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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2810
A Literature Review on Optimization of Input Cutting Parameters for
Improved Surface Finish in Turning Process
Vivek Jakhara,Dr Manoj Nayakb, Nitin Sharmac
aM. Tech Scholar, Manav Rachna International University (MRIU), Faridabad, Haryana, India
bHOD & Associate Professor, Deptt. Of ME, (MRIU), Faridabad, Haryana, India
cAssociate Professor, Krishna Institute of Engg. & Technology, Ghaziabad, UP, India
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - The purpose of this paper is to make an
attempt to review the literature onoptimizationofinput
cutting parameters for improved surface finish by
acquiringminimumsurfaceroughnessinturningprocess
and to present various methodologies andpracticesthat
are being employed for the prediction of surface
roughness. Surface roughness is one of the most
commonly used criteria to determine quality of a turned
surface. This literature review compiles different work
presented on optimization of process parameters and
concludes the most significant cutting parameters and
most frequently used optimization techniques for
improving surface finish The cutting parameters like
Cutting speed, Feed rate, Depth of cut, Insert radius and
Cutting fluid are taken into consideration.
Key Words: Turning process, Optimization Techniques,
Surface Roughness, Taguchi Method
1. INTRODUCTION
Turning is a machining process used to obtain the
desired dimension of round metal. The main target in
present industrial era is to produce low cost quality
product with requireddimensionsinanoptimumtime.
Therefore, the optimum cutting parameters are to be
recognized first. In turning, the metal is in rotational
motion (axially) and a cutting tool is used to shear
away the undesired metals.Thisprocessrequireslathe
or turning machine, cuttingtool,workpieceandfixture
[1]. The work piece is fixed in the machine chuckandis
rotated at high speed. The cutting tool (insert) is fed in
parallel to the axis of rotation as shown in Fig. 1.
During this machining process the cutting parameters
highly depends upon the work piece, cutting tool
material, etc. These are determined by experience or
machine catalogue. Surface roughness is a widely used
attribute of product quality and in most cases a
technical necessity for mechanical products.Achieving
the desirable surface quality is of great importance for
the functional behaviour of a part [2]. Thus the
optimum selection of cutting parameters such as feed
rate, depth of cut, cutting speed, etc, generates
optimum conditions during machining and becomes
the main exigency of manufacturing industry. Surface
roughness of amaterialafterturningismeasuredusing
portablesurfaceroughnesstester.Surface roughnessis
an important criterion to find the qualityofasurface.It
is an important response parameter. Surfacefinishcan
be measured using simple surface roughness tester [3,
4].
In machining process various parameters are:
Input Parameters: Cutting speed, Feed rate, Depth of
cut, Insert radius, Cutting fluid, etc
Output Parameters: Surface roughness, MRR, Tool
wear, Cutting forces, MAZ, etc.
Surface engineeringaimstoachievedesiredproperties
or characteristics of surface-engineered components
including:
 Improved wear resistance;
 Reduced friction energy losses;
 Improved mechanical properties, for example,
enhanced fatigue life, hardness or toughness;
 Improved aesthetic appearance, etc.
Factors influencing surface roughness in turning:
 Cutting parameters i.e. feed, cutting speed and
depth of cut
 Vibration
 Material of work piece
 Rigidity of the system consisting of machine tool,
fixture cutting tool and work
 Type, form, material and sharpness of cutting tool
 Type of coolant used
Cause and effect diagram also called as fishbone
diagram in Figure-1 shows different machining
parameter that affects surface roughness.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2811
Figure-1: Cause and effect diagram for surface
roughness
Various optimization techniques used are:
 Taguchi Methedology
 Response Surface Methodology
 Full Factorial Analysis
 Multiple Regression Analysis
 Artificial Neutral Network
2. LITERATURE SURVEY
Several experimental investigations have been carried
over the years in ordertostudytheinfluenceofvarious
cutting parameters on the surface finish of the
workpiece, tool life using workpieces of different
materials.
M.Nalbant et al. [5] implemented the Taguchi method
to find out optimum cutting parameters for surface
roughness in turning.ANOVAmethodwasemployedto
study the performance characteristics in turning of
AISI 1030 steel bar using TiN-coated tools. The study
reveals that the feedrateandtheinsertradiuswerethe
main machining parameters that affect the surface
roughness in turning of AISI 1030.
Ilhan Asilturk et al. [6] focuses on optimization of
turning parameters based on Taguchi method to
minimize surface roughness (Ra&Rz). Experimental
have been carriedoutusingL9orthogonalarrayinCNC
turning. Dry turning tests were carried out on
hardened AISI 4140 with coated carbide tools. It has
been observed that feed rate has the most significant
effect on the surface roughness.
M. Antony Xavior et al. [7] carried out an
experimental investigation to determine the influence
of different cutting fluids on tool wear and surface
roughness in turning of AISI 304 with carbide cutting
insert. Additionally,anattemptwasmadetodetermine
the influence of coconut oil as cutting fluid in reducing
the tool wear and surface roughness in the turning
process. The performance of coconut oil was in
contrast with another two cutting fluids namely an
emulsion and neat cutting oil (immiscible with water).
The investigation results indicatedthatcoconutoilasa
cutting fluid performed better than the other two
cutting fluids by improving the surface finish and
reducing the tool wear.
M.Z.A. Yazid et al. [8] observed surfaceintegritywhen
finish turning Inconel 718, a highly corrosiveresistant,
nickel-based super alloy, under three cutting
conditions (DRY, MQL 50 mL/h and MQL 100 mL/h).
The microstructure analysis using SEM on the
machined surface suggests that severe deformation
took place, leading to microstructure alteration at
subsurface level measuring from a few to several
micron in thickness. Work hardening under the
machined surface was evident from the micro-
hardness. The results of this study show that MQL may
possibly improve surface integrity characteristics.
Table-1 Shows Tabulated Literature Survey.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2812
CuttingSpeed
Vc(m/min)
Feedf(mm/rev)D.O.C(mm)OtherCuttingFluid1st2nd
12002
MichaelJacobson,
PatrikDahlman
Bainitesteel
310OD170
ID65mm
thickrings
CBN100insertDryTurning(CNC)50to9990.10.1-
Conventional
Cooling
SurfaceRoughness,
ResidualStress
-
Cutting
Speed
-9
22006
N.R.Dhar,
M.Kamruzzaman
AISI4340125x760Carbideinsert
Dry&WetTurning
(LatheMachine)
1100.161.5-
Air:7.0bar,
Lubricant:60
ml/h
SurfaceRoughness,
ToolWear,MQL
-Coolant-10
32006
M.Nalbant,
H.Gokkaya
AISI1030-
TiN-coated
tools
--0.15,0.25,0.350.5,1.5,2.5
0.4,0.8,1.2
*InsertRadius
(mm)
-
SurfaceRoughness
(Ra)
Taguchi
Insert
Radius
FeedRate5
42007
TugrulOzel,
YigitKarpat
AISID2
Not
specified
PCBNinsertDryTurning(CNC)80,115,1500.05,0.10,0.150.2
(5,10,15)min
*CuttingTime
Conventional
Cooling
Roughness
Parameters(Ra,Rt),
Toolflankwear
Multiple
Linear
Regression
Models,
Neural
network
models
FeedRate
Cutting
Speed
11
52008
R.S.Pawade,
SuhasS.Joshi
Inconel718
70OD60ID
5mmthick
rings
PCBNinsertDryTurning(CNC)125,300,4750.05,0.10,0.150.50,0.75,1.00-
Conventional
Cooling
ResidualStress,
Degreeofwork
hardening
Taguchi
Cutting
Edge
DepthOf
Cut
12
62008
D.I.Lalwani,
N.K.Mehta
MDN250
18Ni(250)
20x250
Ceramic
CoatedInsert
(TNMA160408S
01525)
LatheMachine55,74,930.04,0.08,0.120.1,0.15,0.2-
Conventional
Cooling
SurfaceRoughness,
Cuttingforces
Taguchi
Depthof
Cut
FeedRate13
72008
M.AnthonyXavior,
M.Adithan
AISI304
Not
specified
Carbideinsert
(CNMG)
LatheMachine
38.95,61.35,
97.38
0.2,0.25,0.280.5,1.0,1.2-
Coconutoil,
Solubleoil,
Straightcutting
oil
Effectofcutting
fluid,Surface
Roughness
Taguchi
Cutting
Speed
FeedRate7
82010
KhaiderBouacha,
MohamedAthmane
Yallese
AISI5210056x400CBNinsertLatheMachine125,176,2460.08,0.12,0.160.15,0.3,0.45-
Conventional
Cooling
SurfaceRoughness,
Cuttingforces
TaguchiFeedRate
Cutting
Speed
14
92011
A.Devillez,
G.LeCoz
Inconel718
180
(RoundBar)
Coated
Carbide
insertsS05F
Dry&WetTurning
(CNC)
40,60,800.10.5-5%emulsion
SurfaceRoughness,
ResidualStress
-Coolant-15
102011
S.Bissey-Breton,
J.Graviera
Copper
Not
specified
Carbideinsert
Dry&WetTurning
(CNC&Lathe
Machine)
138,860.05,0.20.05to0.3
0.4,0.8
*InsertRadius
(mm)
Notspecified
SurfaceRoughness,
QuadraticStress,
Crystallographic
anisotropy
Taguchi--16
112011
J.Guddat,
R.M’Saoubi
AISI52100
Ring(initial
thickness:
25mm)
PCBNinsertsDryTurning(CNC)120-1800.1-0.30.15
0.4-1.2
*InsertRadius
(mm)
Conventional
Cooling
surfaceintegrity,
Cuttingforces
-
Cutting
Edge
-17
122011
M.Z.A.Yazid,
C.H.CheHaron
Inconel718
103x157
(RoundBar)
PVDcoated
carbideinsert
Dry&WetTurning
(CNC)
90,120,1500.10,0.150.30,0.50-
MQL50mL/h,
MQL100mL/h
SurfaceRoughness
&Texture,
Microstructure
Alteration
-Coolant-8
132011
A.EstevesCorreia,
J.PauloDavim
AISI104551x119
Cemented
carbide
conventional
andwiper
insert
DryTurning(CNC)345,410,4700.075,0.15,0.250.5-
Conventional
Cooling
SurfaceRoughness,
Influenceofthe
wiperinserts
-
Cutting
Edge
FeedRate18
TABLE-1LITERATURESURVEY
MachiningParameters
S.No.
Yearof
Publish
AuthorMachiningMethodMaterial
Tool/Insert
Material
SampleSize
(dxl)(mm)
OutputParameters
Optimization
Methods
MostSignificantFactor
References
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2813
CuttingSpeed
Vc(m/min)
Feedf(mm/rev)D.O.C(mm)OtherCuttingFluid1st2nd
142011
IlhanAsilturk,
HarunAkkus
AISI4140110x600
TiC-coated
Carbideinsert
DryTurning(CNC)90,120,1500.18,0.27,0.360.2,0.4,0.6-
Conventional
Cooling
SurfaceRoughness
(Ra),(Rz)
TaguchiFeedRate-6
152012
AdemCicek,
TurgayKıvak
AISI316
100x170x
15
HSS,(M35)VerticalDrilling12,140.08,0.1-
CHT,CT
*ToolMaterial
Conventional
Cooling
SurfaceRoughness
(Ra),Roughness
Error
Taguchi,
Multiple
regression
analysis
Cutting
Speed
Tool
Material
19
162012
SrinivasAthreya,
DrY.D.Venkatesh
MildSteel-
Tungsten
Carbide
Tippedtool
LatheMachine
960,640,1280
(RPM)
145,130,160
(mm/min)
0.3,0.2,0.4-
Conventional
Cooling
SurfaceRoughness
(Ra)
Taguchi,Full
Factorial
Analysis
Cutting
Speed
DepthOf
Cut
20
172013
Dr.C.J.Rao,
Dr.D.NageswaraRao
AISI1050
40x300
(RoundBar)
Ceramic
(Al2O3+TiC
matrix)
DryTurning(CNC)50,75,950.05,0.10,0.150.25,0.50,0.75-
Conventional
Cooling
SurfaceRoughness
(Ra),CuttingForces
Taguchi,Full
Factorial
Analysis
Depthof
Cut
FeedRate21
182013
Yacovsahijpaul,
Gurpreetsingh
EN8or
AISI1040
32x200
(RoundBar)
Carbide
(CNMG431-PF
4225)
WetTurning(CNC)
1000,2000
(RPM)
0.125,0.2500.5,1.0-
Cool-cut-Nirma
40A,
Cool-cut-Nirma
30A
SurfaceRoughness
(Ra),Effectof
cuttingfluid
TaguchiFeedRateCoolant22
192013
PSubhash,
ChandraBose
NIMONIC75-
PVDcoated
carbideinsert
DryTurning(CNC)100,175,2500.02,0.03,0.040.01,0.125,0.15-
Conventional
Cooling
SurfaceRoughness
(Ra),MRR
Response
Surface
Methodology
FeedRate
DepthOf
Cut
23
202014
RajendraSingh,
Rahulkr.Gupta
SS316L
1000x120x
5(Pipe)
Carbideinsert-110,150,1900.10,0.15,0.200.10,0.15,0.20--
SurfaceRoughness
(Ra)
FullFactorial
Analysis,
MRA,ANN
FeedRate-24
212015
PrajwalkumarM.Patil,
RajendrakumarV.Kadi
AISI316
30x360
(RoundBar)
Carbideinsert
(CVDCoated)
DryTurning(CNC)120,150,1800.20,0.25,0.300.5,1.0,1.5-
Conventional
Cooling
SurfaceRoughness
(Ra,Rz),Hardness
TaguchiFeedRate
Cutting
Speed
25
222015
AswathyVG,
RajeevN,
Ti-6Al-4V
37.9x125
(RoundBar)
Carbideinsert
(CVDCoated)
WetTurning(CNC)50,60,700.010,0.020,0.0300.02,0.035,0.05
0.1,0.4,0.5
*InsertRadius
(mm)
Notspecified
SurfaceRoughness
(Ra),MRR,
RoughnessError
TaguchiFeedRate
DepthOf
Cut
26
232015
RoopaKRao,
VinayMurgod
EN19
25x70
(RoundBar)
CarbideTipDryTurning(CNC)
420,630,1000
(rpm)
0.040,0.048,0.0540.04,0.08,0.12-
Conventional
Cooling
SurfaceRoughness
(Ra),MRR(with
andwithoutHT)
Taguchi,Full
Factorial
Analysis,
Linear
Regression
Model
Depthof
Cut
FeedRate27
242015
MehmetAlperince,
IlhanAsilturk
Co28Cr6Mo
ASTMF1537
50x500
(RoundBar)
PVDcoated
carbideinsert
DryTurning(CNC)
318,477,636
(RPM)
0.1,0.15,0.250.5,0.7,0.9
0.4,0.8,1.2
*InsertRadius
(mm)
Conventional
Cooling
SurfaceRoughness
(Ra)
FullFactirial
Analysis
Insert
Radius
-28
252016
DevendraSingh,
VimanyuChadha
Al6061-CarbideinsertDryTurning(CNC)
1600,1900,
2200(RPM)
0.12,0.18,0.240.25,0.50,0.75
0.4,0.8,1.2
*InsertRadius
(mm)
Conventional
Cooling
SurfaceRoughness
(Ra)
Response
Surface
Methodology
Insert
Radius
FeedRate29
262016
LavishSharma,
JaiPrakashSharma
EN4732x102CarbideinsertWetTurning(CNC)47,79,1030.05,0.1,0.20.4,0.6,0.8
0.4,0.8,1.2
*InsertRadius
(mm)
-
SurfaceRoughness
(Ra)
Taguchi
Depthof
Cut
Cutting
Speed
30
TABLE-1LITERATURESURVEYContinue...
MachiningParameters
S.No.
Yearof
Publish
AuthorMachiningMethodMaterial
Tool/Insert
Material
SampleSize
(dxl)(mm)
OutputParameters
Optimization
Methods
MostSignificantFactor
References
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2814
3. CONCLUSION
Surfaceroughnessisconsideredasthemainresponse
factor. Along with the Machining parameters, output
parameters and the most significant factor is also
tabularized. The percentage distribution of various
methods used during optimization is showninTable-
2 and with the help of histogram in Figure-2.
Table-2: Percentage distribution for Optimization
methods
Optimization Methods for Surface Roughness
Optimization Methods %
Taguchi Methodology 53.57
Response Surface Methodology 7.14
Full Factorial Analysis 17.86
Multiple Regression Analysis 14.29
Artificial Neutral Network 7.14
Total 100.00
Figure-2: Histogram showing % distribution of
Optimization Methods
A Pie Chart is designed to find out the percentage
contribution of the most significant factors in
optimization of surface roughness in review of all
these research papers. Table-3 and Figure-3 shows
the % contribution of the most significant factors.
Table-3: Percentage Contribution of the most
significant factors.
Most Significant Factors for Surface Roughness
Machining Parameter %
Feed Rate 37.50
Cutting Speed 17.50
Depth of Cut 20.00
Insert Radius/Edge 15.00
Cutting Fluid 10.00
Total 100.00
Figure-3: Pie-chart showing % Contribution of the
most significant factors.
From the above literature review it is observed that
various methods are used to minimize surface
roughness by optimizing cutting parameters like
Cutting speed, Feed rate,Depthofcut,toolangle,nose
radius, Cutting Fluid, etc. Among all these methods it
is observed that Taguchi Method is the most widely
used method. The use of other methods like Multiple
Regression Analysis, Response Surface Method and
Artificial Neural Networkare graduallyincreasing.In
optimization of surface roughness Feed Rate is found
to be the most Significant factor followed by Depth of
cut and cutting speed.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2815
4. REFERENCES
[1] A Review on Optimization of Cutting
Parameters on Turning, (IJETT) – Volume 28 Number 2 -
October 2015
[2] Predicting Surface Roughness in Machining: a
Review, International Journal of Machine Tools and
Manufacture · June 2003
[3] A literature review on optimization of cutting
parameters for surface roughness in turning process,
Volume 11, Issue 05 (May 2015), PP.66-69
[4] Montgomery, D.C., “Design and Analysis of
Experiments”, 4th edition, 1997; John Wiley & Sons, New
York.
[5] Nalbant, M., Gokkaya, H., Sur, G., 2007, Application of
Taguchi method in the optimization of cutting parameters
for surface roughness in turning, Materials and DesignVol.
28, pp. 1379–1385.
[6] Asiltürk, Ilhan, Akkus, Harun, 2011, Determining the
effect of cutting parameters on surface roughness in hard
turning using the Taguchi method, Measurement Vol. 44,
pp. 1697– 1704.
[7] M. Anthony Xavior, M. Adithan, Determining the
influence of cutting fluids on tool wear and surface
roughness during turning of AISI 304 austenitic stainless
steel, journal of materials processing technology 2 0 9 (20
0 9 ) 900–909
[8] Yazid M.Z.A., Ibrahim G.A., Said A.Y.M., CheHaron
C.H, Ghani J.A., (2011) ‘Surface integrity of Inconel 718
when finish turning with PVD coated carbide tool under
MQL’, Procedia Engineering , Vol. 19, pp. 396 – 401.
[9] Michael Jacobson, Cutting speed influence on
surface integrity of hard turned bainite steel, 128 (2002)
318–323.
[10] N.R. Dhar, Effect of minimum quantity lubrication
(MQL) on tool wear and surface roughness in turningAISI-
4340 steel, 172 (2006) 299–304
[11] Tugrul O¨ zel, Modelling of surface finish and tool
flank wear in turning, 189 (2007) 192–198
[12] R.S. Pawade, Effect of machining parameters and
cutting edge geometry on surface integrity of high-speed
turned Inconel 718, 48 (2008) 15–28
[13] D.I.Lalwani,Experimental investigationsofcutting
parameters influence on cutting forces and surface
roughness in finish hard turning of MDN250 steel, 2 0 6 ( 2
0 0 8 ) 167–179
[14] Khaider Bouacha, Statistical analysis of surface
roughness and cutting forces using response surface
methodology in hard turning of AISI 52100 bearing steel
with CBN tool, 28, 2008
[15] A. Devillez, Dry machining of Inconel 718,
workpiece surface integrity, 211 (2011) 1590– 1598
[16] S. Bissey-Breton, Impact of superfinish turning on
surface integrity of pure Copper, 19 (2011) 28 – 33
[17] J. Guddat, Hard turning of AISI 52100 using PCBN
wiper geometry inserts and the resulting surface integrity,
19 (2011) 118 – 124
[18] A. Esteves Correia, Surface roughness
measurement in turning carbon steel AISI 1045 using
wiper inserts, 44 (2011) 1000–1005
[19] Adem Çiçek, Application of Taguchi Method for
Surface Roughness and Roundness Error in Drilling ofAISI
316 Stainless Steel, 58(2012)3, 165-174
[20] Srinivas Athreya, Application Of Taguchi Method
For Optimization Of Process Parameters In Improving The
Surface Roughness Of Lathe Facing Operation, Volume 1,
Issue 3 (November 2012), PP.13-19.
[21] Dr. C. J. Rao, Influence of cutting parameters on
cutting force and surface finish in turning operation, 64 (
2013 ) 1405 – 1415
[22] Yacov sahijpaul, Determining the Influence of
Various Cutting Parameters on Surface Roughness during
Wet CNC Turning Of AISI 1040 Medium Carbon Steel,Issue
2 (May. - Jun. 2013), PP 63-72
[23] P Subhash, evaluation of optimum cutting
parameters in turningofNIMONIC75usingRSM,volume-2,
2013
[24] Rajendra Singh, Surface Roughness Analysis And
Compare Prediction And Experimental Value For
Cylindrical Stainless Steel Pipe (Ss 316l) In CNC Lathe
Turning Process Using ANN Method For Re-Optimization
And Cutting Fluid
[25] Prajwalkumar M. Patil, Effect of Cutting
Parameters on Surface Quality of AISI 316 Austenitic
Stainless Steel in CNC Turning, Issue: 04 | July-2015
[26] Aswathy V G, Effect of machining parameters on
surface roughness, material removal rate and roundness
error during the wet turning of Ti-6Al-4V alloy, Vol. 4,
Issue 1, 2015
[27] Roopa K Rao, Analysis of effect of cutting
parameters on responses Surface Roughness and Material
Removal Rate for En 19 work-pieces material with and
without heat treatment, Volume 6, Issue 1, January-2015
[28] Mehmet Alperince, Effects of Cutting Tool
Parameters on Surface Roughness, Volume 4, Issue 8
(August 2015), PP.15-22
[29] Devendra Singh, Effect Of Nose Radius On Surface
Roughness During Cnc Turning Using Response Surface
Methodology, Vol.5, No.2, May 2016 DOI: 10.14810/
[30] Lavish Sharma, Optimization of Cutting
Parameters for Surface RoughnessinTurningofAlloySteel
EN 47, Vol. 2, Issue 4 (Oct. - Dec. 2016)

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A Literature Review on Optimization of Input Cutting Parameters for Improved Surface Finish in Turning Process

  • 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2810 A Literature Review on Optimization of Input Cutting Parameters for Improved Surface Finish in Turning Process Vivek Jakhara,Dr Manoj Nayakb, Nitin Sharmac aM. Tech Scholar, Manav Rachna International University (MRIU), Faridabad, Haryana, India bHOD & Associate Professor, Deptt. Of ME, (MRIU), Faridabad, Haryana, India cAssociate Professor, Krishna Institute of Engg. & Technology, Ghaziabad, UP, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - The purpose of this paper is to make an attempt to review the literature onoptimizationofinput cutting parameters for improved surface finish by acquiringminimumsurfaceroughnessinturningprocess and to present various methodologies andpracticesthat are being employed for the prediction of surface roughness. Surface roughness is one of the most commonly used criteria to determine quality of a turned surface. This literature review compiles different work presented on optimization of process parameters and concludes the most significant cutting parameters and most frequently used optimization techniques for improving surface finish The cutting parameters like Cutting speed, Feed rate, Depth of cut, Insert radius and Cutting fluid are taken into consideration. Key Words: Turning process, Optimization Techniques, Surface Roughness, Taguchi Method 1. INTRODUCTION Turning is a machining process used to obtain the desired dimension of round metal. The main target in present industrial era is to produce low cost quality product with requireddimensionsinanoptimumtime. Therefore, the optimum cutting parameters are to be recognized first. In turning, the metal is in rotational motion (axially) and a cutting tool is used to shear away the undesired metals.Thisprocessrequireslathe or turning machine, cuttingtool,workpieceandfixture [1]. The work piece is fixed in the machine chuckandis rotated at high speed. The cutting tool (insert) is fed in parallel to the axis of rotation as shown in Fig. 1. During this machining process the cutting parameters highly depends upon the work piece, cutting tool material, etc. These are determined by experience or machine catalogue. Surface roughness is a widely used attribute of product quality and in most cases a technical necessity for mechanical products.Achieving the desirable surface quality is of great importance for the functional behaviour of a part [2]. Thus the optimum selection of cutting parameters such as feed rate, depth of cut, cutting speed, etc, generates optimum conditions during machining and becomes the main exigency of manufacturing industry. Surface roughness of amaterialafterturningismeasuredusing portablesurfaceroughnesstester.Surface roughnessis an important criterion to find the qualityofasurface.It is an important response parameter. Surfacefinishcan be measured using simple surface roughness tester [3, 4]. In machining process various parameters are: Input Parameters: Cutting speed, Feed rate, Depth of cut, Insert radius, Cutting fluid, etc Output Parameters: Surface roughness, MRR, Tool wear, Cutting forces, MAZ, etc. Surface engineeringaimstoachievedesiredproperties or characteristics of surface-engineered components including:  Improved wear resistance;  Reduced friction energy losses;  Improved mechanical properties, for example, enhanced fatigue life, hardness or toughness;  Improved aesthetic appearance, etc. Factors influencing surface roughness in turning:  Cutting parameters i.e. feed, cutting speed and depth of cut  Vibration  Material of work piece  Rigidity of the system consisting of machine tool, fixture cutting tool and work  Type, form, material and sharpness of cutting tool  Type of coolant used Cause and effect diagram also called as fishbone diagram in Figure-1 shows different machining parameter that affects surface roughness.
  • 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2811 Figure-1: Cause and effect diagram for surface roughness Various optimization techniques used are:  Taguchi Methedology  Response Surface Methodology  Full Factorial Analysis  Multiple Regression Analysis  Artificial Neutral Network 2. LITERATURE SURVEY Several experimental investigations have been carried over the years in ordertostudytheinfluenceofvarious cutting parameters on the surface finish of the workpiece, tool life using workpieces of different materials. M.Nalbant et al. [5] implemented the Taguchi method to find out optimum cutting parameters for surface roughness in turning.ANOVAmethodwasemployedto study the performance characteristics in turning of AISI 1030 steel bar using TiN-coated tools. The study reveals that the feedrateandtheinsertradiuswerethe main machining parameters that affect the surface roughness in turning of AISI 1030. Ilhan Asilturk et al. [6] focuses on optimization of turning parameters based on Taguchi method to minimize surface roughness (Ra&Rz). Experimental have been carriedoutusingL9orthogonalarrayinCNC turning. Dry turning tests were carried out on hardened AISI 4140 with coated carbide tools. It has been observed that feed rate has the most significant effect on the surface roughness. M. Antony Xavior et al. [7] carried out an experimental investigation to determine the influence of different cutting fluids on tool wear and surface roughness in turning of AISI 304 with carbide cutting insert. Additionally,anattemptwasmadetodetermine the influence of coconut oil as cutting fluid in reducing the tool wear and surface roughness in the turning process. The performance of coconut oil was in contrast with another two cutting fluids namely an emulsion and neat cutting oil (immiscible with water). The investigation results indicatedthatcoconutoilasa cutting fluid performed better than the other two cutting fluids by improving the surface finish and reducing the tool wear. M.Z.A. Yazid et al. [8] observed surfaceintegritywhen finish turning Inconel 718, a highly corrosiveresistant, nickel-based super alloy, under three cutting conditions (DRY, MQL 50 mL/h and MQL 100 mL/h). The microstructure analysis using SEM on the machined surface suggests that severe deformation took place, leading to microstructure alteration at subsurface level measuring from a few to several micron in thickness. Work hardening under the machined surface was evident from the micro- hardness. The results of this study show that MQL may possibly improve surface integrity characteristics. Table-1 Shows Tabulated Literature Survey.
  • 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2812 CuttingSpeed Vc(m/min) Feedf(mm/rev)D.O.C(mm)OtherCuttingFluid1st2nd 12002 MichaelJacobson, PatrikDahlman Bainitesteel 310OD170 ID65mm thickrings CBN100insertDryTurning(CNC)50to9990.10.1- Conventional Cooling SurfaceRoughness, ResidualStress - Cutting Speed -9 22006 N.R.Dhar, M.Kamruzzaman AISI4340125x760Carbideinsert Dry&WetTurning (LatheMachine) 1100.161.5- Air:7.0bar, Lubricant:60 ml/h SurfaceRoughness, ToolWear,MQL -Coolant-10 32006 M.Nalbant, H.Gokkaya AISI1030- TiN-coated tools --0.15,0.25,0.350.5,1.5,2.5 0.4,0.8,1.2 *InsertRadius (mm) - SurfaceRoughness (Ra) Taguchi Insert Radius FeedRate5 42007 TugrulOzel, YigitKarpat AISID2 Not specified PCBNinsertDryTurning(CNC)80,115,1500.05,0.10,0.150.2 (5,10,15)min *CuttingTime Conventional Cooling Roughness Parameters(Ra,Rt), Toolflankwear Multiple Linear Regression Models, Neural network models FeedRate Cutting Speed 11 52008 R.S.Pawade, SuhasS.Joshi Inconel718 70OD60ID 5mmthick rings PCBNinsertDryTurning(CNC)125,300,4750.05,0.10,0.150.50,0.75,1.00- Conventional Cooling ResidualStress, Degreeofwork hardening Taguchi Cutting Edge DepthOf Cut 12 62008 D.I.Lalwani, N.K.Mehta MDN250 18Ni(250) 20x250 Ceramic CoatedInsert (TNMA160408S 01525) LatheMachine55,74,930.04,0.08,0.120.1,0.15,0.2- Conventional Cooling SurfaceRoughness, Cuttingforces Taguchi Depthof Cut FeedRate13 72008 M.AnthonyXavior, M.Adithan AISI304 Not specified Carbideinsert (CNMG) LatheMachine 38.95,61.35, 97.38 0.2,0.25,0.280.5,1.0,1.2- Coconutoil, Solubleoil, Straightcutting oil Effectofcutting fluid,Surface Roughness Taguchi Cutting Speed FeedRate7 82010 KhaiderBouacha, MohamedAthmane Yallese AISI5210056x400CBNinsertLatheMachine125,176,2460.08,0.12,0.160.15,0.3,0.45- Conventional Cooling SurfaceRoughness, Cuttingforces TaguchiFeedRate Cutting Speed 14 92011 A.Devillez, G.LeCoz Inconel718 180 (RoundBar) Coated Carbide insertsS05F Dry&WetTurning (CNC) 40,60,800.10.5-5%emulsion SurfaceRoughness, ResidualStress -Coolant-15 102011 S.Bissey-Breton, J.Graviera Copper Not specified Carbideinsert Dry&WetTurning (CNC&Lathe Machine) 138,860.05,0.20.05to0.3 0.4,0.8 *InsertRadius (mm) Notspecified SurfaceRoughness, QuadraticStress, Crystallographic anisotropy Taguchi--16 112011 J.Guddat, R.M’Saoubi AISI52100 Ring(initial thickness: 25mm) PCBNinsertsDryTurning(CNC)120-1800.1-0.30.15 0.4-1.2 *InsertRadius (mm) Conventional Cooling surfaceintegrity, Cuttingforces - Cutting Edge -17 122011 M.Z.A.Yazid, C.H.CheHaron Inconel718 103x157 (RoundBar) PVDcoated carbideinsert Dry&WetTurning (CNC) 90,120,1500.10,0.150.30,0.50- MQL50mL/h, MQL100mL/h SurfaceRoughness &Texture, Microstructure Alteration -Coolant-8 132011 A.EstevesCorreia, J.PauloDavim AISI104551x119 Cemented carbide conventional andwiper insert DryTurning(CNC)345,410,4700.075,0.15,0.250.5- Conventional Cooling SurfaceRoughness, Influenceofthe wiperinserts - Cutting Edge FeedRate18 TABLE-1LITERATURESURVEY MachiningParameters S.No. Yearof Publish AuthorMachiningMethodMaterial Tool/Insert Material SampleSize (dxl)(mm) OutputParameters Optimization Methods MostSignificantFactor References
  • 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2813 CuttingSpeed Vc(m/min) Feedf(mm/rev)D.O.C(mm)OtherCuttingFluid1st2nd 142011 IlhanAsilturk, HarunAkkus AISI4140110x600 TiC-coated Carbideinsert DryTurning(CNC)90,120,1500.18,0.27,0.360.2,0.4,0.6- Conventional Cooling SurfaceRoughness (Ra),(Rz) TaguchiFeedRate-6 152012 AdemCicek, TurgayKıvak AISI316 100x170x 15 HSS,(M35)VerticalDrilling12,140.08,0.1- CHT,CT *ToolMaterial Conventional Cooling SurfaceRoughness (Ra),Roughness Error Taguchi, Multiple regression analysis Cutting Speed Tool Material 19 162012 SrinivasAthreya, DrY.D.Venkatesh MildSteel- Tungsten Carbide Tippedtool LatheMachine 960,640,1280 (RPM) 145,130,160 (mm/min) 0.3,0.2,0.4- Conventional Cooling SurfaceRoughness (Ra) Taguchi,Full Factorial Analysis Cutting Speed DepthOf Cut 20 172013 Dr.C.J.Rao, Dr.D.NageswaraRao AISI1050 40x300 (RoundBar) Ceramic (Al2O3+TiC matrix) DryTurning(CNC)50,75,950.05,0.10,0.150.25,0.50,0.75- Conventional Cooling SurfaceRoughness (Ra),CuttingForces Taguchi,Full Factorial Analysis Depthof Cut FeedRate21 182013 Yacovsahijpaul, Gurpreetsingh EN8or AISI1040 32x200 (RoundBar) Carbide (CNMG431-PF 4225) WetTurning(CNC) 1000,2000 (RPM) 0.125,0.2500.5,1.0- Cool-cut-Nirma 40A, Cool-cut-Nirma 30A SurfaceRoughness (Ra),Effectof cuttingfluid TaguchiFeedRateCoolant22 192013 PSubhash, ChandraBose NIMONIC75- PVDcoated carbideinsert DryTurning(CNC)100,175,2500.02,0.03,0.040.01,0.125,0.15- Conventional Cooling SurfaceRoughness (Ra),MRR Response Surface Methodology FeedRate DepthOf Cut 23 202014 RajendraSingh, Rahulkr.Gupta SS316L 1000x120x 5(Pipe) Carbideinsert-110,150,1900.10,0.15,0.200.10,0.15,0.20-- SurfaceRoughness (Ra) FullFactorial Analysis, MRA,ANN FeedRate-24 212015 PrajwalkumarM.Patil, RajendrakumarV.Kadi AISI316 30x360 (RoundBar) Carbideinsert (CVDCoated) DryTurning(CNC)120,150,1800.20,0.25,0.300.5,1.0,1.5- Conventional Cooling SurfaceRoughness (Ra,Rz),Hardness TaguchiFeedRate Cutting Speed 25 222015 AswathyVG, RajeevN, Ti-6Al-4V 37.9x125 (RoundBar) Carbideinsert (CVDCoated) WetTurning(CNC)50,60,700.010,0.020,0.0300.02,0.035,0.05 0.1,0.4,0.5 *InsertRadius (mm) Notspecified SurfaceRoughness (Ra),MRR, RoughnessError TaguchiFeedRate DepthOf Cut 26 232015 RoopaKRao, VinayMurgod EN19 25x70 (RoundBar) CarbideTipDryTurning(CNC) 420,630,1000 (rpm) 0.040,0.048,0.0540.04,0.08,0.12- Conventional Cooling SurfaceRoughness (Ra),MRR(with andwithoutHT) Taguchi,Full Factorial Analysis, Linear Regression Model Depthof Cut FeedRate27 242015 MehmetAlperince, IlhanAsilturk Co28Cr6Mo ASTMF1537 50x500 (RoundBar) PVDcoated carbideinsert DryTurning(CNC) 318,477,636 (RPM) 0.1,0.15,0.250.5,0.7,0.9 0.4,0.8,1.2 *InsertRadius (mm) Conventional Cooling SurfaceRoughness (Ra) FullFactirial Analysis Insert Radius -28 252016 DevendraSingh, VimanyuChadha Al6061-CarbideinsertDryTurning(CNC) 1600,1900, 2200(RPM) 0.12,0.18,0.240.25,0.50,0.75 0.4,0.8,1.2 *InsertRadius (mm) Conventional Cooling SurfaceRoughness (Ra) Response Surface Methodology Insert Radius FeedRate29 262016 LavishSharma, JaiPrakashSharma EN4732x102CarbideinsertWetTurning(CNC)47,79,1030.05,0.1,0.20.4,0.6,0.8 0.4,0.8,1.2 *InsertRadius (mm) - SurfaceRoughness (Ra) Taguchi Depthof Cut Cutting Speed 30 TABLE-1LITERATURESURVEYContinue... MachiningParameters S.No. Yearof Publish AuthorMachiningMethodMaterial Tool/Insert Material SampleSize (dxl)(mm) OutputParameters Optimization Methods MostSignificantFactor References
  • 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2814 3. CONCLUSION Surfaceroughnessisconsideredasthemainresponse factor. Along with the Machining parameters, output parameters and the most significant factor is also tabularized. The percentage distribution of various methods used during optimization is showninTable- 2 and with the help of histogram in Figure-2. Table-2: Percentage distribution for Optimization methods Optimization Methods for Surface Roughness Optimization Methods % Taguchi Methodology 53.57 Response Surface Methodology 7.14 Full Factorial Analysis 17.86 Multiple Regression Analysis 14.29 Artificial Neutral Network 7.14 Total 100.00 Figure-2: Histogram showing % distribution of Optimization Methods A Pie Chart is designed to find out the percentage contribution of the most significant factors in optimization of surface roughness in review of all these research papers. Table-3 and Figure-3 shows the % contribution of the most significant factors. Table-3: Percentage Contribution of the most significant factors. Most Significant Factors for Surface Roughness Machining Parameter % Feed Rate 37.50 Cutting Speed 17.50 Depth of Cut 20.00 Insert Radius/Edge 15.00 Cutting Fluid 10.00 Total 100.00 Figure-3: Pie-chart showing % Contribution of the most significant factors. From the above literature review it is observed that various methods are used to minimize surface roughness by optimizing cutting parameters like Cutting speed, Feed rate,Depthofcut,toolangle,nose radius, Cutting Fluid, etc. Among all these methods it is observed that Taguchi Method is the most widely used method. The use of other methods like Multiple Regression Analysis, Response Surface Method and Artificial Neural Networkare graduallyincreasing.In optimization of surface roughness Feed Rate is found to be the most Significant factor followed by Depth of cut and cutting speed.
  • 6. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 2815 4. REFERENCES [1] A Review on Optimization of Cutting Parameters on Turning, (IJETT) – Volume 28 Number 2 - October 2015 [2] Predicting Surface Roughness in Machining: a Review, International Journal of Machine Tools and Manufacture · June 2003 [3] A literature review on optimization of cutting parameters for surface roughness in turning process, Volume 11, Issue 05 (May 2015), PP.66-69 [4] Montgomery, D.C., “Design and Analysis of Experiments”, 4th edition, 1997; John Wiley & Sons, New York. [5] Nalbant, M., Gokkaya, H., Sur, G., 2007, Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning, Materials and DesignVol. 28, pp. 1379–1385. [6] Asiltürk, Ilhan, Akkus, Harun, 2011, Determining the effect of cutting parameters on surface roughness in hard turning using the Taguchi method, Measurement Vol. 44, pp. 1697– 1704. [7] M. Anthony Xavior, M. Adithan, Determining the influence of cutting fluids on tool wear and surface roughness during turning of AISI 304 austenitic stainless steel, journal of materials processing technology 2 0 9 (20 0 9 ) 900–909 [8] Yazid M.Z.A., Ibrahim G.A., Said A.Y.M., CheHaron C.H, Ghani J.A., (2011) ‘Surface integrity of Inconel 718 when finish turning with PVD coated carbide tool under MQL’, Procedia Engineering , Vol. 19, pp. 396 – 401. [9] Michael Jacobson, Cutting speed influence on surface integrity of hard turned bainite steel, 128 (2002) 318–323. [10] N.R. Dhar, Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turningAISI- 4340 steel, 172 (2006) 299–304 [11] Tugrul O¨ zel, Modelling of surface finish and tool flank wear in turning, 189 (2007) 192–198 [12] R.S. Pawade, Effect of machining parameters and cutting edge geometry on surface integrity of high-speed turned Inconel 718, 48 (2008) 15–28 [13] D.I.Lalwani,Experimental investigationsofcutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel, 2 0 6 ( 2 0 0 8 ) 167–179 [14] Khaider Bouacha, Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool, 28, 2008 [15] A. Devillez, Dry machining of Inconel 718, workpiece surface integrity, 211 (2011) 1590– 1598 [16] S. Bissey-Breton, Impact of superfinish turning on surface integrity of pure Copper, 19 (2011) 28 – 33 [17] J. Guddat, Hard turning of AISI 52100 using PCBN wiper geometry inserts and the resulting surface integrity, 19 (2011) 118 – 124 [18] A. Esteves Correia, Surface roughness measurement in turning carbon steel AISI 1045 using wiper inserts, 44 (2011) 1000–1005 [19] Adem Çiçek, Application of Taguchi Method for Surface Roughness and Roundness Error in Drilling ofAISI 316 Stainless Steel, 58(2012)3, 165-174 [20] Srinivas Athreya, Application Of Taguchi Method For Optimization Of Process Parameters In Improving The Surface Roughness Of Lathe Facing Operation, Volume 1, Issue 3 (November 2012), PP.13-19. [21] Dr. C. J. Rao, Influence of cutting parameters on cutting force and surface finish in turning operation, 64 ( 2013 ) 1405 – 1415 [22] Yacov sahijpaul, Determining the Influence of Various Cutting Parameters on Surface Roughness during Wet CNC Turning Of AISI 1040 Medium Carbon Steel,Issue 2 (May. - Jun. 2013), PP 63-72 [23] P Subhash, evaluation of optimum cutting parameters in turningofNIMONIC75usingRSM,volume-2, 2013 [24] Rajendra Singh, Surface Roughness Analysis And Compare Prediction And Experimental Value For Cylindrical Stainless Steel Pipe (Ss 316l) In CNC Lathe Turning Process Using ANN Method For Re-Optimization And Cutting Fluid [25] Prajwalkumar M. Patil, Effect of Cutting Parameters on Surface Quality of AISI 316 Austenitic Stainless Steel in CNC Turning, Issue: 04 | July-2015 [26] Aswathy V G, Effect of machining parameters on surface roughness, material removal rate and roundness error during the wet turning of Ti-6Al-4V alloy, Vol. 4, Issue 1, 2015 [27] Roopa K Rao, Analysis of effect of cutting parameters on responses Surface Roughness and Material Removal Rate for En 19 work-pieces material with and without heat treatment, Volume 6, Issue 1, January-2015 [28] Mehmet Alperince, Effects of Cutting Tool Parameters on Surface Roughness, Volume 4, Issue 8 (August 2015), PP.15-22 [29] Devendra Singh, Effect Of Nose Radius On Surface Roughness During Cnc Turning Using Response Surface Methodology, Vol.5, No.2, May 2016 DOI: 10.14810/ [30] Lavish Sharma, Optimization of Cutting Parameters for Surface RoughnessinTurningofAlloySteel EN 47, Vol. 2, Issue 4 (Oct. - Dec. 2016)