International Journal On Engineering Technology and Sciences IJETS

ISSN(P): 2349-3968, ISSN (O): 2349-3976

Volume III, Issue II, February- 2016

A REVIEW ON MACHINING PARAMETERS INFLUENCING THE

RESPONSES ON CNC: AN OPTIMIZATION TECHNIQUE
Selva Ganesh Kumar1, Tadesse Beyene2, N.Zeelan Basha3
Assistant Professor/Mechanical Engineering1,2, Ph.D Research Scholar /Mechanical Engineering3,
Wollega University1,2, Coimbatore Institute Of Technology3,
[email protected], [email protected]
Abstract
CNC machines are main platform in the contribution of good quality products in industries. Surface Roughness is generally used as a
guide to find out the surface finish for unbroken upgrading of surface quality. A great number of publications by a variety of authors
reproduce the significance in these parameters. Reviews of literature on surface roughness optimization have been done in the past by a
most of the authors. The evolutionary algorithm GA is used to improve many solutions of optimization complex problems in many
applications. This paper reviewed the ideal selection of cutting parameters in turning operation using GA and its variants. This study
deals with GA algorithm in different machining aspects spindle speed, cutting speed, feed rate, depth of cut, rake angle, helix angle etc.
in turning operation like surface roughness, production rate , tool life, production cost, machining time and vibration. The survey showed
that there are many papers in the field of turning parameters optimization using GA, but there is a lack in studies in the field of vibration
optimization in turning operation which is very important problem in machining operation.

Key words: Anova, CNC Machine, Depth of cut, feed rate, Optimization, RSM, Spindle speed, Surface roughness

Artificial Bee Colony and Ant Colony Optimization, It

I. INTRODUCTION posits that use of ABC algorithm began at the latest years
The challenge of modern machining industries is mainly of this decade and concentrated on optimization the
focused on the achievement of high quality, in term of parameters of new cutting operations such as electrical
work dimensional accuracy, surface finish. Surface discharge and electrochemical operations. However, no
texture is concerned with the geometric irregularities. The much papers in the field of using ACO optimization at the
quality of a surface is significantly important factor in latest years. Also when use GA and PSO algorithms, the
estimating the productivity of machine tool and machined most machining operation that is using it was multipass
parts. The surface roughness of machined parts is a turning, while SA algorithm used in end milling and
significant effects on some functional attributes of parts, AJW. On the other hand, most machining performances
such as, contact causing surface friction, wearing, light used surface roughness, machining / production costs and
reflection, ability of distributing and also holding a material removal rate as shown in Figure 1 which shows
lubricant, load bearing capacity, coating and resisting that the papers in the field of temperature measurement
fatigue. In manufacturing industries, manufacturers and dry turning are very rare ( Adnan Jameel, 2013).
attentive on the quality and Productivity of the product.(
Mihir T. Patel, 2014 ). Experiment helps researchers to II. LITERATURE REVIEW
build models, evaluate the effects of several factors mand
achieve the optimum conditions for desirable responses in The optimal machining parameters can be finding using
addition to reducing the number of experiments .Analysis GA evolutionary techniques widely .Three main parts in
of variance (ANOVA) provides the Statistical results and GA can be used; reproduction, crossover and mutation.
diagnostic checking tests which enables researchers to The binary encoding process used to encode the
evaluate adequacy of the models (Khaider Bouacha, parameters as genes. Using of GA in turning operation
2009). After analyzing each response, multiple response improvement is studied ( Adnan Jameel, 2013) .The
optimizations was performed, either by inspection of the combined effects of four machining parameters, including
interpretation plots, or with the graphical and numerical cutting speed, feed rate, depth of cut and tool corner
tools provided for this purpose. It was mentioned radius, on the basis of two performance characteristics
flank wear (VBmax) and surface roughness (Ra), were
investigated and the centered central composite design
Previously that RSM designs also help in quantifying the (CCD) and the analysis of variance (ANOVA) were
relationships between one or more measured responses employed. The quadratic model of RSM associated with
and the vital input factors. In order to determine if there the sequential approximation optimization (SAO) method
exist a relationship between the factors and the response was used to find optimum values of machining
variables investigated, the data collected must be parameters. Results show that the flank wear is influenced
analyzed in a statistically sound manner using regression principally by the cutting speed and the interaction effect
(M.Y. Noordin, 2004). of feed rate with nose radius of tool, and the cutting speed
Optimization algorithms such as Genetic Algorithm, and the tool corner radius have statistic significance on
Simulated Annealing, Particle Swarm Optimization, the surface roughness (Jenn-Tsong Horng, 2007).
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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

The main objectives are firstly focused on delimiting the to locate global optimum. It is because of this feature that
hard turning domain and investigating tool wear and GA goes through solution space starting from a group of
forces behaviour evolution versus variations of workpiece points and not from a single point. The cutting conditions
hardness and cutting speed. Secondly, the relationship are encoded as genes by binary
between cutting parameters (cutting speed, feed rate and encoding to apply GA in optimization of machining
depth of cut) and machining output variables (surface parameters. A set of genes is combined together to form
roughness, cutting forces) through the response surface chromosomes, used to perform the basic mechanisms in
methodology (RSM) are analysed and modeled. The GA, such as crossover and mutation.
combined effects of the cutting parameters on machining Crossover is the operation to exchange some part of two
output variables are investigated while employing the chromosomes to generate new offspring, which is
analysis of variance (ANOVA). The quadratic model of important when exploring the whole search space rapidly.
RSM associated with response optimization technique Mutation is applied after crossover to provide a small
(Khaider Bouacha, 2009). randomness to the new chromosomes.
The prediction of optimal machining conditions for good To evaluate each individual or chromosome, the encoded
surface finish and dimensional accuracy plays a very cutting conditions are decoded from the chromosomes
important role in process planning. The present work and are used to predict machining performance measures.
deals with the study and development of a surface Fitness or objective function is a function needed in the
roughness prediction model for machining mild steel, optimization process and selection of next generation in
using Response Surface Methodology (RSM) (P.V.S. genetic algorithm. Optimum results of cutting conditions
Suresh, 2002). are obtained by comparison of values of objective
The effects of cutting speed, feed rate, work piece functions among all individuals after a number of
hardness and depth of cut on surface roughness and iterations. Besides weighting factors and constraints,
cutting force components in the hard turning were suitable parameters of GA are required to operate
experimentally investigated. Four-factor (cutting speed, efficiently. GA optimization methodology is based on
feed rate, hardness and depth of cut) and three-level machining performance predictions models developed
fractional experiment designs completed with a statistical from comprehensive system of theoretical analysis,
analysis of variance (ANOVA) were performed. experimental (Milon D. Selvam, 2012)
Mathematical models for surface roughness and cutting B. RESPONSE SURFACE METHODOLOGY
force components were developed using the response Surface Roughness Measurement
surface methodology (RSM) (HamdiAouici, 2014).The A portable Surtronic 3+ was used to measure the
best surface roughness was achieved at the lower feed surface roughness (shown in Fig. 1).
rate and the highest cutting speed. Four readings have been taken in the traverse direction. In
Two independent data sets were obtained on the basis of case there is a large deviation, extreme values are
measurement: training data set and testing data set. discarded and Additional readings have been taken so that
Spindle speed, feed rate, depth of cut, and vibrations are the total number of readings is four
used as independent input variables (parameters), while
surface roughness as dependent output variable. On the
basis of training data set, different models for surface
roughness were developed by genetic programming (M.
Brezocnik, 2004). Accuracy of the best model was proved
with the testing data. It was established that the surface
roughness is most influenced by the feed rate, whereas the
vibrations increase the prediction accuracy.
In this framework, the present study is focused on study
of the effect of process Parameters on the surface
roughness for a different value has been investigated.
Moreover, this work treats the effect of spindle speed,
feed rate and depth of cut on surface roughness in turning Figure- 1 SURF TESTER
operation with various tool has been discussed.
The average value of surface roughness is calculated and
recorded. In this study, Ra values were obtained in the
III. METHODOLOGY
range of 1.25 to 3.50 mm (Vikas Pare, 2014)
C.EXPERIMENTAL CUTTING CONDITIONS
A. GENETIC ALGORITHM
Most of the researchers used statistical analysis methods
An algorithm based on mechanics of natural selection and
in the area of high speed machining. They considered
natural genetics, which are more robust and more likely
different sets of input parameters, output
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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

parameters and tried various analysis techniques based on measurements of surface roughness were obtained at
statistics, including structured equation modeling (SEM) different surface of machined work piece and average
analysis, robust design, and Taguchi design approaches. value is used in the further analysis (clinktan, 2016)
observed the results of several projects on high-speed Rough surfaces usually wear more quickly and have
milling for testing the suitability of high-speed milling for
different kinds of materials. The materials machined were
steels, aluminium alloys, graphites and polymer matrix
composites. It is observed that most of the materials can
be machined by high-speed milling. conducted
experiments varying the speed from 2500 to 7500 rpm on
composites. They developed predictive models for
surface roughness and used GSA for optimization. In higher friction coefficients than smooth surfaces
order to determine whether there is uniform variation of Roughness is often a good predictor of the performance
surface roughness over speed variation, the range of 5000 of a quality of the mechanical component, since
to 7500 rpm was taken into consideration. TLBO was irregularities in the surface may form nucleation sites for
used, and the results were studied. studied high-speed cracks or corrosion. On the other hand, roughness may
endmilling of hardened AISI D2 tool steel (58HRC) and promote adhesion. The Surface roughness tester used for
estimated surface roughness and tool wear. measuring surface roughness (Ra) in this experimental
Ozcelik and Bayramoglu considered the step-over ratio in analysis
addition to the three cutting variables and developed a
surface roughness prediction model for wet machining D.CNC MACHINE
conditions. Examined two face milling cutter systems in The CNC Lathe is an automated machine used for
the high-speed cutting of grey cast iron under a machining Purpose and it has greater accuracy and
determined cutting condition productivity (figure 2) shown below which has been used
Deployed mathematical models to enhance the surface in various literature
quality during CNC machining observed, the
experimental results and related empirical models for
Work piece surface integrity (SI) during high-speed
Machining (Vikas Pare, 2015).The experimental work
was divided into two series:
The main aim of the first experiments series was the
determination of the turning domain and the
quantification of surface roughness evolution. This was
carried out through facing operation with continuously
varying cutting parameters.
The purpose behind the second experiments series was to
investigate the effects of cutting parameters on surface
roughness, then to establish a correlation between them
using the response surface methodology
(RSM).Machining process was carried out in CNC lathe.
Figure- 2 CNC Turning Lathe
The measurements of average surface roughness (Ra)
were taken on surface roughness Tester SJ-210P.Three
Table 1. Summary of Review Papers

S.No Title Author Main Findings Material Methodology Year

Used
1 Optimization of K.Saravanakumar, By optimizing input Inconel Genetic August
cnc end milling M.R.Pratheesh parameters such as 718 Algorithm 2012
process Kumar, spindle speed, feed tool.
parameters on rate, and depth of cut,
inconel 718 using etc., the output
genetic parameters like surface
algorithm. finish and metal
removal rate can also
be optimized for
economical production.
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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

2 Optimization of Mr.Ch.Madhu.V.N, The influence of Titanium Artificial April

cutting Prof.A.V.N.L. spindle speed, feed rate neural 2012.
parameters for Sharma, and depth of cut on the network.
surface surface roughness is
roughness examined by using
prediction using optimization technique.
artificial neural
network in cnc
end milling,
3 Selection of J.S.Senthilkumaar; The effects of the Inconel Taguchi November
machining P.Selvarani And machining parameters 718 technique. 2010
parameters based Rm.Arunachalam. of spindle speed, feed
on the analysis of rate and depth of cut on
surface the performance
roughness and measures surface
flank wear in roughness and flank
finish end milling wear were investigated.
and facing of
using taguchi
technique.
4 Application of Oktem , T. Rsm is utilized to Aluminum Response April
response surface Erzurumlu , H. create an efficient 7075 surface 2005
methodology in Kurtaran . analytical model for methodology,
the optimization surface roughness in &Genetic
of cutting terms of cutting algorithm
conditions for parameters: feed, tool.
surface spindle speed, axial
roughness. depth of cut, radial
depth of cut and
machining tolerance. rs
model is further
interfaced with the GA
to optimize the cutting
conditions for desired
surface roughness.
5 Effect of Mathew A. This paper examines Aluminum RSM and the 2010
machining feed kuttolamadom, the achievability of 6065 Taguchi
on surface Sina hamzehlouia. surface roughness Technique
roughness in specifications within
cutting efforts to reduce
6065aluminum. automotive component
manufacture cycle
time,. particularly by
changing cutting feeds
6 Optimizing h.m.somasheka. end milling parameters Al6351-T6 Taguchi May 2012
surface (spindle speed, feed alloy technique and
roughness in end and depth of cut) which Anova.
milling operation results in an optimal
using taguchi value of surface
technique and roughness while
anova. machining al 6351-t6
alloy with uncoated
carbide inserts.

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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

7 Applications of S.k. Deepak. Optimization of cutting Common optimization Sept.

different parameters is technique. (2012)
optimization considered to be a vital
methods for tool for improvement
metal cutting in output quality of a
operation. product as well as
reducing the overall
production time. An
optimization technique
provides optimal or
near optimal solution.
8 The evolutionary Maciej Grzendaa, The vigorous standard Genetic
development of Andres Bustillo B. expansion of wind principal algorithm.
roughness energy power component
prediction generation over the last
models, decade has also
entailed innovative
improvements to
surface roughness
prediction models
applied to high-torque
milling operations.
9 Prediction and Arokiadass, K. Optimal combination Al/SiCp Response
optimization of Palaniradja, N. of these parameters can surface
end milling Alagumoorthi, be used to achieve the methodology.
process minimum tool flank
parameters of wear. From the
cast aluminium developed model, the
based MMCR optimal process
parameter combination,
i.e. spindle speed of
2034.6084r/min, feed
rate of 0.0214 mm/r,
depth of cut of 0.5893
mm, and content of
SiCp of 5% was found
out to achieve the
minimum tool flank
wear as 0.1102 mm.
10 analysis of Hamdi Aouici A In this study, the Cbn tool Anova and Dec 2011
surface effects of spindle RSM
roughness and speed, feed rate, work
cutting force piece hardness and
components in depth of cut on surface
hard end milling roughness and cutting
with cbn tool: force components in
prediction model the hard end milling
and cutting were experimentally
conditions investigated.
optimization

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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

11 Prediction of M.Brezocnik ,M. This paper proposes the common Genetic 2004.
surface Kovacic, M.Ficko genetic programming programming.
roughness with approach to predict
genetic surface roughness
programming based on cutting
parameters (spindle
speed, feed rate, and
depth of cut) and on
vibrations between
cutting tool and work
piece.
12 Optimization of Suleyman Neseli a, In order to find out the AISI 1040 Response November
tool geometry Suleyman Yaldz a. effect of tool geometry steel surface 2010
parameters for parameters on the methodology.
end milling surface roughness
operations based during end milling,
on the response response surface
surface methodology (RSM)
methodology. was used and a
Prediction model was
developed related to
average surface
roughness (Ra) using
experimental data.
13 Study on Chen Lu This paper reviews the common Optimization Nov
prediction of methodologies and techniques. 2007
surface quality in practice that are being
machining employed for the
process. prediction of surface
profile and roughness,
each approach with its
advantages and
disadvantages is
summarized. It is
evident that ANNs are
a powerful tool, easy-
to-use, and have a good
prospect for the future
applications.

IV. CONCLUSIONS DOE and GA Optimization operation is one of the important

From the discussion of literature it has been concluded that goals of manufacturing systems, also it simple to use and are
maximum number of researchers are interested in increasingly used to solve inherently intractable problems
optimization of machining condition with corresponding quickly. From the last one decade study of
surface roughness. The survey showed that there are many Optimization, it is clearly that the genetic algorithm is one of
papers in the field of turning parameters optimization using the best population searches and its variants have been
GA, but there is a lack in studies in the field of vibration extensively used. However, many studies are concentrated
optimization in turning operation which is very important on optimization of surface roughness
problem in machining operation. The Performance of quality
of surface and optimization of cutting parameter with aid of

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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

VII.REFERENCES

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