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B. Surapong et al., International Journal of Emerging 9. No.
Trends 7, July 2021
in Engineering Research, 9(7), July 2021, 929 – 936
International Journal of Emerging Trends in Engineering Research
Available Online at http://www.warse.org/IJETER/static/pdf/file/ijeter16972021.pdf
https://doi.org/10.30534/ijeter/2021/16972021

Determination of the Optimal Parameters in Brass Turning

Process by Taguchi method
B. Surapong1, B. Phiraphan2, B. Wiboonluk3
1
Department of Industrial Technology Education, Faculty of Engineering, Rajamangala University of Technology
Lanna, Thailand, [email protected], [email protected]
2
Department of Industrial Technology Education, Faculty of Engineering, Rajamangala University of Technology
Lanna, Thailand, [email protected]
3
Department of Student development Division, Rajamangala University of Technology Lanna. 128 Huay kaew
Road, Muang District, Chiang Mai 50300, Thailand, [email protected]

 quality assurance tool to identify the important parameters

ABSTRACT to monitor for Statistical Process Control (SPC). The
Taguchi experimental approach allows a statistically sound
This research is a study of the turning process by testing experiment to be completed, while investigating a minimum
with brass material. There are three control factors: spindle number of possible combinations of parameters or factors. A
of speed, feed rate, and depth of cut respectively. The Taguchi experiment can be accomplished in a timely
turning process requires variable control, affect the quality manner and at a reduced cost with results comparable to a
of production productivity and production cost planning an full factorial experiment. Used design of experiments
experiment with the Taguchi Method help in the experiment concepts to optimize the process parameters of
the analysis of variance, orthogonal array, and signal and chemical-mechanical polishing process in wafer
noise ratios were considered as an experiment and survey of manufacturing. Material removal rate and non-uniformity of
brass turning characteristics to determine the lowest surface profiles were selected as the target values, and the
material removal rate. The results obtained from the process parameters such as platen speeds, carrier speeds,
experiment were used to repeat the experiment for back side pressure, slurry flow rate and a head down force
confirmation. This requires the turning process to be reliable were optimized [3]. Conducted experiments to know the
and optimized. influence of forming process parameters with an objective to
minimize the load on the tool [4]. The process parameters
Key words: Optimal, parameter, ANOVA, regression of such as strain, die angle and coefficient of friction were
coefficient, optimization, turning process, taguchi method optimized by using both classical optimization techniques
and design of experiments concepts. The merits and
1. INTRODUCTION demerits of both the classical and DOE methods were
highlighted. In this study, the authors calculated the
Lathes are basic machines used to manufacture parts and maximum expansion ratio of the tube and the fracture
equipment in industrial plants. And educational institutions behavior of the tube. The corresponding changes in the
in various universities, therefore, lathes are very necessary for hardness values were investigated. Studied the influence of
the production or processing of various materials. Therefore, process parameters on the deep drawing of stainless steel.
the operation steps in the turning process there are many Deep drawing process parameters such as die radius, blank
factors involved such as lathe machine, cutting tool, turning holder force and friction-coefficient were studied to find the
knife angle, turning tool material, coolant, workers must be optimum condition for forming. It was found that the die
competent and skilled in the use of the lathe, speed, feed rate, radius followed by the blank holder force and friction
coefficient have the greatest influence on the deep drawing
depth of cut, and the materials used for production.
of stainless steel blank [5]. Optimized aluminium foam
manufacturing process with Taguchi method. In this study,
Taguchi [1], [2] design of experiment (DOE) methods the relative density of aluminium foams were minimized by
incorporate fractional factorial matrixes or orthogonal optimally controlling three process parameters namely
arrays to minimize the number of experiments required to silicon carbide content in powder mixture, the compaction
achieve a given set of performance characteristics. Iterative pressure and the forming temperature [6]. Applied the
Taguchi experiments can be designed to systematically artificial neural networks (ANN) to predict the forming load
approach optimal parameters for a complicated process or as of magnesium alloy under hot extrusion. In this study, ANN
analysis was used to determine the die shapes for various
extrusion ratios [7]. Implemented multi-objective

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optimization to optimize the gear warm forming process emission while metal machining can be very useful in
parameters [8]. identifying relative surface quality of the product and hence
selection of proper cutting parameters. Acoustic emission
The main factors in lathe production include turning, cutting technique can be effectively used in online condition
fluid, coolant, rpm, cutting speed, feed rate, depth of cut monitoring of machining parameters.
operating environment. Operator skills, expertise, and
experience are extremely important. As well as production Nitin Sharma et. al. [14] have used Taguchi method to find
materials, material removal rate. the optimal cutting parameters for surface roughness (Ra) in
turning of AISI-410 steel bars usinf tin coated inserts. The
In this research, the effects of the turning process were studied four cutting parameters namely insert radius, depth of cut,
by testing on brass material. The material is a manufacturing feed and cutting speeds are optimized with consideration of
component that is essential in the manufacture of any surface roughness. The analysis reveals that feed rate has
machine. The Taguchi Method experiment was designed to the most significant effect on Ra. They found that parameter
determine the lowest possible material removal rate per design of the Taguchi method provides a simple systematic
production process, check out the orthogonal array, noise and and efficient methodology for the optimization of the cutting
signal ratio, and the analysis of variance under a significant parameters.
statistical assumption.
Suleman et. al. [15] have investigated the influence of depth
2. LITERATURE REVIEW of cut, feed rate and spindle speed on surface roughness
during turning of mild steel. Analysis of variance (ANOVA)
T. Tamizharasan et. al. [9] had developed a mathematical is used to analyze the influence of machining parameters on
model using multiple regression analysis and artificial surface roughness. Multiple linear regression, mathematical
neural network (ANN) model for artificial intelligent model. model correlating the influence of machining parameters on
They found that depth of cut is most significant parameter surface roughness during the process were developed and
followed by cutting speed, hardness of material and lastly validated.
feed rate. The mathematical model developed by multiple
regression method shows accuracy of 97.41% which is Prof. Atul dhale1 et. Al [16] use as a technique for
reliable to be used on AE signal prediction. The result from quantitative studies of manufacturing processes. Optimum
this research is useful to be implemented in industry to selection of cutting conditions importantly contribute to the
reduce time and cost in AE signal prediction. increase of productivity and the reduction of cost, therefore
utmost attention is paid to this problem in this contribution. In
R S Pawade et. al. [10] has found that analysis of AE Signal this paper we proposed AE as non-contact and indirect
during the machining could help to determine the quality of technique for in-process surface roughness assessment in
the machine surface. Frequency amplitude of the AE signal turning. Three cutting conditions dry cut, cutting with water
is influence by the cutting speed. The feed rate and edge as coolant and normal coolant were used. The material used
geometry are found to influence the number of count in study is EN8. Three cutting parameters namely feed rate,
generated during machining deformation. depth of cut, cutting speed are optimized with consideration
with surface roughness.
T S Reddy et. al. [11] have done the turning operation using
HSS tool on mild steel. The result shows significance 3. TAGUCHI METHOD
relation between surface roughness and AE signals
parameters. The conclusions are made for predicting surface Taguchi’s philosophy, developed by Dr. Genichi Taguchi, is
roughness by suggesting consistence values and ranges for an efficient tool for the design of high quality manufacturing
on-line monitoring of AE signals parameters. system. Taguchi’s Orthogonal Array (OA) provides a set of
well-balanced experiments (with less number of experimental
J Bhaskaran et. al. [12] in study of hard turning, used the runs), and Taguchi’s signal-to-noise ratios (S/N), which are
skew and kurtosis parameters of AE signals to monitor tool logarithmic functions of desired output; serve as objective
wear. The moment parameters of AErms signals such as functions in the optimization process. Taguchi method uses a
skew and kurtosis can be used to reliably monitor the tool statistical measure of performance called signal-to-noise
wear and surface roughness. ratio. The S/N ratio takes both the mean and the variability
into account. The S/N ratio is the ratio of the mean (Signal) to
G. Priyadarshini et. al. [13] found that lower feed rate/rev, the standard deviation (Noise). The ratio depends on the
AErms Value was less and surface roughness of machined quality characteristics of the product/process to be optimized.
surface was also less. Analysis reveal that the acoustic The standard S/N ratios generally used are as follows: -

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Nominal-is-Best (NB), lower-the-better (LB) and conducted. Taguchi thus, recommends the use of the loss
Higher-the-Better (HB). The optimal setting is the parameter function to measure the performance characteristics that are
combination, which has the highest S/N ratio, [17], [18]. deviating from the desired target value. The value of this loss
Because, irrespective of the quality criteria may be (NB, LB, function is further transformed into signal-to-noise (S/N)
HB) S/N ratio should always be maximized. Once ratio. Usually, there are three categories of the performance
experimental data (quality attribute value) is normalized characteristics to analyze the S/N ratio. They are:
using NB/LB/HB criteria; normalized value lies in between nominal-the-best, larger-the-better, and smaller-the-better.
zero to one. Zero represents worst quality to be rejected and
one represents most satisfactory quality. Since S/N ratio is 4.1 Steps Involved in Taguchi Method
expressed as mean (signal) to the noise (deviation from the
target); maximizing S/N ratio ensures minimum deviation The use of Taguchi’s parameter design involves the following
and hence it is (S/N ratio) to be maximized [19]. steps [29].
a. Identify the main function and its side effects.
Experimental design by various Taguchi methods, Taguchi b. Identify the noise factors, testing condition and quality
experimental design offers distinct advantages by which characteristics.
many factors can be examined simultaneously and much c. Identify the objective function to be optimized.
quantitative information can be extracted with a few d. Identify the control factors and their levels.
experimental trials [20], [21]. A few reports are available on e. Select a suitable orthogonal array and construct the
the application of Taguchi’s method in the field of matrix
biotechnology [22]-[24]. The basic principle of this method f. Conduct the matrix experiment.
serves as screening filters which examine the effects of many g. Examine the data; predict the optimum control factor
process variables and identify those factors which have major levels and its performance.
effects on process using a few experiments [25]. Taguchi h. Conduct the verification experiment.
method of DOE involves the establishment of a large number
of the experimental situation described as orthogonal arrays 4.1.1 The process of preparing for efficiency
(OA) to reduce experimental errors and to enhance their
efficiency and reproducibility of the laboratory experiments or The process of preparing equipment and materials to be tested
workshops in university but operation of control under the for efficiency takes the principles of a Taguchi experiment
hypothesis of the experimental according [26]. design to determine the optimization in the manufacturing
process for lathes. The testing procedure of the machining
4. EXPERIMENTAL DESIGN process for the best value by the Taguchi method is shown in
Figure 1 and Table 1 shows the design factors along with their
Experiments will be conducted on a selected lathe, selected level.
tools and materials were carbides the three process
parameters as stated above. Spindle of speed (A), feed rate (B) Material preparation Control
- Materials to make the factor
and depth of cut (C) were considered in the study. Spaced five
workpiece will choose - Spindle of
evenly levels within the operating range of the input
from 1 types of speed
parameters were selected for each process parameter. By
materials, totaling 27 - Feed rate
experimenting with the Taguchi method, A L27 (OA)
orthogonal array has been developed that includes 27
different experiments at three levels. According [27] the Testing for
Taguchi method was selected to obtain the most suitable efficacy
solution for material removal rates in a given input range such As designed by
as rake angle, cutting speed and feed. the Taguchi Take
measurements
Therefore, modern methods of finding the best results above a and visually
given set of inputs can be easily accomplished using the inspect them.
Taguchi method rather than the other conventional methods. Check to
This method has a wide application scope in various fields of find the
engineering science. The experimental data were analyzed optimizatio
using Minitab Release 19.00 software. To overcome this
problem [28] Taguchi suggested a specially designed method Figure 1: The testing process of the machining process for the
called the use of orthogonal array to study the entire optimization by the Taguchi method
parameter space with lesser number of experiments to be

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4.1.2 The objective function Table 2: (cont.) Orthogonal array (OA) L27
Experiment No. Control factors
Objective function: Smaller-the-Better 1 2 3
S/N Ratio for this function: 12 2 1 2
1 n  13 2 2 3
S / N S  10 log   yi2  (1)
n
 i 1  14 2 2 3
15 2 2 3
Where, n= Sample Size, and y= MRR in that run.
16 2 3 1
16 2 3 1
4.1.3 The control factors and parameters used in the
17 2 3 1
experiment 18 2 3 1
19 3 1 3
The factors and parameters used in the experiment were 20 3 1 3
determined in the conduct of the experiment and based on the 21 3 1 3
guidelines outlined in the manufacturer's turning operation. 22 3 2 1
In this study spindle of speed, flow rate and depth of cut was 23 3 2 1
selected as control factors and their levels are shown in (see 24 3 2 1
Table 1).
25 3 3 2
Table 1: Factors and parameters used in the experiment 26 3 3 2
Level Spindle of Flow rate Depth of cut 27 3 3 2
speed (rpm) (mm/rev) (mm.)
1 200 0.25 0.3 4.1.5 Analysis of Variance (ANOVA)
2 220 0.36 0.5
3 270 0.45 0.7 ANOVA is a statistical tool used to test differences between
two or more means. It may seem odd that the technique is
called analysis of variance (ANOVA) rather than analysis of
4.1.4 Selection of orthogonal array means. The analysis of variance is obtained by dividing the
measured the sum of the squared deviations from the total
To select an appropriate orthogonal array for conducting the mean S/N ratio into contributions by each of the control
experiments, the degrees of freedom are to be computed. The factors and the errors. [30] Analysis of variance identify the
percentage of contribution of controlled process parameters.
same is given below:

Degrees of Freedom: 1 for mean value, and 8= (2x4), two each 5. ANALYSIS OF EXPERIMENTAL RESULTS
for the remaining factors
Total degrees of freedom: 9 5.1 Results

The most suitable orthogonal array for experimentation is Table 3 shows the experiment results for the MRR and
L27 array as shown in (see Table 2). Therefore, a total corresponding S/N ratios were obtained with the help of
twenty-seven experiments are to be carried out. Minitab release19.00 software.
Table 2: Orthogonal array (OA) L27
5.2 Cause of spindle of speed, flow rate and depth of cut on
Experiment No. Control factors MRR
1 2 3
1 1 1 1 From the response in (see Table 3), it is clear that cutting
2 1 1 1 speed is the most influencing factor followed by spindle of
3 1 1 1 speed, depth of cut, and flow rate for MRR. The optimum for
4 1 2 2 MRR is a spindle of the speed of 220 rpm, a flow rate of 0.25
5 1 2 2
mm/rev, and a depth of cut of 0.5 mm respectively.
6 1 2 2
5.3 Material removal rate measurement
7 1 3 3
8 1 3 3 The Material removal rate is employed to work out the
9 1 3 3 quantity of material removed per second. It's given by the
10 2 1 2 formula
11 2 1 2 MRR = SS FR DC

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Where SS = Spindle of speed (rpm) Table 5: Response Table for means

FL = Flow rate (mm/rev) Level SS FL DC
1 9.918 6.355 11.478
DC = Depth of cut (mm)
2 10.650 13.409 11.259
MRR = Material removal rate (mm3/ min) 3 14.043 14.848 11.874
Delta 4.125 8.493 0.615
As the conditions for feed, cutting rate and depth of cut area Rank 1 2 3
unit mounted therefore, this formula is employed to calculate
the MRR rather than hard the initial and also the final weight,
the higher than formula was won’t to calculate the MRR [31]. Main Effects Plot for SN ratios
Data Means
SS FL
-16
Table 3: Factors and parameters used in the experiment -18
Level Spindle of Flow rate Depth of -20

Mean of SN ratios
speed (mm/rev) cut (mm.) -22
(rpm) MRR -24
200 220 270 0.25 0.36 0.45
N0 SS FL DC DC
1 SS FL DC MRR -16

2 200 0.25 0.3 4.638 -18

-20
3 200 0.25 0.3 4.621
-22
4 200 0.25 0.3 4.625
-24
5 200 0.36 0.5 11.933 0.3 0.5 0.7
6 200 0.36 0.5 11.820 Signal-to-noise: Smaller is better

7 200 0.36 0.5 11.905

8 200 0.45 0.7 13.333
Figure 2: Main effects plot for SN ratios
9 200 0.45 0.7 13.193
10 200 0.45 0.7 13.193
11 220 0.25 0.5 4.888 Main Effects Plot for Means
Data Means
12 220 0.25 0.5 4.864
SS FL
13 220 0.25 0.5 4.840
14
14 220 0.36 0.7 12.853
12
15 220 0.36 0.7 12.788 10
16 220 0.36 0.7 12.788
Mean of Means

8
17 220 0.45 0.3 14.493 6
200 220 270 0.25 0.36 0.45
18 220 0.45 0.3 13.966 DC
19 220 0.45 0.3 14.368 14
20 270 0.25 0.7 9.653 12
21 270 0.25 0.7 9.506 10
22 270 0.25 0.7 9.560 8

23 270 0.36 0.3 15.773 6

0.3 0.5 0.7
24 270 0.36 0.3 15.480
25 270 0.36 0.3 15.337
26 270 0.45 0.5 17.065 Figure 2: Main effects plot for means
27 270 0.45 0.5 17.182
From Tables 4 and 5, and Figure 2 and 3 above that flow
and edge condition after that spindle of speed plays an
5.4 Analysis of signal to noise ratio and means important role for MRR, a spindle of speed = 220 rpm, feed
rate = 0.25 mm/rev and depth of cut = 0.30 mm
Smaller is better performance characteristic was selected to respectively.
obtain material removal rate.
5.5 Analysis of variance (ANOVA) and estimated model
Table 4: Response Table for signal to noise ratios (Smaller is better)
Level SS FL DC
coefficients
1 -19.08 -15.56 -20.08
2 -19.66 -22.49 -19.95 Minitab release 19.00 was used to investigate the process
3 -22.69 -23.38 -21.40 parameters. Analysis of variance and estimate coefficient
Delta 3.61 7.83 1.45 defines the percentage of contribution for each process
Rank 1 2 3 parameters.

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Table 6: Analysis of variance for means 5.8 Regression equation

Source DF Seq SS Adj SS MS F P The regression equation for material removal rate as shown
SS 2 29.072 29.072 14.5360 38.95 0.02 by equation (1) is calculated in Minitab release 19.00
29.072 5
software. The regression equation shows the significant
FR 2 123.94 123.94 61.9736 166.0 0.00
7 7 5 6 effect of each process parameter on the material removal
DC 2 0.583 0.583 0.2914 0.78 0.56 rate. From this equation, it is cleared that the current and
2 pulse on time have positively affected the material removal
Residua 2 0.746 0.746 0.3732 rate whereas spindle of speed, feed rate, and depth of cut
l Error effect on response i.e. material removal rate.
Total 8 154.34
8
MRR
=11.5370(constant) + (-1.6191)(SS200)+(-0.8873)(SS220)
Table 7: Estimated model coefficients for means
+(-5.1821)(FL0.25)+(1.8716)(FL0.36)+(-0.05890)(DC0.3)
Term Coef SE Coef T P
Constant 11.5370 0.2036 56.655 0.000 +(-0.2779)(DC0.5)
(2)
SS 200 -1.6191 0.2880 -5.622 0.030
SS 220 -0.8873 0.2880 -3.081 0.091
6. CONCLUSION AND FURTHER RESEARCH
FL 0.25 -5.1821 0.2880 -17.994 0.003 From the Experimental results as we observed that the
FL 0.36 1.8716 0.2880 6.499 0.023 optimum condition for our input data to get maximum
DC 0.3 -0.0590 0.2880 -0.205 0.857 material removal rate (MRR) is 9 degrees of the spindle of
DC 0.5 -0.2779 0.2880 -0.965 0.436
the speed of 220 rpm, 0.25 mm/rev of flow rate, and depth
of cut of 0.3 mm. The maximum material removal rate that
S =0.6109 R-Sq =99.5 % R-Sq(adj) =98.1 % we get from our experiment and the Taguchi method is
4.621 grams. The minimum material removal rate that we
get from our experiment by the Taguchi method is 4.621
5.6 ANOVA for material removal rate (MRR) grams. This concludes that spindle of speed, flow rate, and
depth of cut is consumed and from analysis, we got the
Results obtained for the material removal rate (MRR) square minimum material removal rate conditions which would
measure shown in (see Table 3). The results for material directly save power in small-scale productions. This would
removal rate (MRR) were obtained from the nine also save the lead time in the industrial production process.
experiments performed of Taguchi. The experimental results
analyzed with multivariate analysis square measure shown Taguchi method is one method that has been used in
in (see Table 6). The F value calculated through Minitab research to create confidence and reliability in the
release 19.00 computer code is shown within the second last production process significantly under statistical
column of multivariate analysis table that suggests the experimental assumptions.
importance of the factors on the required characteristics.
Larger is that the F worth higher is that the significance In the following research, the experimental level has been
(considering confidence level of 95%). The results show that increased to five experimental levels, five variables, and
solely feed is that the most vital issue. The results are surface roughness. Because brass materials are used to make
consistent with the research of [32]. materials in milling machines, turning machines, etc.,
because the lowest material removal rate is needed to
5.7 Signal –to - noise ratio optimize the value. Next, find the appropriate surface
roughness. And in further research or in the future, the
Parameters that effect on the output are often divided into 2 cause and effect diagram principle will be used to help find
parts: governable (or design) factors and uncontrollable (or factors that may affect the production process, such as
noise) factors. The value of governable factors is often people, machines, materials, methods, measurements, etc.
adjusted by the designer however the worth of
uncontrollable factors can't be modified as a result of they're
the sources of variation as a result of operational ACKNOWLEDGEMENTS
surroundings. The most effective set of management factors
as they influence the output is set by performing arts Financial support Department of Industrial Technology
experiments. Smaller-the-Better is employed for material Education, Faculty of Engineering RMUTL: Rajamangala
removal rate shown in Figure 2 and 3 respectively. The University of Technology Lanna, Chiang Mai, Thailand is
values were consistent with the research of [32]. gratefully acknowledged.

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