Optimization of parameters in CNC turning process to enhanced

surface finish & MRR

GURUNANAKDEVENGINEERINGCOLLEGEBIDAR-585403
(AffiliatedtoVTUBel
agavi,ApprovedbyA
ICTE)

A PROJECT REPORT ON
“OPTIMIZE PARAMETERS IN CNC TURNING
PROCESS TO ENHANCED SURFACE FINISH AND
MRR ”
Submitted by
VISHAL MEHTRE
(3GN16ME112) CHHAGAN
GAVANDE (3GN17ME403)
MAHESH HATTI
(3GN17ME405)
YOGESH
(3GN17ME418)
Under the guidance of
Prof. Md Ashfaq
Hussain
DEPARTMENT OF MECHANICAL
ENGINEERING GURU NANAK DEV
ENGINEERING COLLEGE BIDAR –
585 403

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

2019-20

GURUNANAKDEVENGINEERINGCOLLEGEBIDAR-585403
(Affiliated to VTU Belagavi, Approved by AICTE)

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

DEPARTMENTOFMECHANICALENGINEERING
CERTIFICATE

This is to certify that the project work entitled “OPTIMIZE

PARAMETERS IN CNC TURNING PROCESS TO
ENHANCED SURFACE FINISH AND MRR” is
a bonafide work carried out by VISHAL MEHTRE, CHHAGAN
GAVANDE, MAHESH HATTI, YOGESH in partial fulfillment
for the award of Bachelor of Engineering in Mechanical
Engineering in GURU NANAK DEV ENGINEERING COLLEGE,
BIDAR affiliated to VISVESVARAYA TECHNOLOGICAL
UNIVERSITY,
BELAGAVI during the year 2019-20.
It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report and a copy of the report
is deposited in the department library .The project has been approved as it
satisfies the academic requirements in respect of project work prescribed
for the said degree.

Guide Head of
Department

Name of the Examiners: Signature

Dept. of Mechanical, GNDEC
Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

with date
1.

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

2.
CONTENT
• Synopsis/Abstract
• Introduction
• Scope of the Project
• Literature Survey and Summery
• Problem Definition
• Methodology Adopted
• Design & Drawing
• Cost Estimation
• Conclusion
• Future Scope
• References

Dept. of Mechanical, GNDEC

 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

ABSTRACT

Machining process is the most essential operations in many manufacturing

industries. One of the important parts of machining is turning process.
Turning is a manufacturing process where the excess of materia1 is removed
from the work-piece. Machining process consists of characteristics such as
surface roughness, materia1 remova1 rate and accuracy which will
determine the qua1ity of the product. The qua1ity of the product is
dependent on surface roughness, where as the materia1 remova1 rate wi11
determine the rate of productivity and the accuracy will give the dimensional
tolerance. These characteristics are dependent on the factors such
asspind1e speed, feed rate and depth of cut.
Turning is the fundamenta1 operations for machining processes. Turning can
generally be done on inner as we11 as on outer surface. The operationa1
materia1 is a work- piece which is genera11y processed by casting, forging,
extrusion or drawing.
Proper setting of cutting parameters is important to obtain the better surface
finish, accuracy and materia1 remova1 rate. Unfortunately, conventional
tria1 and error technique is most time overwhelming and requires high cost.
The purpose of this study is to find out the most considerable parameters
and its optimum range in CNC turning using various statistical tools such as
Taguchi’s Grey re1ationa1 ana1ysis and Ana1ysis of Variance (ANOVA).
Surface roughness, materia1 remova1 rate and accuracy are predicted using
the predictor’s spind1e speed, feed rate and depth of cut. For initial
investigation ANOVA and grey relationa1 ana1ysis are used to find the most
significant factor among spind1e speed, feed rate and depth of cut that
influences surface roughness, accuracy and materia1 remova1 rate.
With the optimum combination levels from ANOVA and grey re1ationa1
ana1ysis, conformation test is proposed to be conducted

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

Keywords – Turning operation, Ana1ysis of Variance

(ANOVA), Signa1 to N0ise Rati0

Dept. of Mechanical, GNDEC

 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

(SN), Grey Relational Grade, Taguchi’s Method

CHAPTE
R 1:
INTRODUCTION

Machining process is the most essential operations in many

manufacturing industries. One 0f the important parts of machining is
turning process. Turning is a manufacturing process where the excess of
materia1 is removed from the work- piece. Machining process consists of
characteristics such as surface roughness, materia1 remova1 rate and
accuracy which will determine the qua1ity of the product.

The qua1ity of the product is dependent on surface roughness, where as

the materia1 remova1 rate will determine the rate of productivity and
the accuracy will give the dimensional tolerance. These characteristics
are dependent on the factors such asspind1e speed, feed rate and depth
of cut. Turning is the fundamental operations for machining processes.
Turning can generally be done on inner as well as on outer surface. The
operationa1 materia1 is a work- piece which is genera11y processed by
casting, forging, extrusion or drawing. Proper setting of cutting
parameters is important to obtain the better surface finish, accuracy and
materia1 remova1 rate. Unfortunately, conventional tria1 and error
technique is most time overwhelming and requires high cost.

Turning is a metal removing process in which unwanted material is

removed in form of chips to obtain the desired shape and size. This is the
most basic operation used for the metal removal. The most effective
parameters or variables which affect the tuning operation are speed,
feed and depth of cut. While turning, our prime focus is to obtain the

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

material with smooth surface finish so that it is of utmost quality level

and should be fit for use. But the products obtained do not exhibit
good

Dept. of Mechanical, GNDEC

 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

surface finish and we have to perform various finishing or polishing

operations so as to obtain better quality. But these operations are very
much time consuming and are very costly process. So the cost of
manufacturing the component increases which is very dangerous in the
market.

1.1 Material Removal Rate (MRR)

It is the amount of material removed per time unit (usually per minute) when
performing machining operations such as using a lathe or milling machine.
The more material removed per minute, the higher the material removal
rate. The MRR is a single number that enables you to do this. It is a direct
indicator of how efficiently you are cutting, and how profitable you are. MRR
is the volume of material removed per minute.

Material removal rate (MRR) is the amount of material removed per time
unit, directly aiming at the process productivity. In roughing operations and
the production of large batches, this needs to be maximized. However, in
finishing operations, it is a factor to be put on hold, bringing roughness and
precision to the forefront. For low roughness, usually low cutting speeds and
feed per tooth are both applied, as MRR is usually very low for finishing.

There are a few ways to evaluate the MRR (Q), the following one is for the
instantaneous calculus:
Q=vc · Ac
Where Qis the MRR in mm3/min, vc is the cutting speed in m/min and Ac is
the chip section in mm2.
The chip section is calculated as:
Ac=h· b
Where his the chip thickness in mm, bis the chip width (usually the axial
depth of cut) in mm. The chip thickness depends on the ae and the
tool edge position angle Kr. Thickness value is variable with rotation

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

angle, so the chip section is variable as well. Considering Eq. [3.4], and
due to the cutting force being directly related to the chip

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

section, the MRR is thus related to the power consumed in the machining
process. Instantaneous MRR is not very useful; another value is the mean
MRR, measured and calculated as the quotient between the total amount
of material removed and the operation time. Hence, this productivity
parameter is calculated as follows:

The MRR is the amount of material erosion from the workpiece per unit of
time. It expresses the speed of the machining of the workpiece. A high
machining rate is always desirable because it is directly related to
productivity. At the same time, with high productivity aspect, the desired
dimensional accuracy and surface quality are significant features in micro-
EDM. The MRR in micro-EDM is calculated by the volume of the material
removed or the difference in the weight of the workpiece before and after
the machining operation, as given in Eq. (4.2). Process parameters
(electrical and nonelectrical) have significant effects on MRR. Higher MRR
can be achieved at high discharge voltage, peak current, pulse duration,
and duty cycle. However, other desirable process performances such as
TWR, surface finish, and dimensional accuracy are also important aspects
and taken into account in micro- EDM.

MRR = Weight of Work piece Before Matching - Weight Of Work piece After
Matching
Matching Time

The material removal rate in EEM process depends on the concentration of

powder particle, spherical head rotational speed during finishing
operation. As the concentration of particle increases the material removal
rate initially increases and then decreases. Initially with the increase in
concentration of abrasive particles in the slurry, the number of active
particles supplied to the workpiece surface increases, as a result material
Dept. of Mechanical, GNDEC
Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

removal rate increases.

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

With higher concentration of powder particles, the resistance of the

lubrication film increases, as a result MRR decreases. As the spherical
head rotational speed increases, the material removal rate decreases due
to increase of near surface flow velocity. The number of powder particles
supplied to the workpiece surface decreases as the near surface flow
velocity increases. The material removal rate depends on type of abrasive
powders. The material removal increases with the increase in machining
time, but the machining rate is different for different workpiece materials.
The thickness of abrasive slurry film is an important parameter to control
the performance of the EEM process.

This fluid film thickness is maintained by controlling the applied load and
the rotation of spherical head. The surface roughness and geometrical
accuracy during EEM process are influenced by the applied load, size and
concentration of abrasive powders and rotational speed of spherical head.
By controlling the process parameters of EEM, atomic level surface finish
can be achieved during finishing of flat as well as curved optical surface.

1.2 Surface Roughness

It's often shortened to roughness, is a component of surface texture. It is

quantified by the deviations in the direction of the normal vector of a real
surface from its ideal form. If these deviations are large, the surface is
rough; if they are small, the surface is smooth. In surface metrology,
roughness is typically considered to be the high- frequency, short-
wavelength component of a measured surface. However, in practice it is
often necessary to know both the amplitude and frequency to ensure that
a surface is fit for a purpose.

Surface roughness Ra is commonly used to indicate the level of surface

roughness. In order to get good surface finish and high accuracy in micro
milling operation, it is essential to cut at a low-chip load. This feed per

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

tooth and the cutting depth should be maintained less than 1 µm, if
machining tolerance is desired to be less than 1 µm.

Dept. of Mechanical, GNDEC

 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

An important ploughing phenomenon will emerge when the ratio of chip

load and tool edge radius is less than a critical value.17,19–21 Chip load is
the most influential factor that affects surface roughness since surface
roughness deteriorates with the increase of chip load.22 However, due to
dynamic behavior (low vibration), surface roughness decreases when high
feed and depth of cut are used.23 A micromilled surface roughness
reduces with chip load until embedded built-up-edges (BUEs) become
significant

Orthogonal Array Model

While there are many standard orthogonal arrays available, each of the
arrays is meant for a specific number of independent design variables and
levels .
For example, if one wants to conduct an experiment to understand the
influence of 4 different independent variables with each variable having 3 set
values (level values), then an L9 orthogonal array might be the right choice.
The L9 orthogonal array is meant for understanding the effect of 4
independent factors each having 3 factor level values. This array assumes
that there is no interaction between any two factor. While in many cases, no
interaction model assumption is valid, there are some cases where there is a

Dept. of Mechanical, GNDEC

 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

clear evidence of interaction. A typical case of interaction would be the

interaction between the material properties and temperature

Dept. of Mechanical, GNDEC

 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

Properties of an orthogonal array

The orthogonal arrays has the following special properties that reduces the
number of experiments to be conducted.
1. The vertical column under each independent variables of the above
table has a special combination of level settings. All the level settings
appears an equal number of times. For L9 array under variable 4 ,
level 1 , level 2 and level 3 appears thrice. This is called the balancing
property of orthogonal arrays.
2. All the level values of independent variables are used for conducting
the experiments.
3. The sequence of level values for conducting the experiments shall not
be changed. This means one cannot conduct experiment 1 with
variable 1, level 2 setup and experiment 4 with variable 1 , level 1
setup.

Minimum number of experiments to be conducted

The design of experiments using the orthogonal array is, in most cases,
efficient when compared to many other statistical designs. The minimum
number of experiments that are required to conduct the Taguchi method
can be calculated based on the degrees of freedom approach.

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

1.4 Relevance of the Project in Present Context

In machining of parts, surface quality or surface roughness is one of the

most specified customer requirements and it is one of the primary criteria
which decide the acceptance and quality of the product along with
improved or maximum material removal rate as an economical constraint.
Surface roughness mainly depends on work piece hardness, tool geometry
like nose radius, edge geometry, rake angle, and various process
parameters like feed rate, cutting speed, depth of cut etc. There are
various machining parameters those have an effect on the surface
roughness, but those effects have not been adequately quantified yet. In
order for manufacturers to maximize their gains from machining, accurate
predictive models for surface roughness and tool wear must be
constructed. Another significant factor that determines the product quality
is its sensitivity to external and uncontrollable variations. To effectively
address these issues, this research work proposes a methodical approach
that integrates multi criteria optimization concepts with Statistical Robust
Design techniques.

This proposed work will concentrate on the optimization of various process

parameters that influence surface roughness and tool wear through
investigation using Quality Engineering approach in machining process.
Surface roughness is one of the major quality attribute and which will be
Dept. of Mechanical, GNDEC
Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

used to determine and evaluate the

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

quality of the product as response. Considering the process parameters

such as Feed rate, Cutting speed, Depth of cut etc, experiments are to be
performed to measure Ra ( arithmetic mean value) and Rz (sum of absolute
values) of surface roughness. Taguchi orthogonal arrays, signal- to- noise
(S/N) ratio and Analysis of Variance (ANOVA) may be used to find out
optimal levels and the effect of process parameters on surface roughness
and Tool wear.

CHAPTE
R 2
LITERATURE SURVEY

• Sayak M , et, al, optimize MRR during turning SAE 1020, by

considering spindle speed, depth of cut, and feed rate as there
optimum parameters at 5 levels. The tool used was carbide tool.
Here author use gray Taguchi method to predict their response as
material removal rate (MRR). He also gives predictive equation. The
Analysis shows that the Depth of cut is most influencing parameter
on MRR

• K Venkatesan, et, al, study and optimize CNC turning process

considering, cutting speed & feed rate as parameter and cutting
force, surface roughness and tool are the responses. Material
selected was Inconel 617 super Alloy, he found that if cutting speed
increase tool wear and surface values were also increased

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

• E Gacia P,et al,. Monitor Taper turning CNC process, with the help of
Neural network and acoustic emission, by considering feed rate,
dept of cut, cutting

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

speed, cutting forces, mechanical vibrations, as parameters to

reduce production time and cost, workpiece was stainless steel AISI
1045, Machine was CNC Lathe, he found that both technique are
good in predicting the responses

• Surendra K S, et al, optimize multiple objectives, by considering feed

rate, dept of cut, cutting speed as parameters, according to Taguchi
design of experiment (DOE) experiment is conduct on CNC turning. A
Taguchi orthogonal array (OAs) is use for minimum number sets of
operation instead of large, the Fuzzy Logic is use to predict optimum
range of parameter. Material is Aluminium 8011 Alloy and carbide
tool is used for machining through EMCO Concept CNC turn 250
Turning machine. He found feed is a most significant parameter.

• Zhou et al. (1995) investigated on tool life criteria in raw turning. A

new tool- life criterion depending on a pattern-recognition technique
was proposed and neural network and wavelet techniques were used
to realize the new criterion. The experimental results showed that
this criterion was applicable to tool condition monitoring in a wide
range of cutting conditions.
• Lin et al. (2001) adopted an abdicative network to construct a
prediction model for surface roughness and cutting force. Once the
process parameters: cutting speed, feed rate and depth of cut were
given; the surface roughness and cutting force could be predicted by
this network. Regression analysis was also adopted as second
prediction model for surface roughness and cutting force.
Comparison was made on the results of both models indicating that
adductive network was found more accurate than that by regression
analysis.

• Feng and Wang (2002) investigated for the prediction of surface

roughness in finish turning operation by developing an empirical
model through considering working parameters: work piece

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

hardness (material), feed, cutting tool point angle, depth of cut,

spindle speed, and cutting time. Data mining techniques,

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

nonlinear regression analysis with logarithmic data transformation

were employed for developing the empirical model to predict the
surface roughness.

• Suresh et al. (2002) focused on machining mild steel by TiN-coated

tungsten carbide (CNMG) cutting tools for developing a surface
roughness prediction model by using Response Surface Methodology
(RSM). Genetic Algorithms (GA) used to optimize the objective
function and compared with RSM results. It was observed that GA
program provided minimum and maximum values of surface
roughness and their respective optimal machining conditions.

• Lee and Chen (2003) highlighted on artificial neural networks (OSRR-

ANN) using a sensing technique to monitor the effect of vibration
produced by the motions of the cutting tool and work piece during
the cutting process developed an on-line surface recognition system.
The authors employed tri- axial accelerometer for determining the
direction of vibration that significantly affected surface roughness
then analyzed by using a statistical method and compared
prediction accuracy of both the ANN and SMR. Choudhury and
Bartarya (2003) focused on design of experiments and the neural
network for prediction of tool wear. The input parameters were
cutting speed, feed and depth of cut; flank wear, surface finish and
cutting zone temperature were selected as outputs. Empirical
relation between different responses and input variables and also
through neural network (NN) program helped in predictions for all
the three response variables and compared which method was best
for the prediction.

• Chien and Tsai (2003) developed a model for the prediction of tool
flank wear followed by an optimization model for the determination
of optimal cutting conditions in machining 17-4PH stainless steel.

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

The back-propagation neural network (BPN) was used to construct

the predictive model. The genetic algorithm (GA) was used for model
optimization.

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

• Kirby et al. (2004) developed the prediction model for surface

roughness in turning operation. The regression model was
developed by a single cutting parameter and vibrations along three
axes were chosen for in-process surface roughness prediction
system. By using multiple regression and Analysis of Variance
(ANOVA) a strong linear relationship among the parameters (feed
rate and vibration measured in three axes) and the response
(surface roughness) was found. The authors demonstrated that
spindle speed and depth of cut might not necessarily have to be
fixed for an effective surface roughness prediction model.

• Őzel and Karpat (2005) studied for prediction of surface roughness

and tool flank wear by utilizing the neural network model in
comparison with regression model. The data set from measured
surface roughness and tool flank wear were employed to train the
neural network models. Predictive neural network models were
found to be capable of better predictions for surface roughness and
tool flank wear within the range in between they were trained.

• Luo et al. (2005) carried out theoretical and experimental studies to

investigate the intrinsic relationship between tool flank wear and
operational conditions in metal cutting processes using carbide
cutting inserts. The authors developed the model to predict tool
flank wear land width which combined cutting mechanics simulation
and an empirical model. The study revealed that cutting speed had
more dramatic effect on tool life than feed rate.
• Kohli and Dixit (2005) proposed a neural-network-based
methodology with the acceleration of the radial vibration of the tool
holder as feedback. For the surface roughness prediction in turning
process the back-propagation algorithm was used for training the
network model. The methodology was validated for dry and wet

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

turning of steel using high speed steel and carbide

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

tool and observed that the proposed methodology was able to make
accurate prediction of surface roughness by utilizing small sized
training and testing datasets.

• Pal and Chakraborty (2005) studied on development of a back

propagation neural network model for prediction of surface
roughness in turning operation and used mild steel work-pieces with
high speed steel as the cutting tool for performing a large number of
experiments. The authors used speed, feed, depth of cut and the
cutting forces as inputs to the neural network model for prediction of
the surface roughness. The work resulted that predicted surface
roughness was very close to the experimental value.

• Őzel and Karpat (2005) developed models based on feed forward

neural networks in predicting accurately both surface roughness and
tool flank wear in finish dry hard turning.

• Sing and Kumar (2006) studied on optimization of feed force through

setting of optimal value of process parameters namely speed, feed
and depth of cut in turning of EN24 steel with TiC coated tungsten
carbide inserts. The authors used Taguchi’s parameter design
approach and concluded that the effect of depth of cut and feed in
variation of feed force were affected more as compare to speed.

• Ahmed (2006) developed the methodology required for obtaining

optimal process parameters for prediction of surface roughness in Al
turning. For development of empirical model nonlinear regression
analysis with logarithmic data transformation was applied. The
developed model showed small errors and satisfactory results. The
study concluded that low feed rate was good to produce reduced
surface roughness and also the high speed could produce high
surface quality within the experimental domain.
Dept. of Mechanical, GNDEC
Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

• Abburi and Dixit (2006) developed a knowledge-based system for

the prediction of surface roughness in turning process. Fuzzy set
theory and neural networks were utilized for this purpose. The
authors developed rule for predicting the surface roughness for
given process variables as well as for the prediction of process
variables for a given surface roughness.

• Zhong et al. (2006) predicted the surface roughness of turned

surfaces using networks with seven inputs namely tool insert grade,
work piece material, tool nose radius, rake angle, depth of cut,
spindle rate, and feed rate.

• Kumanan et al. (2006) proposed the methodology for prediction of

machining forces using multi-layered perceptron trained by genetic
algorithm (GA). The data obtained from experimental results of a
turning process were explored to train the proposedartificial neural
networks (ANNs) with three inputs to get machining forces as output.
The optimal ANN weights were obtained using GA search. This
function-replacing hybrid made of GA and ANN was found
computationally efficient as well as accurate to predict the
machining forces for the input machining conditions.

• Mahmoud and Abdelkarim (2006) studied on turning operation using

High- Speed Steel (HSS) cutting tool with 450 approach angle. This
tool showed that it could perform cutting operation at higher speed
and longer tool life than traditional tool with 900 approach angle. The
study finally determined optimal cutting speed for high production
rate and minimum cost, tool like, production time and operation
costs.

• Doniavi et al. (2007) used response surface methodology (RSM) in

order to develop empirical model for the prediction of surface

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

roughness by deciding the optimum cutting condition in turning. The

authors showed that the feed rate influenced surface roughness
remarkably. With increase in feed rate

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

surface roughness was found to be increased. With increase in

cutting speed the surface roughness decreased. The analysis of
variance was applied which showed that the influence of feed and
speed were more in surface roughness than depth of cut.
• Kassab and Khoshnaw (2007) examined the correlation between
surface roughness and cutting tool vibration for turning operation.
The process parameters were cutting speed, depth of cut, feed rate
and tool overhanging. The experiments were carried out on lathe
using dry turning (no cutting fluid) operation of medium carbon steel
with different level of aforesaid process parameters. Dry turning was
helpful for good correlation between surface roughness and cutting
tool vibration because of clean environment. The authors developed
good correlation between the cutting tool vibration and surface
roughness for controlling the surface finish of the work pieces during
mass production. The study concluded that the surface roughness of
work piece was observed to be affected more by cutting tool
acceleration; acceleration increased with overhang of cutting tool.
Surface roughness was found to be increased with increase in feed
rate.

• Al-Ahmari (2007) developed empirical models for tool life, surface

roughness and cutting force for turning operation. The process
parameters used in the study were speed, feed, depth of cut and
nose radius to develop the machinability model. The methods used
for developing aforesaid models were Response Surface
Methodology (RSM) and neural networks (NN).

• Thamizhmanii et al. (2007) applied Taguchi method for finding out

the optimal value of surface roughness under optimum cutting
condition in turning SCM 440 alloy steel. The experiment was
designed by using Taguchi method and experiments were conducted
and results thereof were analyzed with the help of ANOVA (Analysis

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

of Variance) method. The causes of poor surface finish as detected

were machine tool vibrations, tool chattering whose effects were

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

ignored for analyses. The authors concluded that the results

obtained by this method would be useful to other researches for
similar type of study on tool vibrations, cutting forces etc. The work
concluded that depth of cut was the only significant factor which
contributed to the surface roughness.

• Natarajan et al. (2007) presented the on-line tool wear monitoring

technique in turning operation. Spindle speed, feed, depth of cut,
cutting force, spindle- motor power and temperature were selected
as the input parameters for the monitoring technique. For finding out
the extent of tool wear; two methods of Hidden Markov Model (HMM)
such as the Bar-graph Method and the Multiple Modeling Methods
were used. A decision fusion centre algorithm (DFCA) was used for
increasing the reliability of this output which combined the outputs
of the individual methods to make a global decision about the wear
status of the tool. Finally, all the proposed methods were combined
in a DFCA to determine the wear status of the tool during the turning
operations.

• Ozel et al. (2007) carried out finish turning of AISI D2 steels (60 HRC)
using ceramic wiper (multi-radii) design inserts for surface finish and
tool flank wear investigation. For prediction of surface roughness
and tool flank wear multiple linear regression models and neural
network models were developed. Neural network based predictions
of surface roughness and tool flank wear were carried out, compared
with a non-training experimental data and the results thereof
showed that the proposed neural network models were efficient to
predict tool wear and surface roughness patterns for a range of
cutting conditions. The study concluded that best tool life was
obtained in lowest feed rate and lowest cutting speed combination.

• Wang and Lan (2008) used Orthogonal Array of Taguchi method

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

coupled with grey relational analysis considering four parameters

viz. speed, cutting depth, feed rate, tool nose run off etc. for
optimizing three responses: surface

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

roughness, tool wear and material removal rate in precision turning

on an ECOCA-3807 CNC Lathe. The MINITAB software was explored
to analyze the mean effect of Signal-to-Noise (S/N) ratio to achieve
the multi-objective features. This study not only proposed an
optimization approaches using Orthogonal Array and grey relational
analysis but also contributed a satisfactory technique for improving
the multiple machining performances in precision CNC turning with
profound insight.

• Srikanth and Kamala (2008) evaluated optimal values of cutting

parameters by using a Real Coded Genetic Algorithm (RCGA) and
explained various issues of RCGA and its advantages over the
existing approach of Binary Coded Genetic Algorithm (BCGA). They
concluded that RCGA was reliable and accurate for solving the
cutting parameter optimization and construct optimization problem
with multiple decision variables. These decision variables were
cutting speed, feed, depth of cut and nose radius. The authors
highlighted that the faster solution can be obtain with RCGA with
relatively high rate of success, with selected machining conditions
thereby providing overall improvement of the product quality by
reduction in production cost, reduction in production time, flexibility
in machining parameter selection.

• Sahoo et al. (2008) studied for optimization of machining

parameters combinations emphasizing on fractal characteristics of
surface profile generated in CNC turning operation. The authors used
L27 Taguchi Orthogonal Array design with machining parameters:
speed, feed and depth of cut on three different work piece materials
viz. aluminum, mild steel and brass. It was concluded that feed rate
was more significant influencing surface finish in all three materials.
It was observed that in case of mild steel and aluminum feed
showed some influences while in case of brass depth of cut was

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

noticed to impose some influences on surface finish. The factorial

interaction was responsible for controlling the fractal dimensions of
surface profile produced

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

in CNC turning.

• Reddy et al. (2008) adopted multiple regression model and artificial

neural network to deal with surface roughness prediction model for
machining of aluminium alloys by CNC turning. For judging the
efficiency and ability of the model in surface roughness prediction
the authors used the percentage deviation and average percentage
deviation.

• Wannas (2008) carried out experiments for hard turning of graphitic

cast iron for the prediction of status of tool wear by using radial
basis function neural network (RBFNN) model. The RBFNN had three
inputs: speed, feed and depth of cut and one output: state variable
node. The error was less as obtained from neural network model
than the regression model.

• Lan et al. (2008) considered four cutting parameters: speed, feed,

depth of cut, and nose runoff varied in three levels for predicting the
surface roughness of CNC turned product. Thamma (2008)
constructed the regression model to find out the optimal
combination of process parameters in turning operation for
Aluminium 6061 work pieces. The study highlighted that cutting
speed, feed rate, and nose radius had a major impact on surface
roughness. Smoother surfaces could be produced when machined
with a higher cutting speed, smaller feed rate, and smaller nose
radius.

• Fnides et al. (2008) studied on machining of slide-lathing grade

X38CrMoV5-1 steel treated at 50 HRC by a mixed ceramic tool
(insert CC650) to reveal the influences of cutting parameters: feed
rate, cutting speed, depth of cut and flank wear on cutting forces as
well as on surface roughness. The authors found that tangential

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

cutting force was very sensitive to the variation of cutting depth. It

was observed that surface roughness was very sensitive to the
variation of feed rate and that flank wear had a great influence
on the

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

evolution of cutting force components and on the criteria of surface

roughness.

• Biswas et al. (2008) studied that on-line flank wear directly

influenced the power consumption, quality of the surface finish, tool
life, productivity etc. The authors developed a Neuro-Fuzzy model for
prediction of the tool wear

2.2 SUMMERY OF LITERATURE

• From the study of the literature survey we have come to see that
different researchers have conducted different experiments to
optimize the parameters that will give the required dimensional
surface r9oughness and with the higher materia1 remova1 rate.

• Different researchers took different parameters such as speed; feed

rate and depth of cut & by varying these parameters they have try
to optimize the surface roughness and materia1 remova1 rate.

• From this summary we have come to understand that some

parameters are more effective and can be easily varied so that we
could optimize the final results. The parameters that are more
effective are speed, feed rate and depth of cut. Thus varying these
given parameters we can obtain the optimum parameters that will
give us a good result such as good surface finish and we could have
a maximum material removal rate.

Problem Definition
Many researches in our country investigated the effect of cutting
parameters on surface quality and material removal rate while CNC
turning, but haven’t utilized. Hence it became essential to conduct
investigation using these specific materials, which are widely used in

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

chemical industries, aerospace, heat treating industries, pulp and paper

industries, food processing, Nuclear Energy and in the manufacture of

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

gas turbine components. Similarly global scenario is also no way different.

CHAPTE
R 3
OBJECTIVES AND METHODOLOGY

3.1 INTRODUTION

Literature depicts that a considerable amount of work has been carried out
by previous investigators for modeling, simulation and parametric
optimization of surface properties of the product in turning operation.
Issues related to tool life, tool wear, cutting forces have been addressed
to.

3.2 OBJECTIVES

1) Studying the various turning process parameters on the selected

responses
2) Performing Gray relational analysis and ANOVA on multiple
responses to determine the optimum parameters combination.
3) Development of an Mathematical model for prediction through
Regression analysis

3.3 METHODOLOGY

The methodology adopted for CNC Turing as follows

1. Initial study is made to determine the various controllable and

uncontrollable parameters
2. Selection of work material based on literature
3. Selection of parameters, responses and their levels

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

4. Selection of Experimental Layout using Taguchi’s Method

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

5. Conduction of experiment
6. Measurement of response using standard equipments
7. Analysis of data using statistical tools
8. Conduction of final experiment
9. Development of Mathematical Model.
10. Comparison of result was done to optimize the responses

SELECTION OF RAW MATERIAL:

From literature it is found that, the many researchers have been used
different raw materials for carrying out their works. These materials are
Aluminium 7015, Martensite stainless steel, MS 1010, AISI 52100, SAE 1020,
AISI 1045, Aluminum 8011 alloy, S45C,
EN31, Aluminum 6061.
From these materials we have selected EN31 because of more number of
Applications in Aerospace industries.

APPLICATION OF EN31
• EN31 Steel includes taps, ball and roller bearings.
• It is a good quality steel for wear resisting machine parts and for
press tools which do not merit a more complex quality.

CHEMICAL COMPOSITION OF EN31

Elements Values Specificatio

Obtained n
(%) Requireme
nt
Carbon 1.066 0.90-1.20
Silicon 0.216 0.10-0.35
Manganese 0.325 0.30-0.75
Sulphur 0.022 <0.04

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Optimization of parameters in CNC turning process to enhanced
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Phosphorous 0.013 <0.04

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 Optimization of parameters in CNC turning process to enhanced
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Chromium 1.415 1.00-1.60

Molybdenum 0.022 -
Nickel 0.005 -
Iron remaining Remaining

SELECTION OF PARAMETERS:
From literature it is found that, the many researchers have been used different
controllable parameters for carrying out their works. These parameters are
cutting speed, Feed, Depth of cut, types of tools, coolants used and tool angle.
Out of these parameters we have selected cutting speed, feed, and depth of
cut. These parameters are found to more influencing.

SELECTION OF CUTTING TOOL:

The cutting tools such as carbide, HSS are widely used in industries for
machining. Based on availability carbide or HSS tool may be used for
machining.
Cutting Tool Specification Carbide Tool

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Optimization of parameters in CNC turning process to enhanced
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RESPONSES:
From literature it is found that, the many researchers have been used
different uncontrollable parameters for carrying out their works. These
parameters are Material removal rate, Surface finish, Tolerances, tool wear,
cutting force etc. From these parameters we have selected material removal
rate, surface roughness are the responses based on availability and cost.
3.5 THE FLOW CHART

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

3.6 APPLICATION OF THE PROJECT

• Increase the rate of production
• Improve in the cutting parameter like material removal
rate, depth of cut, feed and surface finish

CHAPTER 4

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 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

DESIGN OF EXPERIMENT
No. of parameters = 3
No. of levels for each parameters = 3
Total degree of freedom for 3 parameters 3*(3-1)= 6
Therefore the minimum no.of experiments =total DOF for parameters+1=
6+1= 7 Therefore minimum no.of experiments =7
As we have 3 factors and 3 levels in the experiment ,so L9 orthogonal
array of Taguchi is to be selected.

EXPERIMENTATION TABLE
Parameters Levels
1 2 3
Cutting speed 3000 3200 3400
Feed rate 0.06 0.08 0.10
Depth of cut 0.20 0.25 0.30

MACHINE SPECIFICATION
Machine name: CNC MICRO
VC 400 Specifications

Pallet size:
650.24mm*449.58mm Pallet
number: 2
Indexing:1
degree x-
axis:558.8mm
y-
axis:398.78mm
z-

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 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

axis:568.96mm
spindle speed:
12,000rpm spindle
motor:25 HP

Dept. of Mechanical, GNDEC

 Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

rapid transverse(x &y/z):1575/1260

IPM cutting feed rate:0.1 to 630
IPM
ATC:40 positions
Machine weight :approximately 17,000 LBS

L9 Orthogonal Array Model

SL .No Cutting Feed rate Depth of Result

cut
speed
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 2 1 2 3
5 2 2 3 1
6 2 3 1 2
7 3 1 3 2
8 3 2 1 3
9 3 3 2 1

4.3 Cost of Estimation

S.No Specification Quantity Estimation

Cost
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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

01 Raw material 5kg (300/kg) 1500/-

02 Maching 9( 300/ piece) 2700/-
03 Carbide tool 9( 300/ piece) 2700/-
04 Printing - 2500/-
books

05 Other - 3000/-
expenses

Tota 12,400/
l
-

CHAPTER
5
CONCLUSION AND FUTURE SCOPE

5.1 Con
clusion

This work is propose to get an optimized turning condition by selecting

optimum ranges of turning parameters to provide good surface quality
with higher production rates.
The experiment was car ried out u sing L9 or thogonal array which is based on
9 3 7

Taguchi a Design. Here Spind1e Speed, Feed rate and Depth of Cut are the
main input parameters form which the output parameters such as Surface
R0ughness, Materia1 Remova1 Rate and accuracy are optimized.

Formulating a suitable cutting force model with respect to several

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

criteria and

Dept. of Mechanical, GNDEC

Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

constraints has been one of the most valued research topics for the
researchers in the machining field for quite a long time. Again with recent
advances in the field of expert systems it has become easier to optimize
this model with the appropriate expert system. In this research, a model of
the main cutting force (Pz ) has been formulated during turning of steel in
dry machining condition, where the cutting force is considered as a
function of the cutting speed (Vc ) and feed rate (S0). Using this model,
the value of the cutting force can be predicted for a given set of cutting
speed and feed rates. This will help in setting the machining parameters
for a particular machining condition. It has been observed that, this model
performs satisfactorily when tested against a new set of experimental
data. Optimization of the cutting parameters has also been performed
using GA to find the set of cutting parameters for which the cutting force
value is minimum.

However, in this research, depth of cut (t) has been kept constant. But it
may have significant effect on the main cutting force. This research can be
extended by adding some significant machining variables and changing
the machining conditions.

5.2 Future Scope

Based on the present work there are considerableamount
of possibilities for
future scope and they are given below.
• The experiment can further carryout by varying the
parameters so that we could optimize the output results
to higher extent.
• Linear co-relation and regression can be used to create
a mathematical model for the optimization of output
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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

parameters.
• Principle component analysis, discriminate analysis and
multi- correspondence can be used for more accurate
results.

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

5.3 References
• Todd, Robert H.; Allen, Dell K.; Al ting, Leo (1994), Manufacturing
Processes Reference Guide, Industrial Press Inc., p. 153, ISBN 0-
8311-3049-0.

• Workshop Technology by W.A.J. Chapman Ph.D. M.Sc.(Eng.),

M.I.Mech.E., M.I.Prod.E. Principal Hatfield College of Technology,
Hertfordshire first published 1951 part one, two and three
published by Edward Arnold (publishers Limited Koepfer, Chris
(2010-01-22). "Hard Turning as an Alternative to Grinding".
Production Machining. Retrieved 2010-03-04.

• "Threading On A Lathe : Modern Machine Shop". Mmsonline.com.

2003-01-
15. Retrieved 2012-03-13. Taguchi G., Choudhary S., Wu Y.,
(2005), Taguchi’s Quality Engineering Handbook, John Wiley &
Sons Inc., New Jersey.

• Quazi T Z, Pratik More, Vipul sonawane, A Case Study of Taguchi

Method in the Optimization of Turning Parameters, International
Journal of Emerging Technology and Advanced Engineering, ISSN
2250-2459, Volume 3, Issue 2, February 2013, pp. 616-626.

• Kadirgama K., Noor M.M., Rahman M.M., Rejab M.R.M., Haron C.H.C.,
Abou
-EI-Hossein K.A., (2009), “Surface Roughness Prediction Model of
6061-T6 Aluminum Alloy Machining Using Statistical Method”,
European Journal of Scientific Research, Vol. 25(2), pp. 250-256.

• P.Samivel, S.Gopal, J.Prabahkaran, K.Kannan, Investigate the

Effect of Mechanical and Water Absorption behavior of Kenafand

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

Banana Fiber Reinforced Composites for Sustainable

Development, International Journal of Applied Engineering
Research ISSN 0973-4562 Volume 10, Number 9

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Optimization of parameters in CNC turning process to enhanced
surface finish & MRR

(2015)

• Sayak Mukherjee,Anurag Kamal ,Kaushik Kumar,Optimization of

material removal rate during turning of SAE 1020material in CNC
lathe using Taguchi Technique ,12th global congress on
Manufacturing and management,GCMM 2014.

• K Venkatesan ,Arun Tom Mathew,S Devendiran ,Nouby M

Ghazaly
.Machinability study and multiresponce optimization of cutting
force surface roughness and tool wear on CNC turn Inconel 617
superalloy using Al2O3 Nanofluids in coconut oil ,14 th global
congress on manufacturing and managemet GCMM2018

• E.Garcia plaza
,P..J.Nunez,D.R.salgado,I.Cambero,J.M.Herera Olivenza.surface finish
monitoring in Taper turning CNC using artificial neural network
and multiple regression method.The manufacturing engineering
society international conference MESIC 2013

• Surendra kumar saini.Sharad kumar pradhan , Optimisation of

Multiobjective response during CNC turning, using taguchi fuzzy
application, 12th global congress on Manufacturing and
management,GCMM 2014.

• Senthil kumar .M.P and Rajendran,optimization of cnc turning

parameter of aluminium 7015 hybrid metal matrix ,by using
Taguchi robust design. International journal of engineering and
technology(IJET).

• Harish kumar, Mohd.Abbas , Dr.Aas mohammad, Hasan Zakri

Jafri,optimization of cutting parameters of MS 1010 by using
Taguchi L9 orthogonal array method, international journal of
engineering and application(IJERA).

• Poornima , Sukumar , optimization of machining parameters in

cnc turning of martensite stainless steel using RSM and GA, by
using Genetic algorithm and ANOVA technique, international
journal of modern engineering research(IJMER).

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Optimization of parameters in CNC turning process to enhanced
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• Rony Mohan, Josephkunju paul C, George Mathew ,optimization of

surface

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Optimization of parameters in CNC turning process to enhanced
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roughness of bearing steel during CNC hard turning process by

using Taguchi orthogonal array and ANOVA technique,
international journal of engineering trends and technology (IJETT).

• Satya prakash, DR.Arvind gupta,DR.Sanjeev kumar, optimization

of process parameters in CNC turning operation for SS430 by
using Taguchi method, international journal of management and
technology and engineering(IJMTE).

• Kshirsagar,P.R.,Pise, S.R.,Pokalekar, S.A.,Goudadaba,M., &

Badkar, D.S.(2008). Optimization of surface roughness of EN8
steel in CNC Turning operation by Taguchi concept. International
journal of advanced technology engineering and
science.ISSN,2348-7550.

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