4] Analysis of Influence
approach based on the optimization of turning parameters with of Shaping Process Parameters on MRR and Surface roughness of
response to the surface methodology (RSM) is proved. This article Al6061 using Taguchi method. Mihir T. Patel, Vivek A. Deshpande
is about minimizing adequate surface roughness and maximizing [5] Experimental Investigation of Effect of Process Parameters
the material removal rate in machining AA6063A using Tungsten on MRR and Surface Roughness In Turning Operation on
carbide tool. Cutting Speed, Feed rate and Depth of Cut are the Conventional Lathe Machine For Aluminum 6082 Grade Material
machining parameters selected to explain the process parameters. Using Taguchi Method. Gulhane U. D., Ayare S. P., Chandorkar
To study the performance characteristics in CNC various analysis V.S., Jadhav M [6] Investigation of turning process to improve
like turning operation, the orthogonal array, signal to noise ratio productivity (MRR) for better surface finish of Al-7075-T6 using
are employed. In terms of cutting parameters, mathematical model DOE. Mihir T. Patel, Vivek A. Deshpande [7] Experimental
is proved using response surface model. Investigation of Effect of Process Parameters on MRR and Surface
Roughness In Turning Operation on Conventional Lathe Machine
Keywords For Aluminum 6082 Grade Material Using Taguchi Method.
Composite, Machining, Surface Roughness, Material Removal A designed experiment is a test or series of tests in which purposeful
Rate, Response Surface Methodology changes are made to the input variables of a process or system so
that we may observe and identify the reasons for changes in the
I. Introduction output response. Experimental design is used as an important tool
In metal cutting and manufacturing industries, surface finish in numerous applications. For instance it is used as a vital tool in
and strength of a product is very crucial in determining the improving the performance of a manufacturing process and in the
quality. Good surface finish not only assures quality, but also engineering design activities. The use of the experimental design
reduces manufacturing cost. Surface finish is important in terms in these areas results in products those are easier to manufacture,
of tolerances, it reduces assembly time and avoids the need for products that have enhanced field performance and reliability,
secondary operation, thus reduces operation time and leads to lower product cost, and short product design and development
overall cost reduction. Besides, good-quality turned surface is time.
significant in improving fatigue strength, corrosion resistance, Response surface methodology is a collection of mathematical
and creep life. It is well known that the final geometry of surface and statistical techniques for empirical model building. By careful
roughness is influenced by various machining conditions such as design of experiments, the objective is to optimize a response
spindle speed, feed rate and depth of cut. (output variable) which is influenced by several independent
Aluminium is a Light weight, density is about 1/3 that of steel variables (input variables). An experiment is a series of tests,
or copper Alloys, Certain aluminium have a better strength to called runs, in which changes are made in the input variables in
weight Ratio than that of high strength steel have good malleability order to identify the reasons for changes in the output response.
and formability, high corrosion resistance and high electrical This paper is to obtain the study of the analysis of the input
and thermal conductivity. High machinability and workability parameters Cutting Speed, Feed and Depth of cut, the
Aluminium alloys are prone to porosity due to gases dissolved output parameters are Material Removal Rate (MRR), Surface
during melting process alloying elements in Commercial Al Roughness. Using this value to accomplished the Response surface
alloys include Cu, Si, Mg, Mn, and occasionally Zn, Ni, and Cr. methodology design approach. We selected the smaller is better
Aluminium alloy 6063Ais a medium strength alloy commonly in the Roughness and Larger is better in the Material Removal
referred to as an architectural alloy. It is normally used in intricate Rate criteria for each response to calculate S/N ratio.
extrusions. It has a good surface finish high corrosion resistance
is readily suited to welding and can be easily anodized. Most II. Experimental Details
commonly available as T6 temper, in the T4 condition it has good
formability. A. Work Material
This Project performed with turning of material AA6063A. This
A. Literature Review material was selected Light weight, density is about 1/3 that of
S.V.Alagarsamy, N.Rajakumar [1] This project deals with the steel or copper Alloys, Certain aluminium have a better strength to
analysis of influence of turning process parameters on MRR weight Ratio than that of high strength steel have good malleability
& Surface Roughness of AA7075 using Taguchis method and and formability, high corrosion resistance and high electrical and
Response surface methodology. Md. Tayab Ali, Dr. Thuleswar thermal conductivity. Following tables shows the Chemical and
Nath [2] Cutting Parameters Optimization for Turning AA6063- Mechanical Properties of selected material.
T6 Alloy by Using Taguchi Method. Ashok Kumar Sahoo,
Achyuta Nanda Baral [3] Multi-objective Optimization and

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IJRMET Vol. 5, Issue 2, May - Oct 2015 ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print)

Table 1: Chemical Composition & Mechanical Properties of E. Responses

AA6063A 1. Surface Roughness.
Elements % Mechanical Properties 2. Material Removal Rate (MRR).
Si 0.3 to 0.6 Proof Stress 190Mpa
F. Methodology
Fe 0.15 to 0.35 Tensile Strength 220Mpa
Cu 0.1 Elongation 5% 1. Array Selection
Mn 0.15 The degrees of freedom is defined as the number of relations
between machining parameters that need to be made to determine,
Mg 0.6 to 0.9
which step is better and particularly how much better it is. As per
Zn 0.1 to 0.15 the RSM experimental philosophy a set of three levels of process
Ti 0.1 parameters has to degrees of freedom (DOF) and Orthogonal Array
Cr 0.05 (OA) to be selected must consider the following conditions. The
experiment under the consideration has 9 D.O.F. and requires an
Al Balance
O.A. with more D.O.F. then O.A with 27 experiments is to be
selected to effect of all factors.
B. Cutting Tool
The Cutting tool used for experimentation with all standard 2. Process
specification is Tungsten carbide insert. 27 pieces were taken of selected material of diameter (D) 25mm
and length (L) 100mm of material to be selected for this experiment
as shown in fig 3. Using CNC machine 27 jobs were machined with
simple turning operations as per the array values. Machining Time
was calculated after machining each job. Using the Following
Formula to find out the MRR value was calculated. Using
Surface roughness tester the each jobs were measured the surface
roughness after machining Using Response Surface Methodology
via Minitab-16 software the analysis was carried out.
Fig. 1: Tungsten Carbide Insert
MRR = [/4*(D2-d2)*L]
C. Three Parameters and Process Variables 4L (or) machining time
In this investigation, considering three cutting parameters: Cutting fN
Speed (m/min), Feed rate (mm/rev), Depth of cut (mm) and L27
experiment were carried out. The following table indicates the
value of different parameters for experiments:

Table 2: Values of Various Parameters used for Experiments

Levels
Sr.No Process Parameter
Low Medium High
1 Speed(m/min) 500 1000 1500
2 Feed(mm/rev) 0.10 0.15 0.20 Fig. 3: AA6063A Finished Work Piece Diagram
3 Depth of cut(mm) 0.2 0.5 0.8
Table 3A: Orthogonal Array
V F D
D. CNC Lathe Machine Specifications S.NO
Type: MTAB XLTURN (rpm) (mm/rev) (mm)
Controller: Fanuc 1 500 0.10 0.2
Spindle Power: 400V, 3.4Amp 2 1000 0.10 0.2
Speed Range: 1523000 Rpm
3 1500 0.10 0.2
4 500 0.15 0.2
5 1000 0.15 0.2
6 1500 0.15 0.2
7 500 0.20 0.2
8 1000 0.20 0.2
9 1500 0.20 0.2
10 500 0.10 0.5
11 1000 0.10 0.5
12 1500 0.10 0.5
Fig. 2: CNC Lathe MTAB 13 500 0.15 0.5
8 International Journal of Research in Mechanical Engineering & Technology w w w. i j r m e t. c o m
ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print) IJRMET Vol. 5, Issue 2, May - Oct 2015

14 1000 0.15 0.5 A. Response Surface for MRR

15 1500 0.15 0.5 From the observed data for material removal rate, the estimated
regression coefficients for average material removal rate in un-
16 500 0.20 0.5 coded units have been determined.
17 1000 0.20 0.5 Analysis of Variance for MRR:
18 1500 0.20 0.5 R-Sq = 99.44%
R-Sq(pred) = 97.70%
19 500 0.10 0.8
R-Sq(adj) = 99.14%
20 1000 0.10 0.8
21 1500 0.10 0.8 Table 4: Analysis of Variance for MRR
22 500 0.15 0.8 Source DF Seq-SS Adj-MS F- Value
23 1000 0.15 0.8 Regression 9 1064090463 118232274 332.67
24 1500 0.15 0.8
Linear 3 927604757 6186556 17.41
25 500 0.20 0.8
26 1000 0.20 0.8 Square 3 1319084 439695 1.24
27 1500 0.20 0.8 Interaction 3 135166622 45055541 126.77
Residual Error 17 6041941 355408
III. Result and Discussions
The above Table 3A and below Table 3B was shows that the 27 Total 26 1070132404
experimental setup with measured surface roughness and Material
removal rate. This was the complete result for the 27 machining
jobs for AA6063A. Surface Plot for MRR
Hold Values
SPEED 1500
Table 3B: Response Values FEED 0.2
DOC 0.8
TIME MRR 30000
S.NO Ra 24000

(min) (mm3/min) MRR 18000

12000
MRR
20000

10000
0.20

1 21 1182.80 0.847 6000 0.70

0.15 FEED 0
0.45 DOC
500 500
1000 0.10 1000 0.20
2 21 2365.61 0.986 SPEED
1500
SPEED
1500

3 21 3548.42 1.009
4 15 1774.21 0.921
5 15 3548.42 0.943
6 15 5322.64 1.078 MRR
20000

10000
7 12 2365.61 1.082 0
0.45
0.70
DOC

8 12 4731.23 2.253
0.10
0.15 0.20
0.20
FEED

9 12 7096.85 1.192
10 21 2715.90 0.821 Fig. 4: Surface Plots of MRR
11 21 5431.81 0.813
12 21 8147.72 1.759 B. Response Surface for Ra
13 15 4073.86 0.947 From the observed data for surface roughness, the estimated
regression coefficients for average surface roughness in un-coded
14 15 8147.72 0.727
units have been determined.
15 15 12221.58 1.152 Analysis of Variance for Ra:
16 12 5431.81 1.680 R-Sq = 67.24%
17 12 10863.62 1.121 R-Sq(pred) = 6.72%
18 12 16295.44 0.972 R-Sq(adj) = 49.90%
19 21 4561.59 0.820
Table 5: Analysis of Variance for Ra
20 21 9123.18 1.137
21 21 13684.77 2.704 Source DF Seq-SS Adj-MS F- Value
22 15 6842.38 0.874
Regression 9 5.51409 0.61268 3.88
23 15 13684.77 0.883
Linear 3 1.97988 0.08522 0.662
24 15 20527.16 1.693
Square 3 1.00859 0.33620 0.134
25 12 9123.18 0.928
Interaction 3 2.52561 0.84187 0.009
26 12 18246.37 0.943
Residual
27 12 27369.55 1.973 17 2.68645 0.15803
Error
Total 26 8.20053

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IJRMET Vol. 5, Issue 2, May - Oct 2015 ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print)

2. Optimization Plot for Surface Roughness

Surface Plot for Ra
Hold Values
SPEED 1000
FEED 0.1
DOC 0.5
1.5 2.0
Ra Ra 1.5
1.0
0.20 1.0
0.70
0.5 0.5
0.15 FEED 0.45 DOC
500 500
1000 0.10 1000 0.20
1500 1500
SPEED SPEED

1.4
1.2
Ra
1.0
0.8 0.70
0.45 DOC
0.10
0.15 0.20
0.20
FEED

Fig. 4: Surface Plots of Ra

IV. Optimization Fig. 6: Response Optimization for Ra Parameters

A. Predicted Result by Response Surface Method V. Conclusion

1. In this Project, turning process of AA6063A using CNC
Table 6: Predicted Result by Response Surface Method Machine through consideration of three input parameters
Output Predicted Value that was applied for Response Surface Methodology and
Response (by RSM method) Analyzing to get a minimum surface roughness and maximum
material removal rate.
MRR (mm3/min) 26368.6
2. The optimize value for surface roughness denote that the
Surface Roughness, Ra(m) 0.7818 input parameters feed has most important to the quality
characteristics of surface roughness best parameters found
for surface finish machining are cutting speed 1000 Rpm,
B. Optimization Result Obtained of RSM by Minitab16 feed 0.10 mm /rev, depth of cut 0.5 mm.
3. Depth of Cut in the most affecting the parameters. When the
Table 7: Optimization result obtained of RSM by minitab16 MRR increases feed and depth of cut proportionally increases
Global/Local Solution Predicted the best parameter found for MRR are cutting speed 1500
Output Goal rpm, feed 0.20 mm/rev, depth of cut 0.8 mm.
Depth Value
Response Speed Feed 4. The equations obtained from Response Surface Methodology
of Cut
MRR (mm3/ for Surface Roughness, MRR are having R-sq values as
min) Maximum 1500 0.20 0.8 26368.6 99.44%, and 99.14% respectively.
5. Predicted response values are calculated from Response
Surface Surface Methodology are very similar as shown in tables
Roughness, (6).
Minimum 1000 0.10 0.5 0.7818
Ra(m) 6. Conformation tests were performed to validate the second order
response surface model for MRR and surface roughness. The
predicted test results are in conformance to the experimental
test results.
1. Optimization Plot for MRR
Reference
[1] S.V.Alagarsamy, N.Rajakumar,Analysis of influence of
turning process parameters on MRR & Surface Roughness
of AA7075 using Taguchis method and Response surface
methodology, International Journal of Applied Research
and Studies, Vol. 3, Issue 4 (Apr - 2014).
[2] Md. Tayab Ali, Dr. Thuleswar Nath,Cutting Parameters
Optimization for Turning Aluminim Alloy 6063-T6 Alloy by
Using Taguchi Method, IJRMET, Vol. 4, Issue 2, May-
October 2014.
[3] Ashok Kumar Sahoo, Achyuta Nanda Baral,Multi-objective
Optimization and Predictive Modelling of Surface roughness
and Material removal rate in Turning using Grey relational
and Regression Analysis, Elsevier Procedia Engineering
Fig 5: Response Optimization for MRR Parameters 38, pp. 1606-1627, 2012.
[4] U.D.Gulhane, B.D. Sawant, P.M.Pawar,Analysis of
Influence of Shaping Process Parameters on MRR and Surface

10 International Journal of Research in Mechanical Engineering & Technology w w w. i j r m e t. c o m

ISSN : 2249-5762 (Online) | ISSN : 2249-5770 (Print) IJRMET Vol. 5, Issue 2, May - Oct 2015

roughness of Al6061 using Taguchi method, International

Journal of Applied Research and Studies, Vol. 2, Issue 4 C.JohnJoshua is a final year M.E
(April-2013). Manufacturing Student in Chendhuran
[5] Mihir T. Patel, Vivek A. Deshpande,Experimental College of engineering and technology,
Investigation of Effect of Process Parameters on Mrr and Pudukkottai, AnnaUniversity,Chennai.
Surface Roughness In Turning Operation on Conventional He had completed his B.E Mechanical
Lathe Machine For Aluminum 6082 Grade Material Using Engineering in Shanmuganathan
Taguchi Method, Journal of Engineering Research and Engineering College, Pudukkottai,
Applications, Vol. 4, Issue 1, January 2014, pp. 177-185. AnnaUniversity, Chennai in the year
[6] Gulhane U. D., Ayare S. P., Chandorkar V.S., Jadhav M 2013.
.M.,Investigation of turning process to improve productivity
(MRR) for better surface finish of al-7075-T6 using
DOE, International Journal of Design and Manufacturing
Technology (IJDMT), Vol. 4, Issue 1, January-April, 2013, Raja Kumar N received his B.E degree
pp. 59-67. in Mechanical Engineering from
[7] Mihir T. Patel, Vivek A. Deshpande,Experimental Coimbatore Institute of Technology,
Investigation of Effect of Process Parameters on Mrr and Coimbatore, Tamilnadu, India, in
Surface Roughness In Turning Operation on Conventional 1995, the M.E post graduate degree
Lathe Machine For Aluminum 6082 Grade Material Using in manufacturing engineering
Taguchi Method, Journal of Engineering Research and from Alagappa Chettiar College of
Applications, Vol. 4, Issue 1, January 2014, pp. 177-185. Engg. & Technology, Karaikudi,
[8] B. Sidda Reddy, J. Suresh Kumar, K. Vijaya Kumar Tamilnadu, in 2005 and undergoing
Reddy,Prediction of Surface Roughness in Turning Using Ph.D in Mechanical Engineering at
Adaptive Neuro-Fuzzy Inference System, Jordan Journal Anna University, Chennai. He was a
of Mechanical and Industrial Engineering Vol. 3, No. 4, lecturer, assistant professor, associate professor with department
December- 2009. of Mechanical engineering from 1998 onwards. His research
interests include powder metallurgy. At present, he is Associate
Professor and Head in Department of Mechanical Engineering at
Chendhuran College of Engineering and Technology, Affiliated
with Anna University, Chennai, Lenavilakku, Pudukkottai,
Tamilnadu, INDIA.

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