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Machining parameter optimization using Taguchi Approach.

Conference Paper · February 2015

DOI: 10.1109/ABLAZE.2015.7154964

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2015 1st International Conference on Futuristic trend in Computational Analysis and Knowledge Management (ABLAZE-2015)

Machining parameter optimization using Taguchi

Approach
Saurabh1,, J.S.Jassi2, Dr.Aas Mohammad2, D.P.Singh3, Hasan Zakir Jafri3
1
Assistant Professor, ABES, Ghaziabad
2,3
Amity University, Gr.Noida
2
(Dr.A.M), Jamia Millia Islamia University, New Delhi
3
(H.Z.Jafri) Al-Falah University, Haryana
Author’s e-mail: [email protected]

Abstract––Among several industrial CNC machining the cut is vital parameters, which results in a good turning
processes, Turning is a fundamental machining process. job. These parameters govern the surface finish of the job.
Turning operation is widely used in industry including
the aerospace and automotive sectors because of its Turning operation is universally accepted operation in
versatility and efficiency. In order to get desired quality industry including automotive sectors because of its
of the product by machining operation proper selection versatility and efficiency. In CNC Turning operation, the
of process parameter is essential. Taguchi method is an cutting conditions such as Cutting speed, depth of cut, and
effective tool for optimizing process parameters. The aim feed rate play significant role to obtain the finished work
behind present work is to find surface roughness, which piece.
is key parameter to justify quality of machining
operation. By this approach process parameter and their Turning is the machining operation by which a cylindrical
optimal settings is investigated. During machining surface is produced. It can be achieved by:
operation influence of process parameter and their
· Rotation of work piece about Polar Axis.
interaction during machining is also analyzed by
ANOVA. Al- Alloys are universally acceptable materials · Linear motion of single-point cutting tool along the polar
due to their excellent corrosion resistance, formability, axis.
high strength-weight ratio that is unaltered at elevated
temperatures. This work reflects the Depth of cut as the · Cutting tool motion feeding perpendicular to the polar axis
key factor for surface roughness optimization. of the work piece.

Keywords––Turning operation; Taguchi Method; Turning is carried out on a lathe Machine that turns the
Surface Finish. work piece at a given cutting speed. Feeding the cutting tool
at specified rate and depth of cut are two other parameters of
I. INTRODUCTION tool motion. So mostly three parameters namely cutting
speed, feed and depth of cut are to be determined in a
Turning is a basic machining process to obtain cylindrical turning operation.
surfaces of the desired diameter. It can be external as well as
internal (also known as boring). The bare essentials to
achieve this process is, a means to rotate the job, a cutting
tool whose material has to be harder than the job and a
mechanism to hold the tool and feed it into the job. These
aspects are fulfilled by the lathe machine. The tool is held
firmly in a tool post and it is advanced to the rotating job
held by the chuck of the lathe. When the tool is moved
parallel along the rotating job it removes the material from
the job which is dependent on the feed of the tool. The
speed of the rotation of job, the feed of the tool and depth of
978-1-4799-8433-6/15/$31.00©2015IEEE

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2015 1st International Conference on Futuristic trend in Computational Analysis and Knowledge Management (ABLAZE-2015)

work L9 (33) Array has used in experimental design for

optimization of input parameters. This paper attempt to
introduce and then verify experimentally as how the
Taguchi design can be used in targeting the significant
processing parameters and optimizing the surface roughness
in the turning operation.

In order to optimize the turning of operation, Taguchi

method is used to find optimal parameters for surface finish
in turning. The basic parameters of feed rate, speed and
depth of cut are optimized to get a desired surface finish.
Beside these, the use of coolant also plays an important role
in getting the desired surface finish.

Optimization refers to technique of allocation of scarce

Fig.No.1 Parrameters of Turning operation resources to give best possible effect. The Taguchi method
is an important technique that gives an organized and
The quality of the machined surface after turning depends effective methodology for design and process optimization.
on many factors, besides the major three mentioned above. This is due to the benefit of the design of experiment using
The material of the cutting tool and its life in terms of Taguchi’s technique that includes simplification of
number of cuts it has already endured plays a significant experimental plan and feasibility of study of interaction
role. The cutting tip is subjected to lots of stresses during between different parameters. Study of Variance (ANOVA)
the process of cutting, which may impair its cutting is then used to determine which process parameter is
capabilities and which in turn affects the surface finish. statistically important and the contribution of each
Thus, the most important factor is upkeeps, and parameter for the output feature.
maintenance of cutting tool. There are chances that part of
the metal being cut, can smear with cutting edge and II. LITERATURE REVIEW
subsequently getting welded to it, thus, damaging the tool.
The quality of machined surface depends upon The controlled factors in a turning process are, cutting
factors that are surface finish and geometrical error. The speed, feed rate and depth of cut; each of which may have
height, shape, and direction of these surface irregularities on an effect on surface finish. Cutting speed and depth of cut
the work piece depend upon a number of factors such as: were found to have differing levels of effect in each study,
often playing a stronger role as part of an interaction. The
a) Cutting speed. controlled parameters in a turning process that under normal
b) Feed. conditions affect surface finish most profoundly are feed
c) Depth of cut. rate and cutting speed by kopec & Bahor [1]. Several studies
d) Cutting tool wears. exist which explore the effect of feed rate, spindle speed,
e) Material of tool and work piece and depth of cut on surface finish [3, 9, 12, 15]. Recent
f) Tool life, etc. studies that explore the effect of setup and input parameters
on surface finish all find that there is a direct effect of feed
rate and spindle speed’s effect is generally nonlinear and
Optimization refers to technique of allocation of responsible often interactive with other parameters, and that depth of cut
resources to give best possible effect. The Taguchi method can have some effect due to heat generation or chatter by
is a well known technique that provides efficient and venom & ozel and others [4, 7, 8, and 10]. These studies all
systematic methodology for process optimization. This is supported the idea that feed rate has a strong influence on
due to the advantage of the design of experiment using surface finish. Feng and Wang [9] investigated and
Taguchi’s technique that includes simplification of developed an empirical model for turning operation through
experimental plan and feasibility of study of interaction considering working parameters for optimization of surface
between different parameters. Analysis of Variance roughness. Rafi & Islam [2] present analytical and
(ANOVA) is then used to determine which process experimental results of an investigation into dimensional
parameter is statistically significant and the contribution of accuracy and surface finish achievable in dry turning.
each parameter towards the output characteristic. In this Lalwani [14] developed the prediction model for surface

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2015 1st International Conference on Futuristic trend in Computational Analysis and Knowledge Management (ABLAZE-2015)

roughness in turning operation. Tzeng Yih-Fang [11] has g) Cutting condition(Dry/Wet)

taken a set of optimal turning parameters for producing high h) Operator’s skill
dimensional precision and accuracy.Ghani, J.A., Chaudhury i) Working temperature.
[3] has also performed an experiment to evaluate & evaluate j) Make of the CNC machine.
end milling process parameter by Taguchi Approach. k) Noise and chatter
Gilbert [13] studied the optimization of machining
parameters in turning with respect to maximum production
rate and minimum production cost as criteria. Armarego & In order to identity the process parameters, affecting the
Brown [8] find the solution of unconstrained machine-
parameters optimization using differential calculus. Brewer Selected machining quality characteristic of turned parts, an
&Rueda [15] carried out optimum analysis for non-ferrous
materials.Petropoulos [17] investigated optimal selection of Ishikawa cause-effect diagram was constructed as shown in
machining rate variables say,cutting speed and feed rate, by
Fig No.2
geometric programming.

These reviews demonstrate that the use of Taguchi

parameter design in order to identify the optimum Surface
Finish with a particular combination of cutting parameters
in a CNC turning operation is considerable option to find a
systematic approach for parameter design of process control
of individual CNC turning machine.

III. PROBLEM DESCRIPTION:

The machining process on a CNC lathe is programmed by

Cutting speed, feed rate and depth of cut, which are
frequently determined based on the job shop experiences.
However, the machine performance and the product
characteristics are not guaranteed to be acceptable.
Therefore, the optimum turning conditions have to be
accomplished.

Aluminum alloy work piece (ø=20 mm) is taken for

analysis. R.P.M of lathe chuck is varied as 1800, 1500 and
1200 as the level of experiment. Corresponding Cutting
speed in mm/min. is found for work piece is (1884, 1570, Fig.No.2 Ishikawa cause-effect diagram of a
1256 mm/min.) by turning process.
V= (3.14*20*N)/60
With all the viewpoints, this study proposes an Parameters under consideration are as;
optimization approach using orthogonal array and ANOVA, 1. Cutting speed – (A),
S/N ratios to optimize precision CNC turning conditions. 2. Feed rate – (B),
3. Depth of cut – (C),
VI. PARAMETER IDENTIFICATION
Machinery and Accessories under consideration are as;
The input parameters which affect the mentioned output parameters arespeed steel is taken as Tool material
1. High
numerous such as: 2. Work material is Aluminum Alloy (AM40).
3. Condition of cutting atmosphere is Dry.
a) Depth of cut 4. The machine tool selected for the operation is HE-100-
b) Feed rate. CNC-PC (Dc motor, 2 hp)
c) Cutting speed
d) Geometry of Tool
e) Power consumption Together with,speed, feed and depth of cutare the primary
f) Cutting tool material. factors investigated while the secondary factors are not

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2015 1st International Conference on Futuristic trend in Computational Analysis and Knowledge Management (ABLAZE-2015)

considered. In this study, L9(33) orthogonal array of Taguchi 1 1884 0.05 0.30
experiment was selected for three parameters (speed, feed, 1884
depth of cut) with three levels for optimizing the objective 2 0.03 0.25
(surface roughness ) in precision turning on an CNC lathe. 1884
Through the examination of surface roughness (Ra); the 3 0.02 0.20
multiple objectives are then obtained. The multiple 4 1570 0.05 0.20
objectives can additionally be integrated and introduced as 5 1570 0.03 0.30
the S/N (signal to noise) ratio into the Taguchi experiment. 6 1570 0.02 0.25
The mean effects for S/N ratios are moreover analyzed to 7 1256 0.05 0.25
achieve the optimum turning parameters. Through the 8 1256 0.03 0.20
verification results, it is shown that surface roughnesses
from present optimum parameters are greatly improved. 9 1256 0.02 0.30

The possible space for the cutting parameters was defined Table 2: Experimental Layout Using an L-9 Orthogonal
by variation in parameters, speed in the rangeof 1200- Array
1800rpm, feed in the range of 0.02-0.05mm/rev. and depth
of cut in the range of 0.20 to 0.30mm. Three levels of each Nine experiments are conducted for the above mentioned
cutting parameters were selected as shown in table 1. nine sets of parameters (speed, feed rate & depth of cut) and
Selected cutting parameters were fed with the help of in- in each experiment 20 numbers of pieces are made and are
built control panel of the CNC machine itself. checked with air gauge for dimensional tolerance and for
surface roughness thepieces are tested. The average value of
Parameters

surface roughness in microns is listed in table 3.

Level – 1

Level – 2

Level – 3
Symbols

Units

Exp Speed Feed rate Depth of cut

No. (A) (B) ( C)
Cutting
A mm/min. 1884 1570 1256 1 +1 +1 +1
Speed
Feed B mm/rev. 0.05 0.03 0.02 2 +1 0 0
3 +1 -1 -1
Depth of
C Mm 0.30 0.25 0.20 4 0 +1 -1
cut
5 0 0 +1
Table 1: Parameters and their levels
6 0 -1 0
7 -1 +1 0
8 -1 0 -1
9 -1 -1 +1

Table No.3: Experimental Design

Factor Results

CUTTING SURFACE
EXP.NO. DEPTH
SPEED FEED ROUGHNESS
OF CUT
(A) (B) (MICRONS)
V. RESULTS (C)
The results have shown in the tables below 2.81
1884 0.05 0.35
1
1884 0.03 0.30 2.89
2
PROCESS PARAMETER LEVELS 1.37
3 1884 0.02 0.25
Exp. Cutting
No. Feed rate Depth of cut 2.58
Speed 1570 0.05 0.25
B(mm) C(mm) 4
A(mm/min)

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2015 1st International Conference on Futuristic trend in Computational Analysis and Knowledge Management (ABLAZE-2015)

1570 0.03 0.35 1.38 Main Effects Plot for SN ratios

5 Data Means

1570 0.02 0.30 2.76 Cutting Speed Feed

6 -6.5
-7.0

1256 0.05 0.30 2.54 -7.5

Mean of SN ratios
-8.0
-8.5

1256 0.03 0.25 2.46 1256 1570 1884 0.02 0.03 0.05
8 Depth of Cut

1256 0.02 0.35 2.86 -6.5

-7.0
9 -7.5

Table 4: Experimental Results -8.0

-8.5

0.25 0.30 0.35

5.1 Interpretation of plots Signal-to-noise: Smaller is better

The following graphs have been obtained by the use of Fig No.4Main effect plot for S/N Ratio
MINITAB software:
1)Main Effect plots for Means for Surface Roughness
5.2 Influence of the parameters
2) Main Effect plots for S/N ratios for Surface Roughness
shown in Fig No.3 The influence of the parameters are listed below
Sr. No Factor Sum of DOF %P
Roughness shown in shown in Fig No.4
Square
1 A .2276 2 7.87
Main Effects Plot for Means
Data Means
2 B .2659 2 9.20
Cutting Speed Feed 3 C .5422 2 18.76
2.8
Table 4: Analysis of Surface roughness
2.6

2.4
VI. CONCLUSION
Mean of Means

2.2
The above work, experimently verify that the Taguchi
1256 1570 1884 0.02 0.03 0.05 approch gives us the optimal parameters in the CNC
Depth of Cut
2.8 turnning process using High Speed Steel cutting tools the
2.6
optimum set of speed, feed rate and depth of cut are and the
most affecting parameters having the impact of 18.76
2.4
%(Percentage influance factor) is cutting Depth of
2.2 cut.Remaining percentage for the influece on this
0.25 0.30 0.35 experiment will definetly associated with cutting condition,
tool material selection, vibration of machine tool etc. .
Fig No.3 Main effect plot for means

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