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IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

Effects of machining parameters on tool life and its optimization

in turning mild steel with brazed carbide cutting tool

S Dasgupta1, S Mukherjee
Department of Mechanical Engineering, Jalpaiguri Government Engineering College,
Jalpaiguri-735102, West Bengal, India
1
E-mail: [email protected]

Abstract. One of the most significant factors in metal cutting is tool life. In this research work, the
effects of machining parameters on tool under wet machining environment were studied. Tool life
characteristics of brazed carbide cutting tool machined against mild steel and optimization of
machining parameters based on Taguchi design of experiments were examined. The experiments
were conducted using three factors, spindle speed, feed rate and depth of cut each having three
levels. Nine experiments were performed on a high speed semi-automatic precision central lathe.
ANOVA was used to determine the level of importance of the machining parameters on tool life.
The optimum machining parameter combination was obtained by the analysis of S/N ratio. A
mathematical model based on multiple regression analysis was developed to predict the tool life.
Taguchi’s orthogonal array analysis revealed the optimal combination of parameters at lower levels
of spindle speed, feed rate and depth of cut which are 550 rpm, 0.2 mm/rev and 0.5mm
respectively. The Main Effects plot reiterated the same. The variation of tool life with different
process parameters has been plotted. Feed rate has the most significant effect on tool life followed
by spindle speed and depth of cut.

1. Introduction
During the course of history people have changed the manufacturing process dramatically. Instead of
items being produced by hand, the owners of the facilities created ways to have machines to produce the
items. This change in production, which saw its peak during the Industrial Revolution, gave rise to metal
cutting process which over the years has advanced a long way. Metal cutting process is widely used in
engineering industries. For a machining process such as turning, cutting conditions like cutting speed,
feed, depth of cut plays salient role in the efficient use of a machine tool and thus improving its tool life.
Optimization of the process and accurate estimation of tool life has become indispensable in this age of
automation. The goal is to find combinations of these parameters that achieve saving in power
consumption, increase in tool life, correct lubrication method and improved surface quality. The results
presented in this work should create the window of optimization. It has been established experimentally
that there is a definite relationship between spindle speeds, feed rate, depth of cut and tool life. Most

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IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

published works on metal cutting has regarded these three parameters as having the greatest influence on
tool wear and tool life.
A significant improvement in process efficiency may be accomplished by optimization of process
parameter that identifies and determines the areas of critical process control factors leading to desired
outputs or responses within acceptable variations which ensures a lower cost of manufacturing. This
research work deals with the optimization of these process parameters in order to improve tool life.

2. Design of Experiments using Taguchi Method

Genichi Taguchi, Japanese engineer and statistician invented the Taguchi techniques, which is a
methodology that utilizes process control and control charts with product and process design to achieve a
robust parameter design. The experiments were conducted by following factorial design of experiments.
Design of experiment is an effective approach to optimize the parameters in various manufacturing related
process, and one of the best intelligent tool for optimization and analyzing the effect of process variables.
The selection of such points in design space is commonly called design of experiments (DOE).
To consider the variation of results, Taguchi method uses the S/N ratio to identify the quality
characteristics applied in engineering design problems. In this case, signal is denoted as mean and noise as
standard deviation. Thus, optimality is reached by Taguchi method by the maximization of S/N ratio so
that the effect of noise is minimized. For the present case of maximization of tool life, higher the better,
HB characteristic needs to be used. Again, to know which of the process parameters have a significant
influence on the tool life; analysis of variance (ANOVA) as discussed by Montgomery [9] is also applied.
A mathematical model based on multiple regression analysis was developed to predict the tool life by
relating it with process parameters.

3. Experimental Details

3.1. Experimental Setup

The experimental investigation is carried out on a high speed precision lathe (Make-Hindusthan Machine
Tools Limited) under wet condition with soluble oil. The work piece used for turning operation is mild
steel. Samples used are round bars of 32 mm diameter and 600 mm length. The cutting tool used for
experiment is brazed carbide tool of Sandvik Coromant make. It has rectangle shank-metric 20x20 with
tool cutting edge angle of 90° and 0.8mm corner radius.

3.2. Choice of Process Parameters

The working ranges of the parameters for subsequent design of experiment have been selected in
accordance with the normal working ranges for such operation. In the present experimental study only
spindle speed, feed rate and depth of cut have been considered as process variables since these are the
most important process parameters affecting the tool wear and hence tool life. The process parameters and
their limits are listed in Table 1.

3.3. Response Variable

In this research work, the main aim is to analyse the effect of machining parameters on tool life and its
optimization in turning mild steel. Hence, in this case the response variable used to accomplish this study
is the tool life. The tool life was calculated as-

RPM x mmPR = mmPM and T = L x 60/mmPM

2
IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

Where, RPM = Revolution per minute, mmPR = Millimeter per revolution, L = Effective length of cut,
T= Tool life in second

Table1. Design factors and parameters.

Design Unit Levels

factors 1 2 3

Spindle RPM 550 930 1210

speed (V)

Feed rate (F) mm/revolution 0.2 0.4 0.72

Depth of cut mm 0.5 0.7 1

(D)

3.4. Design of Experiments

In this experimental work related to turning of a mild steel work piece by brazed carbide cutting tool, the
experiments were conducted considering three main process parameters namely spindle speed, feed rate
and depth of cut under three different levels, low, medium and high. Thus, accordingly, a three level full
factorial design of experiments would give (3 3 = 27) number of combinations. However, considering
Taguchi’s design of experiments, we get 9 combinations for 3 parameters and 3 levels.

4. Statistical Analysis on Results Obtained

4.1. Analysis of Signal to Noise Ratio

The idea of Taguchi method is to maximize the S/N ratio, to minimize the effect of random noise factors,
which have an impact on the process performance. In the present work, S/N ratio analysis is done with
tool life as the performance index and all the calculations are conducted in Minitab software [10]. As tool
life is to be maximized, S/N ratio is calculated using HB (Higher the Better) criterion and is given by:

1 n 1 
S / N  10 log   2  (1)
 n i 1 yi 
Where y is the observed data and n is the number of observations.

The mean of the S/N ratio for each level of the factors of V, F, and D are given in Table 3. The delta
value is the difference between the largest and the lowest from among the values in each column. A large
difference in the S/N ratio indicates that the factor or design parameter is a significant contributor to the
achievement of the performance characteristic. A little difference in the S/N ratio from one factor setting
to another, hints at the insignificance of the factor with respect to the performance characteristic. It is
found from Table 3 that feed rate (F) possesses the highest delta value, and hence, has the greatest
influence over the tool life.

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IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

Table2. Taguchi combination of process parameters with S/N Ratios.

Spindle Feed rate (F) Depth of Tool life S/N ratio

speed (V) cut (D) (T)
mm/revolution
RPM mm.

550 0.2 0.5 693 56.8112

550 0.4 0.7 391 51.8515

550 0.72 1 72 37.1418

930 0.2 0.7 315 49.9530

930 0.4 1 77 37.7771

930 0.72 0.5 58 35.3044

1210 0.2 1 187 45.4457

1210 0.4 0.5 126 42.0384

1210 0.72 0.7 15 23.6083

Table 3. Response table for S/N Ratio.

Spindle speed Feed rate Depth of cut

Level RPM mm/revolution mm.

1 48.60 50.74 44.72

2 41.01 43.89 41.80

3 37.03 32.02 40.12

Delta 11.57 18.72 4.60

Rank 2 1 3

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IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

Main Effects Plot for SN ratios

Data Means
SPINDLE SPEED FEED RATE DEPTH OF CUT

50
Mean of SN ratios

45

40

35

30
550 930 1210 0.20 0.40 0.72 0.5 0.7 1.0

Signal-to-noise: Larger is better

Figure 1. Main effects plot for signal to noise ratio.

The main effects plot (Figure.1) gives the optimal combination of turning process parameters for
maximum tool life. Since Taguchi method obtains the optimal level combination by selecting those levels
at which S/N ratio is the highest, the optimal combination of parameters is found to be V1F1D1, i.e.
lower-levels of spindle speed, feed rate and depth of cut. Moreover, the main effect plot throws some light
on the significance of the parameters on the system response. The slope of the main effect plot for each
parameter is the determining factor in this case. The plot having higher inclination will have higher
influence. From Figure.1, it can be observed that both the factors feed rate and spindle speed are very
much significant while factor depth of cut is almost negligible and hence, insignificant.

4.2. Analysis of Variance (ANOVA)

In this study, ANOVA was performed to investigate the statistical significance of the process parameters
affecting the tool life. The objective was to analyze the influence of spindle speed, feed rate and depth of
cut on the total variance of the results. Table 4 shows the results of the ANOVA with the tool life.
This analysis was undertaken for a level of significance of 0.5%, i.e. for a level of confidence of
99.5%. The ANOVA table also consists of the F-values and the percentage contributions. By comparing
the F-values with the tabulated ones, the significance of the factors can be understood. If the obtained F-
value of a parameter is greater than the tabulated one, then that particular parameter has a significant
influence over the response variable. From Table 4, it can be seen that feed rate has got the most
significant influence on tool life at the confidence level of 99.5% within the specific test range. But
parameters spindle speed and depth of cut has almost no significance on the tool life.

4.3. Confirmation Test

The experimental confirmation test is the final step for the verification of results based on Taguchi’s
design approach. The optimal conditions are set at economic levels and a selected number of
experiments are performed at specified cutting conditions. Average of the results from the confirmation
experiment is compared against the predicted average based on the parameters and levels tested. This

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IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

confirmation experiment is highly recommended by Taguchi to verify the experimental results [11]. In this
study, a confirmation experiment was conducted by utilizing the levels of the optimal process parameters
(V1F1D1) for which the tool life was found to be 688 seconds

Table 4. ANOVA table.

Source DF SS MS F Contribution
(%)

Spindle 2 207.34 103.67 5.50 25.42021700

speed

Feed rate 2 538.19 269.09 14.28 a 65.98295837

Depth of 2 32.45 16.22 0.86 3.97842211

cut

Error 2 37.68 18.84 4.61962851

Total 8 815.65 100

a
Significant parameters and interactions
(F0.005, 2, 8= 11.042)

4.4 Multiple Regression Modeling

A mathematical model has been developed to predict the tool life by relating it with process parameters.
The spindle speed, feed rate, depth of cut and interaction among them were considered. The nonlinear
2nd.order regression equation for tool life involving control parameters is obtained through regression
analysis. MATLAB software package [12] was used to obtain the generalized mathematical model as
follows:

T = b0 + b1V + b 2F + b 3D +b11V2 +b22F2 +b33D2 +b12VF +b23FD +b13VD (2)

Tabulating the value of constants b0, b1……b13, we get the following equation:
T = 0.4608 + 1.2288*F -0.8192*D -1.0240*F2 -0.8192*D2 -0.0008*V*F -2.0480*F*D +0.0004*V*D (3)

Arithmetic mean of V, F and D were considered. From equation (3), the following curves have been
obtained.

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IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

1050

900

750

600
Tool life
(Seconds) 450

300

150

0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7

Feed Rate (mm/revolution)

Figure 2.Variation of tool life with feed rate.
900

800

700

600

Tool life 500

(Seconds) 400

300

200

100
0
500 600 700 800 900 1000 1100 1200 1300

Spindle speed (RPM)

Figure 3.Variation of tool life with spindle speed

800

700

600

500

Tool life 400

(seconds) 300

200

100

0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1
Depth of cut (mm)

Figure 4.Variation of tool life with depth of cut.

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IConAMMA-2016 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 149 (2016) 012005 doi:10.1088/1757-899X/149/1/012005

Figures 2, 3 and 4 show the variation of tool life with feed rate, spindle speed and depth of cut
respectively. Graphs were plotted between tool life and one parameter, keeping the other two constant at
their mean values

5. Conclusion
This study has discussed the importance of the Taguchi method for investigating the effects of process
parameters on the tool life in turning of mild steel. From the analysis of the results in the turning process
by the signal-to-noise (S/N) ratio approach, analysis of variance (ANOVA), and optimization method of
Taguchi, the following can be inferred from the present study:
Statistically designed experiments were performed based on Taguchi’s L9 orthogonal array to analyze
the tool life as response variable. Data analysis through S/N ratio and ANOVA approaches drew similar
conclusions.
Statistical results (at a 99.5% confidence level) show that the spindle speed, feed rate and depth of cut
affects the cutting process by 25.42%, 65.98% and 3.97% in the turning of mild steel by brazed carbide
cutting tool, respectively.
The maximum tool life is calculated as 688 seconds by Taguchi’s optimization method. The analysis of
the confirmation experiment for metal removal rate has verified the optimum cutting parameters
(V1F1D1), which are spindle speed=550 RPM (V1), feed rate=0.2 mm/rev (F1) and depth of cut =0.5 mm
(D1).

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