IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
The document summarizes a study that used Taguchi methods and Grey Relational Analysis to optimize machining parameters (cutting speed, feed rate, depth of cut) for turning AISI H13 steel to maximize material removal rate and minimize surface roughness. Experiments were conducted based on an L18 orthogonal array design. Analysis of variance identified the significant parameters affecting each response. Optimal conditions for combined effects were found to be a cutting speed of 270m/min, feed rate of 0.1mm/rev, and depth of cut of 1.5mm, resulting in a surface roughness of 1.0828μm and material removal rate of 554.04mm3/sec.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Application of taguchi method in optimization of tool flank wear width ...Alexander Decker
1) The document applies Taguchi techniques to optimize tool flank wear width in turning AISI 1045 steel. An L9 orthogonal array is used to experiment with cutting speed, feed rate, and depth of cut as parameters.
2) Analysis of mean responses and S/N ratios found minimum wear at high speed, low feed rate, and shallow depth of cut. ANOVA showed cutting speed most influential.
3) Confirmation experiments verified 23.85% reduction in wear width at the optimal parameter levels of high speed, low feed rate, and shallow depth of cut.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
“Optimization of Cutting Parameters for Turning AISI 316 Stainless Steel Base...IOSRJMCE
The objective of this work is the optimization of the cutting parameters for turning AISI 316 stainless steel to achieve the better surface finish using Taguchi’s methodology. Taguchi Parameter Design is a powerful and efficient method for optimizing quality and performance output of manufacturing processes, thus a powerful tool for meeting this challenge. This work discusses an investigation into the use of Taguchi Parameter Design for optimizing surface roughness generated by a Turning operation. In this method, four control factors viz. cutting speed, feed rate, depth of cut, three different cutting fluids (sherol B, sherol ENF, straight cutting oil) and one work piece material (AISI 316 stainless steel) were investigated at three different levels and the turning operations are done on Banka 1000 lathe machine. Cutting speed followed by cutting fluid has the significant role. The quality characteristic identified is surface roughness. Experiments carried out using L9 (34 ) Orthogonal Array with three different levels of control factors.The test results were analyzed using “smallerthe-better” criteria for Signal-to-Noise ratio in order to optimize the process. The experimental results were analyzed, conformed and successfully used to achieve good surface finish on work piece materials.
This document summarizes a study that used finite element modeling to simulate the hot rolling process and investigate the effects of various process parameters. The study developed a 3D finite element model of the hot rolling process using Abaqus software. It then analyzed how changes in parameters like slab thickness, rolling speed, roll diameter, thickness reduction, and temperature affect outcomes like temperature distribution, stress, strain, and roll force. The model was validated by comparing its predictions to theoretical results from previous studies. The results showed that increasing rolling speed, roll diameter, or thickness reduction increased roll force, while increasing temperature decreased roll force. Higher speeds also decreased minimum slab surface temperature.
The document summarizes a study that used Taguchi methods and Grey Relational Analysis to optimize machining parameters (cutting speed, feed rate, depth of cut) for turning AISI H13 steel to maximize material removal rate and minimize surface roughness. Experiments were conducted based on an L18 orthogonal array design. Analysis of variance identified the significant parameters affecting each response. Optimal conditions for combined effects were found to be a cutting speed of 270m/min, feed rate of 0.1mm/rev, and depth of cut of 1.5mm, resulting in a surface roughness of 1.0828μm and material removal rate of 554.04mm3/sec.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Application of taguchi method in optimization of tool flank wear width ...Alexander Decker
1) The document applies Taguchi techniques to optimize tool flank wear width in turning AISI 1045 steel. An L9 orthogonal array is used to experiment with cutting speed, feed rate, and depth of cut as parameters.
2) Analysis of mean responses and S/N ratios found minimum wear at high speed, low feed rate, and shallow depth of cut. ANOVA showed cutting speed most influential.
3) Confirmation experiments verified 23.85% reduction in wear width at the optimal parameter levels of high speed, low feed rate, and shallow depth of cut.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
“Optimization of Cutting Parameters for Turning AISI 316 Stainless Steel Base...IOSRJMCE
The objective of this work is the optimization of the cutting parameters for turning AISI 316 stainless steel to achieve the better surface finish using Taguchi’s methodology. Taguchi Parameter Design is a powerful and efficient method for optimizing quality and performance output of manufacturing processes, thus a powerful tool for meeting this challenge. This work discusses an investigation into the use of Taguchi Parameter Design for optimizing surface roughness generated by a Turning operation. In this method, four control factors viz. cutting speed, feed rate, depth of cut, three different cutting fluids (sherol B, sherol ENF, straight cutting oil) and one work piece material (AISI 316 stainless steel) were investigated at three different levels and the turning operations are done on Banka 1000 lathe machine. Cutting speed followed by cutting fluid has the significant role. The quality characteristic identified is surface roughness. Experiments carried out using L9 (34 ) Orthogonal Array with three different levels of control factors.The test results were analyzed using “smallerthe-better” criteria for Signal-to-Noise ratio in order to optimize the process. The experimental results were analyzed, conformed and successfully used to achieve good surface finish on work piece materials.
This document summarizes a study that used finite element modeling to simulate the hot rolling process and investigate the effects of various process parameters. The study developed a 3D finite element model of the hot rolling process using Abaqus software. It then analyzed how changes in parameters like slab thickness, rolling speed, roll diameter, thickness reduction, and temperature affect outcomes like temperature distribution, stress, strain, and roll force. The model was validated by comparing its predictions to theoretical results from previous studies. The results showed that increasing rolling speed, roll diameter, or thickness reduction increased roll force, while increasing temperature decreased roll force. Higher speeds also decreased minimum slab surface temperature.
This document summarizes a study that used Taguchi methodology and Grey Relational Analysis to optimize machining parameters for CNC end milling of stainless steel 304. The goals were to minimize surface roughness (Ra) and maximize material removal rate (MRR). Experiments were conducted using an L9 orthogonal array to test cutting speed, feed rate, and depth of cut at three levels. Response data was normalized and Grey Relational Coefficients were calculated to determine the optimal parameter combination. The analysis found that a cutting speed of 75 m/min, feed rate of 0.15 mm/rev, and depth of cut of 1.5 mm provided the best results for achieving the combined objectives of lower Ra and higher MRR.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Process Parametric Optimization of CNC Vertical Milling Machine Using Taguchi...IOSR Journals
Abstract- An experiment was conducted to perform the parametric optimization of CNC end milling machine
tool in varying condition. The tool used for experiment was of Solid Carbide and the Mild Steel work piece was
used during experiment. The experiment has been taken place efficiently and completes its all objective of
optimization. The practical result can be used in industry to get the desirable Surface Roughness and Material
Removal Rate for the work piece by using suitable parameter combination.
This document summarizes a study that used the Taguchi method to optimize drilling parameters for minimizing surface roughness when drilling mild steel. Experiments were conducted using an L27 orthogonal array to examine the effects of cutting speed, feed rate, and point angle on surface roughness. Analysis of the experimental results found that the lowest surface roughness was achieved with a low cutting speed, low feed rate, and medium point angle. Feed rate was found to be the most significant factor influencing surface roughness, followed by cutting speed. The optimal combination of drilling parameters to minimize surface roughness in mild steel is a cutting speed of 7 m/min, feed rate of 0.035 mm/rev, and point angle of 90 degrees.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes a study that used the Taguchi method to investigate optimal process parameters for tool wear in hard turning of AISI H11 steel. Three factors (tool material, hardness, and speed/feed) were examined at three levels each in an L9 orthogonal array. Tool wear was measured and transformed to a signal-to-noise ratio to determine the optimal level combination. Analysis of variance was also used to determine the influence of each factor on tool wear. The results identified the best levels for minimizing tool wear in hard turning of hardened steel.
Analysis and simulation of chip formation & thermal effects on tool life usin...IAEME Publication
This document summarizes a study that used finite element modeling to analyze chip formation and thermal effects on tool life during metal cutting operations. The study modeled orthogonal cutting using MARC software to simulate the cutting process and predict tool temperature distributions and vibration. A Johnson-Cook material model was used to represent the workpiece material. Friction during cutting was also modeled. The simulation analyzed how factors like cutting speed and depth affected tool temperature and stability.
Optimization of tungsten inert gas welding on 6063 aluminum alloy on taguchi ...RSIS International
In this paper, the Taguchi method is used for the
Optimization of Tungsten Inert Gas Welding on 6063
Aluminum Alloy. The Taguchi method L27 is used to
optimize the pulsed TIG welding process parameters of 6063
aluminum alloy weldments for maximizing the mechanical
properties. Analysis of Variance is used to find the impact of
individual factors. Then the optimal parameters of the TIG
welding process is determined and the experimental results
illustrate the proposed approach.
This paper focus on monitoring of surface roughness and cutting forces while
machining on two different grade stainless steels under dry and mist conditions.
Stainless steels like AISI 304 and AISI 316L are considered for study. Process
variables like workpiece speed, tool feed and depth of cut are taken for
experimentation on CNC lathe. Responses like surface roughness, power consumption
and cutting forces are predicted while machining on the two different stainless grades
under dry and mist. Taguchi design of experiments is considered for experimental
design. Signal-to-noise ratio of the responses are used for determining individual
optimization, while Analysis of Variance is used for knowing significant effect of
process variables over the generated responses. This paper shows novelty of using
power consumption for calculating cutting forces and also comparisons of two
different stainless steel grades simultaneously under dry and mist conditions. In
addition, comparison of AISI 304 material with two different diameters is also studied
The document experimentally investigates the material removal rate (MRR) and tool wear in turning hardened AISI 52100 steel using the Taguchi technique. Experiments were conducted using different cutting speeds, feed rates, and depths of cut based on an L9 orthogonal array. The results were analyzed using signal-to-noise ratios and ANOVA to determine the optimal process parameters for maximizing MRR and minimizing tool wear. The analysis found that cutting speed had the greatest influence on MRR, followed by depth of cut and feed rate. The optimal parameters for MRR were a cutting speed of 1120 rpm, feed rate of 0.12 mm/rev, and depth of cut of 0.4 mm.
Experimental Approach of CNC Drilling Operation for Mild Steel Using Taguchi...IJMER
Drilling is the most common (multi-point) cutting technique targeted for the production of
small-diameter holes. Hole making is among the most important operations in manufacturing, and
drilling is a major and common hole-making process in components. Productivity can be interpreted in
terms of material removal rate in any machining operation. It is, therefore, essential to optimize quality
and productivity simultaneously. Mild steel are soft, ductile, easily machined and is extensive used us a
main engineering material in various industry such as air craft and aerospace industry. The Taguchi
method is applied to formulate the experimental layout to ascertain the Element of impact each
optimum process parameters for CNC drilling machining with drilling operation of mild steel. A total of
27 experimental runs were conducted using an orthogonal array, and the ideal combination of
controllable factor levels was determined for the material removal rate, time of machining and
circularity has been measured. Design optimization for quality was carried out and single to noise ratio
and analysis of variance (ANOVA) were employed using experiment result to confirm effectiveness of
this approach.
Modeling and Analysis for Cutting Temperature in Turning of Aluminium 6063 Us...IOSR Journals
Deviation in machining process due to the temperature influence, cutting force, tool wear leads to
highly inferior quality of finished product, especially in high speed machining operations where product quality
and physical dimensions seems to be meticulous. Moreover, temperature is a significant noise parameter which
directly affects the cutting tool and work piece. Hence the aim of this project work is to study the machining
effect on 6063 Aluminium alloy at varies combinations of process parameters such as speed, feed rate and depth
of cut; and also to determine the effect of those parameters over the quality of finished product. A L27
Orthogonal Array (OA) based Design of Experiments (DOE) approach and Response Surface Methodology
(RSM) was used to analyse the machining effect on work material in this study. Using the practical data
obtained, a mathematical model was developed to predict the temperature influence and surface quality of
finished product. The ultimate goal of the study is to optimize the machining parameters for temperature
minimization in machining zone and improvement in surface finish.
Fracture Analysis of FDM Manufactured Acrylonitrile Butadiene Styrene Using Fempaperpublications3
Abstract: The research paper gives the study about the fracture behavior of the rapid prototyping polymer material- Acrylonitrile Butadiene Styrene (ABS). The present work is performed for fracture analysis with experimental as well as finite element method. In this research, 9 specimens of ABS was produced by FDM technique, all of having different crack length and infill (parameter of FDM). The shape & size of specimen is selected as per ASTM D 5045. Experiment for fracture testing is conducted to measure stress intensity factor (SIF) and crack mouth opening displacement (CMOD) for each & every specimen. Then fracture analysis have been done in FEM software- ANSYS and the comparison have been done for both results data for analysis.
Optimization of Cutting Parameters Based on Taugchi Method of AISI316 using C...IRJET Journal
This document summarizes an experiment that optimized cutting parameters for machining austenitic stainless steel AISI 316 on a CNC lathe machine. The experiment used Taguchi methods to design experiments that varied cutting speed, feed rate, and depth of cut. 27 experiments were conducted and surface roughness was measured. Analysis of variance (ANOVA) was used to determine the percentage contribution of each factor on surface roughness. The results showed that feed rate had the maximum effect on surface roughness, while depth of cut had the minimum effect. Cutting speed had the least effect on surface roughness of the workpiece surface.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
This document summarizes a study that used Taguchi methodology and Grey Relational Analysis to optimize machining parameters for CNC end milling of stainless steel 304. The goals were to minimize surface roughness (Ra) and maximize material removal rate (MRR). Experiments were conducted using an L9 orthogonal array to test cutting speed, feed rate, and depth of cut at three levels. Response data was normalized and Grey Relational Coefficients were calculated to determine the optimal parameter combination. The analysis found that a cutting speed of 75 m/min, feed rate of 0.15 mm/rev, and depth of cut of 1.5 mm provided the best results for achieving the combined objectives of lower Ra and higher MRR.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Process Parametric Optimization of CNC Vertical Milling Machine Using Taguchi...IOSR Journals
Abstract- An experiment was conducted to perform the parametric optimization of CNC end milling machine
tool in varying condition. The tool used for experiment was of Solid Carbide and the Mild Steel work piece was
used during experiment. The experiment has been taken place efficiently and completes its all objective of
optimization. The practical result can be used in industry to get the desirable Surface Roughness and Material
Removal Rate for the work piece by using suitable parameter combination.
This document summarizes a study that used the Taguchi method to optimize drilling parameters for minimizing surface roughness when drilling mild steel. Experiments were conducted using an L27 orthogonal array to examine the effects of cutting speed, feed rate, and point angle on surface roughness. Analysis of the experimental results found that the lowest surface roughness was achieved with a low cutting speed, low feed rate, and medium point angle. Feed rate was found to be the most significant factor influencing surface roughness, followed by cutting speed. The optimal combination of drilling parameters to minimize surface roughness in mild steel is a cutting speed of 7 m/min, feed rate of 0.035 mm/rev, and point angle of 90 degrees.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes a study that used the Taguchi method to investigate optimal process parameters for tool wear in hard turning of AISI H11 steel. Three factors (tool material, hardness, and speed/feed) were examined at three levels each in an L9 orthogonal array. Tool wear was measured and transformed to a signal-to-noise ratio to determine the optimal level combination. Analysis of variance was also used to determine the influence of each factor on tool wear. The results identified the best levels for minimizing tool wear in hard turning of hardened steel.
Analysis and simulation of chip formation & thermal effects on tool life usin...IAEME Publication
This document summarizes a study that used finite element modeling to analyze chip formation and thermal effects on tool life during metal cutting operations. The study modeled orthogonal cutting using MARC software to simulate the cutting process and predict tool temperature distributions and vibration. A Johnson-Cook material model was used to represent the workpiece material. Friction during cutting was also modeled. The simulation analyzed how factors like cutting speed and depth affected tool temperature and stability.
Optimization of tungsten inert gas welding on 6063 aluminum alloy on taguchi ...RSIS International
In this paper, the Taguchi method is used for the
Optimization of Tungsten Inert Gas Welding on 6063
Aluminum Alloy. The Taguchi method L27 is used to
optimize the pulsed TIG welding process parameters of 6063
aluminum alloy weldments for maximizing the mechanical
properties. Analysis of Variance is used to find the impact of
individual factors. Then the optimal parameters of the TIG
welding process is determined and the experimental results
illustrate the proposed approach.
This paper focus on monitoring of surface roughness and cutting forces while
machining on two different grade stainless steels under dry and mist conditions.
Stainless steels like AISI 304 and AISI 316L are considered for study. Process
variables like workpiece speed, tool feed and depth of cut are taken for
experimentation on CNC lathe. Responses like surface roughness, power consumption
and cutting forces are predicted while machining on the two different stainless grades
under dry and mist. Taguchi design of experiments is considered for experimental
design. Signal-to-noise ratio of the responses are used for determining individual
optimization, while Analysis of Variance is used for knowing significant effect of
process variables over the generated responses. This paper shows novelty of using
power consumption for calculating cutting forces and also comparisons of two
different stainless steel grades simultaneously under dry and mist conditions. In
addition, comparison of AISI 304 material with two different diameters is also studied
The document experimentally investigates the material removal rate (MRR) and tool wear in turning hardened AISI 52100 steel using the Taguchi technique. Experiments were conducted using different cutting speeds, feed rates, and depths of cut based on an L9 orthogonal array. The results were analyzed using signal-to-noise ratios and ANOVA to determine the optimal process parameters for maximizing MRR and minimizing tool wear. The analysis found that cutting speed had the greatest influence on MRR, followed by depth of cut and feed rate. The optimal parameters for MRR were a cutting speed of 1120 rpm, feed rate of 0.12 mm/rev, and depth of cut of 0.4 mm.
Experimental Approach of CNC Drilling Operation for Mild Steel Using Taguchi...IJMER
Drilling is the most common (multi-point) cutting technique targeted for the production of
small-diameter holes. Hole making is among the most important operations in manufacturing, and
drilling is a major and common hole-making process in components. Productivity can be interpreted in
terms of material removal rate in any machining operation. It is, therefore, essential to optimize quality
and productivity simultaneously. Mild steel are soft, ductile, easily machined and is extensive used us a
main engineering material in various industry such as air craft and aerospace industry. The Taguchi
method is applied to formulate the experimental layout to ascertain the Element of impact each
optimum process parameters for CNC drilling machining with drilling operation of mild steel. A total of
27 experimental runs were conducted using an orthogonal array, and the ideal combination of
controllable factor levels was determined for the material removal rate, time of machining and
circularity has been measured. Design optimization for quality was carried out and single to noise ratio
and analysis of variance (ANOVA) were employed using experiment result to confirm effectiveness of
this approach.
Modeling and Analysis for Cutting Temperature in Turning of Aluminium 6063 Us...IOSR Journals
Deviation in machining process due to the temperature influence, cutting force, tool wear leads to
highly inferior quality of finished product, especially in high speed machining operations where product quality
and physical dimensions seems to be meticulous. Moreover, temperature is a significant noise parameter which
directly affects the cutting tool and work piece. Hence the aim of this project work is to study the machining
effect on 6063 Aluminium alloy at varies combinations of process parameters such as speed, feed rate and depth
of cut; and also to determine the effect of those parameters over the quality of finished product. A L27
Orthogonal Array (OA) based Design of Experiments (DOE) approach and Response Surface Methodology
(RSM) was used to analyse the machining effect on work material in this study. Using the practical data
obtained, a mathematical model was developed to predict the temperature influence and surface quality of
finished product. The ultimate goal of the study is to optimize the machining parameters for temperature
minimization in machining zone and improvement in surface finish.
Fracture Analysis of FDM Manufactured Acrylonitrile Butadiene Styrene Using Fempaperpublications3
Abstract: The research paper gives the study about the fracture behavior of the rapid prototyping polymer material- Acrylonitrile Butadiene Styrene (ABS). The present work is performed for fracture analysis with experimental as well as finite element method. In this research, 9 specimens of ABS was produced by FDM technique, all of having different crack length and infill (parameter of FDM). The shape & size of specimen is selected as per ASTM D 5045. Experiment for fracture testing is conducted to measure stress intensity factor (SIF) and crack mouth opening displacement (CMOD) for each & every specimen. Then fracture analysis have been done in FEM software- ANSYS and the comparison have been done for both results data for analysis.
Optimization of Cutting Parameters Based on Taugchi Method of AISI316 using C...IRJET Journal
This document summarizes an experiment that optimized cutting parameters for machining austenitic stainless steel AISI 316 on a CNC lathe machine. The experiment used Taguchi methods to design experiments that varied cutting speed, feed rate, and depth of cut. 27 experiments were conducted and surface roughness was measured. Analysis of variance (ANOVA) was used to determine the percentage contribution of each factor on surface roughness. The results showed that feed rate had the maximum effect on surface roughness, while depth of cut had the minimum effect. Cutting speed had the least effect on surface roughness of the workpiece surface.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Este documento describe un curso de orientación profesional de 4 semanas que ayuda a los estudiantes a elegir una carrera a través de 6 herramientas: 1) charlas sobre orientación profesional con psicólogos, 2) pruebas psicotécnicas, 3) cursos virtuales sobre exploración vocacional, toma de decisiones y proyecto de vida, 4) análisis del contexto educativo y 5) recomendaciones personalizadas. El objetivo es que los estudiantes puedan tomar decisiones informadas sobre su futuro profesional.
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The document summarizes a study that used Taguchi methods and Grey Relational Analysis to optimize machining parameters (cutting speed, feed rate, depth of cut) for turning AISI H13 steel to maximize material removal rate and minimize surface roughness. Experiments were conducted based on an L18 orthogonal array design. Analysis of variance identified the significant parameters affecting each response. Optimal conditions for combined effects were found to be a cutting speed of 270m/min, feed rate of 0.1mm/rev, and depth of cut of 1.5mm, achieving a surface roughness of 1.0828μm and material removal rate of 554.04mm3/sec.
The selection of optimal cutting parameters in turning operation is very important to
achieve high cutting performance. This paper deals with the optimization of performance
characteristics of turning EN-16 steel alloy using tungsten carbide inserts by Taguchi approach. The
experiments were performed on the basis of an L-18 orthogonal array given by Taguchi’s parameter
design approach. The performance characteristics such as thrust force and Material Removal Rate
(MRR) are optimized with the optimal combination of cutting parameters such as nose radius,
cutting speed, feed rate and depth of cut. Analysis of variance (ANOVA) is applied to identify the
most significant factor using MINITAB-16 software. The cutting parameters are varied to observe
the effects on performance characteristics and find the optimal results. Finally, confirmation tests are
performed to verify the experimental results. The results from the confirmation tests proved that the
performance characteristics such as thrust force and MRR are improved simultaneously through
optimal combination of process parameters obtained from Taguchi approach
This document presents a study that uses Taguchi design of experiments and regression analysis to optimize the machining parameters of cutting speed, feed rate, and depth of cut during CNC turning of EN-19 steel. The goal is to minimize surface roughness, feed force, and radial force. An orthogonal array experiment is designed using Taguchi's L9 array. Regression models are developed to predict the optimal settings, which are then verified with confirmation experiments. The Taguchi method aims to optimize the process parameters to obtain high quality products efficiently with minimal experimentation.
Investigations of machining parameters on surface roughness in cnc milling u...Alexander Decker
This document summarizes a study that investigated the effect of machining parameters on surface roughness in CNC milling of H-13 die steel using the Taguchi technique. The parameters examined were spindle speed, feed rate, and depth of cut. Experiments were conducted using an L9 orthogonal array. Surface roughness measurements showed that lower feed rates, higher spindle speeds, and greater depths of cut produced lower surface roughness values. Analysis of variance identified feed rate as the most influential parameter on surface roughness. The optimized parameters determined were a low feed rate of 0.08 mm/tooth, high spindle speed of 358.8 RPM, and high depth of cut of 0.3 mm.
Modeling of Morphology and Deflection Analysis of Copper AlloysIRJET Journal
This document discusses modeling the morphology and deflection analysis of copper alloys during thin wall machining. It presents an experimental investigation to determine optimal cutting conditions for machining thin walls of copper plates. The experiments used Taguchi methods to analyze the impact of cutting speed, feed rate, and depth of cut on surface roughness and part deflection. Analysis of variance (ANOVA) was then used to determine the correlation between these output responses and the cutting parameters, identifying the optimum conditions for thin wall machining of copper. The results showed that with appropriate process parameters, it is possible to end mill thin walls in copper as thin as 0.5mm with an aspect ratio of 48 and achieve a good surface finish and minimal deflection.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Experimental Investigation and Parametric Studies of Surface Roughness Analys...IJMER
The modern machining industries are focused on achieving high quality, in terms of
part/component accuracy, surface finish, high production rate and increase in product life. Surface
roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter.
The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other
parameters such as cutting force and power consumption in different conditions.
This document summarizes an experimental study that optimized machining parameters for turning EN24 alloy steel using the Taguchi method. Five parameters were investigated at three levels each: cutting speed, feed rate, depth of cut, nose radius, and cutting environment (wet vs. dry). Experiments were conducted according to an L18 orthogonal array design. The responses measured were surface roughness and material removal rate (MRR). Optimal parameters were identified that minimized surface roughness and maximized MRR. The Taguchi method was employed to efficiently analyze the large parameter space with a small number of experiments.
A literature review on optimization of cutting parameters for surface roughne...IJERD Editor
This document summarizes literature on optimizing cutting parameters to improve surface roughness in turning processes. Several studies used Taguchi methods to optimize parameters like cutting speed, feed rate, depth of cut, and nose radius. Most found feed rate was the most influential parameter on surface roughness. Other key findings include that lower feed rates and depths of cut produce better surface finishes, and coatings on carbide inserts can improve tool performance and surface roughness when machining steels. Future work could optimize additional parameters and study different tool coatings.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Taguchi based Optimization of Cutting Parameters Affecting Surface Roughness ...IRJET Journal
This document summarizes a study that used the Taguchi method to optimize cutting parameters (speed, feed rate, depth of cut) for minimizing surface roughness during CNC dry turning of 16MnCr5 steel. Experiments were conducted based on an L27 orthogonal array with three factors at three levels. Analysis of variance (ANOVA) was used to determine the percentage contribution of each factor on surface roughness. Results showed that depth of cut had the highest influence on surface roughness, followed by speed and then feed rate.
Full factorial method for optimization of process parameters for surface roug...Editor IJMTER
The document summarizes research on optimizing process parameters for surface roughness and material removal rate during CNC turning of 316L stainless steel. It discusses using a full factorial design of experiments approach to optimize cutting speed, feed rate, and depth of cut. The document reviews previous research optimizing these parameters for different materials and discusses the problem statement of finding the best parameter combination. The scope of the current study and literature reviewed is also summarized.
IRJET-Optimization of Machining Parameters Affecting Metal Removal Rate of Al...IRJET Journal
The document discusses optimizing machining parameters to increase the metal removal rate in dry end milling of aluminum alloy 6082. The machining parameters investigated are spindle speed, feed rate, and depth of cut. Experiments were performed using a Taguchi design of experiments with the parameters tested at three levels. The experimental data was analyzed using Minitab software to identify the most significant factor affecting metal removal rate. The goal is to determine the optimal settings of the machining parameters to maximize productivity during end milling of aluminum alloy 6082.
IRJET- Optimization of Machining Parameters for Turning on CNC Machine of Sta...IRJET Journal
This document discusses an experimental investigation into optimizing machining parameters for turning stainless steel 316 on a CNC machine. Taguchi methods were used to determine the optimal levels for cutting speed, feed rate, and depth of cut. Eighteen experiments were conducted using an L18 orthogonal array with different combinations of the parameters. The results found that depth of cut and feed rate significantly affected material removal rate and surface roughness, while cutting speed did not have a significant impact. Analysis of variance (ANOVA) identified depth of cut as the most influential factor. Optimization found the maximum material removal rate occurred at high cutting speeds, low feed rates, and high depth of cuts.
EFFECT OF NOSE RADIUS ON SURFACE ROUGHNESS DURING CNC TURNING USING RESPONSE ...ijmech
The work and study presented in this paper aims to investigate the effect of nose radius on surface
roughness, in CNC turning of Aluminium (6061) in dry condition. The effect of cutting conditions (speed,
feed and depth of cut) and tool geometry (nose radius) on surface roughness were studied and analysed.
Design of Experiments (DOE) were conducted for the analysis of the influence of the turning parameter on
the surface roughness by using Response Surface Methodology (RSM) and then followed by optimization of
the results using Analysis of Variance (ANOVA) to minimize surface roughness. The nose radius was
identified as the most significant parameter. Surface roughness value decreased with increase in nose
radius.
Effect of process factors on surface roughness in dip cryogenic machining of ...eSAT Journals
Abstract A large number of structures that are being constructed at present tend to be wind-sensitive because of their slenderness, shapes, size, lightness and flexibility. With the ever increase in the vertical growth of urban cities, high rise buildings are being constructed in large numbers. In this study, analytical investigation of different shapes of buildings are taken as an example and various analytical approaches are performed on the building. These plans are modeled and wind loads are found out according to I.S 875(part 3)-1987 by taking gust factor and without taking gust factor. These models are compared in different aspects such as storey drift, storey displacement, storey shear, etc. for different shapes of buildings by using finite element software package ETAB’s 13.1.1v. Among these results, which shape of building provide sound wind loading to the structure as well as the structural efficiency would be selected. Key Words: Storey displacement, Storey drift, Storey shear, Gust, Wind load
This document reviews optimization of process parameters for surface roughness and material removal rate (MRR) when machining stainless steel 316 on a CNC machine. It begins with an abstract that describes using design of experiments and grey relational analysis to optimize surface roughness based on data from 27 specimens produced via straight turning. The introduction provides background on the importance of surface roughness and challenges of achieving desired quality features on CNC machines. The literature review summarizes several previous studies on optimizing parameters like speed, feed rate, and depth of cut to minimize surface roughness and maximize MRR using techniques like Taguchi methods. The document aims to identify optimal parameter combinations to simultaneously optimize multiple quality objectives.
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGYIAEME Publication
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results
NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGY
Bq32429436
1. Pankaj Sharma, Kamaljeet Bhambri / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 2, March -April 2013, pp.429-436
Experimental Investigation of Parameters of CNC Turning by
Taguchi based Grey Relational Analysis
Pankaj Sharma*, Kamaljeet Bhambri**
*(Department of Mechanical Engg., M.M. University, Mullana, Ambala (Haryana) - India)
** (Department of Mechanical Engg., S.U.S.C.E.T., Tangori, Mohali (Punjab) – India)
Abstract As we know in actual machining there are many
The AISI H13, a chromium based hot work tool factors which affect the surface roughness and
Steel has a wide variety of applications in material removal rates i.e. cutting conditions, tool
aluminum casting and extrusion dies, forging dies, variables and work piece variables. Cutting
hot nut tools, hot header dies, extrusion mandrels, conditions includes speed, feed and depth of cut. The
plastic molds, cores, die holder blocks, hot press tool variables includes tool material, nose radius, rake
dies and specially hot work punches etc. In this angle, cutting edge geometry, tool vibration, tool
study, the optimization of two response overhang, tool point angle etc. The work piece
parameters (Surface roughness and Material variables include hardness and mechanical properties
Removal Rate) by three machining parameters of the material. It is very difficult to take all the
(cutting speed, feed rate and depth of cut) is parameters that control the response parameters for a
investigated in high speed turning of H13 in dry particular manufacturing process. In a turning
conditions. Taguchi’s L’18 orthogonal array and operation, it is very difficult to select the cutting
analysis of variance (ANOVA) are used for parameters to achieve the high surface finish with
individual optimization. The simultaneous optimal material removal rate. This study would help
optimization is done by Grey Relational Analysis the operator to select the cutting parameters.
approach. The different levels of all machining The hot work tool steels have the ability to resist
parameters are used and experiments are done on softening under hot working conditions and after
HMT STALLION-100 HS CNC lathe machine. numerous exposures to elevated operating
The optimum condition for combined effects was temperatures. Hot work material used for the present
found V5-F1-D1 and the optimal value of the study is H13 steel. The nominal chemical
surface roughness (Ra) comes out to be 0.84 (μm) compositions are {Chromium (5%), Vanadium (1%),
and of MRR is 488.8 (mm³/sec). The optimum Molybdenum (1.5%), Carbon (0.4%), Maganese
results are also verified with the help of (0.35%)}. This H13 tool steel is suitable for forging
confirmation experiments. dies, forging die inserts, hot gripper dies, hot nut
tools, hot header dies, brass forging and pressing
Keywords: CNC Turning, Optimization, ANOVA, dies, aluminum base dies, aluminum casting and
MRR, Surface Roughness (Ra), Taguchi Method, extrusion dies, zinc die casting dies, extrusion
Grey Relational Analysis, GRG. mandrels, plastic molds, cores, die holder blocks, hot
press dies and hot work punches etc.
1. Introduction This paper is about experimentally investigating and
Quality plays a major role in today‟s manufacturing optimizing the machining parameters for Material
market. From Customer‟s viewpoint quality is very Removal Rate (MRR) and Surface Roughness in
important because the quality of products affects the CNC turning by Taguchi method and grey relational
degree of satisfaction of the consumers during usage analysis approach.. Taguchi‟s orthogonal arrays are
of the product. It also improves the goodwill of the highly fractional designs, used to estimate main
company. effects using very few experimental runs. These
High speed turning operation is done on CNC lathe. designs are not only applicable for two level factorial
The quality of the surface plays a very important role experiments, but also can investigate main effects
in the performance of dry turning because a good when factors have more than two levels. Designs are
quality turned surface surely improves fatigue also available to investigate main effects for some
strength, corrosion resistance and creep life. Surface mixed level experiments where the factors included
roughness also affects on some functional attributes do not have the same number of levels.
of parts, such as, contact causing surface friction, For example, a four-level full factorial design with
wearing, light reflection, ability of distributing and five factors requires 1024 runs while the Taguchi
also holding a lubricant, load bearing capacity, orthogonal array reduces the required number of runs
coating and resisting fatigue. to 16 only.
429 | P a g e
2. Pankaj Sharma, Kamaljeet Bhambri / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 2, March -April 2013, pp.429-436
Ojel, T. et al. (2004) has studied the effects of cutting 2. Design of Experiment
edge geometry, work piece hardness, feed rate and The experiments are designed using Taguchi method
cutting speed on surface roughness and resultant so that effect of all the parameters could be studied
forces in the finish hard turning of AISI H13 steel. with minimum possible number of experiments.
Cubic Boron Nitrite inserts with two distinct edge Using Taguchi method, Appropriate Orthogonal
preparations (chamfered and honed) and through Array has been chosen and experiments have been
hardened AISI H13 steel bars were used. The honed performed as per the set of experiments designed in
Edge geometry and lower work piece surface the orthogonal array. Signal to Noise ratios are also
hardness resulted in better surface roughness. calculated for analyzing the effect of machining
Ghani, M.U. et al. (2007) has presented results of an parameters more accurately. The results of the
investigation into the tool life and the tool wear experimentation are analyzed analytically and
behaviour of low content CBN cutting tools used in graphically as well. ANOVA is used to determine the
hard turning of hardened H13 tool steel using finite percentage contribution of all factors upon each
element thermal modeling. It involved measuring the response individually.
cutting forces, cutting temperatures, tool wear and the
contact area. Using the measured cutting forces and 3. Taguchi Method
the contact area in the orthogonal cutting model, he The traditional experimental design methods are very
calculated the heat flux on the tool. The heat partition complicated and difficult to use. Additionally, these
into the tool was estimated to be around 21–22% for methods also require a large number of experiments
conventional speeds, 14% for high-speed turning. when the number of process parameters increases. In
The tool wear, however, was found to be dominated order to minimize the number of tests required,
by chipping for both cutting speeds and could be Taguchi experimental design method, a powerful tool
reduced considerably by reducing the amount of heat for designing high-quality system, was developed by
entering the tool. Taguchi. Taguchi method uses a design of orthogonal
Jaharah, A.G. et al (2009) has studied the effect of arrays to study the entire parameter space with small
uncoated carbide tool geometries in turning AISI number of experiments only. Taguchi recommends
1045 using finite element analysis. This paper analyzing the mean response for each run in the
presents the application of Finite element method array, and he also suggests to analyze variation using
(FEM) in simulating the effect of cutting tool an appropriately chosen signal-to-noise ratio (S/N).
geometries on the effective stress and temperature There are 3 Signal-to-Noise ratios of common
increased in turning. The tool geometries studied interest for optimization of static problems:
were various rake (α) and clearance (β) in the
different ranges. The minimum effective stress of 1. Smaller The Better
1700MPa is achieved using rake and clearance angles S ∑Yi 2
of 5° and 5° respectively with cutting speed of = −10 log
N n
300mm/min, and feed rate of 0.25mm/rev.
Chakradhar, D. and Venu Gopal, A. (2011) has done 2. Larger The Better
S 1
the multi objective optimization of electrochemical
N
= −10 log ∑ yi ²)/n)
((
machining of EN-31 steel by grey relational analysis.
The process parameters considered are electrolyte
3. NOMINAL-THE-BEST
concentration, feed rate and applied voltage and are 𝑆 𝑦2
optimized with considerations of multiple 𝑁
= 10 log 𝑠 2 )
(
performance characteristics including material Where,
removal rate, over cut, cylindricity error and surface Yi - ith observed value of the response,
roughness. With the help of Analysis of variance n - Number of observations in a trial,
(ANOVA) it was observed that feed rate is the y - Average of observed values (responses)
significant process parameter that affects the ECM s - Variance.
robustness.
Hassan, K. et al. (2012) has done the experimental Regardless of the category of the performance
investigation of material removal rate (MRR) in CNC characteristics, the higher S/N ratio corresponds to a
turning of C34000 using Taguchi method using L‟27 better performance. Therefore, the optimal level of
array. When the MRR is optimized alone the MRR the process parameters is the level with the highest
comes out to be 8.91. The optimum levels of process S/N value. The statistical analysis of the data is
parameters for simultaneous optimization of MRR performed by analysis of variance (ANOVA) to study
have been identified. Optimal results were verified the contribution of the various factors and
through confirmation experiments. It was concluded interactions and to explore the effects of each process
that MRR is mainly affected by cutting speed and on the observed values.
feed rate.
430 | P a g e
3. Pankaj Sharma, Kamaljeet Bhambri / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 2, March -April 2013, pp.429-436
4. Experimentation to determine the optimum combination of the
In this study, three machining parameters were machining parameters.
selected with different levels as given in Table 1. The A series of turning tests are conducted to assess the
experimental design was according to an L‟18 array effect of turning parameters on surface roughness in
based on Taguchi method. A set of experiments turning of H13. The Material Removal Rate
designed and conducted to investigate the relation calculations and experimental results of the surface
between the process parameters and response factor. roughness for turning of H13 with different turning
Minitab 16 software is used for optimization and parameters are shown in Table 3.
graphical analysis of obtained data.
Table 3 Design of experiment and calculations
Table 1 Turning parameters and levels S. Weight Weight Machining Means of
Levels CS F DOC No. before after Time Material
(m/sec) (mm/rev) (mm) turning turning (sec.) Removal
1 150 0.1 0.5 (gm) (gm) Rate
2 180 0.2 1 (mm³/sec)
3 210 0.3 1.5 1 454.1 425.2 12.0 304.85
4 240 2 425.2 406.7 7.0 334.53
5 270 3 406.7 386.7 5.7 444.14
6 300 4 456.4 424.2 10.4 391.91
5 424.2 399.4 8.0 392.40
The work material selected for this experiment is 6 399.4 380.9 5.5 425.77
H13 of Ø 32 mm, length 70 mm in the present study. 7 456.2 421.2 10.1 438.65
The chemical composition of H13 sample can be 8 421.2 399.3 6.4 433.14
seen in Tables 2. 9 399.3 382.9 5.2 399.22
10 454.0 415.9 9.6 502.37
Table 2 Chemical composition of H13 sample 11 415.9 392.2 6.2 483.87
Ele- C Cr V Mo SI S P 12 392.2 377.4 3.9 480.36
ments 13 452.0 418.8 8.5 494.41
% 0.36 4.9 0.9 1.4 1.04 0.03 0.03 14 418.8 390.1 7.2 504.57
15 390.1 372.9 4.4 494.82
The turning tests were carried out to determine the 16 457.0 424.4 8.5 483.99
Material Removal Rate and Surface Roughness under 17 424.4 402.7 6.5 422.59
various turning parameters. A HMT STALLION-100 18 402.7 384.4 4.9 459.82
HS CNC lathe machine is used for experimentation.
Roughness is measured using stylus type surface Table 4 Design of experiment and calculations
roughness tester „Surftest SJ-201‟ made of Mitutoyo, Ex. CS F D MRR Ra
Japan. The cut-off length (λ) was chosen as 0.8cm for No. (m/ ( mm/ (mm (mm³/ (μm)
each roughness measurement. An average of 5 min) rev) ) sec)
measurements of the surface roughness was taken to 1 150 0.1 0.5 304.85 0.57
use in the multi-criteria optimization. 2 150 0.2 1.0 334.53 0.96
The Material Removal Rate, MRR (mm³/ min) was
3 150 0.3 1.5 444.14 1.04
calculated using formula:
4 180 0.1 0.5 391.91 0.59
𝑊𝑖 −𝑊𝑓 5 180 0.2 1.0 392.40 0.96
𝑀𝑅𝑅 = 𝜌𝑠 𝑡
𝑚𝑚³/𝑠𝑒𝑐 6 180 0.3 1.5 425.77 1.09
Where, Wi = Initial weight of work piece in gm 7 210 0.1 1.0 438.65 0.82
Wf= Final weight of work piece in gm 8 210 0.2 1.5 433.14 0.88
t = Machining time in seconds 9 210 0.3 0.5 399.22 0.86
ρs= Density of mild steel (7.9 x 10ˉ³ gm/mm³). 10 240 0.1 1.5 502.37 0.97
11 240 0.2 0.5 483.87 0.84
5. Results and Discussions 12 240 0.3 1.0 480.36 0.94
In high speed turning operation, surface roughness is 13 270 0.1 1.0 494.41 0.92
an important criterion. The purpose of the analysis of 14 270 0.2 1.5 504.57 1.06
variance (ANOVA) is to investigate which design 15 270 0.3 0.5 494.82 1.04
parameter significantly affects the surface roughness. 16 300 0.1 1.5 483.99 1.06
Based on the ANOVA, the relative importance of the 17 300 0.2 0.5 422.59 1.02
machining parameters with respect to material 18 300 0.3 1.0 459.82 0.98
removal rate and surface roughness was investigated
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Vol. 3, Issue 2, March -April 2013, pp.429-436
Table 5 ANOVA Table for means of MRR
V D SS MS F P C
F
C 5 41373 8274. 11.83 0.002 73.79
S 7 ***
F 2 1526 762.9 1.09 0.381 2.7 2*
D 2 7566 3783. 5.41 0.033 13.49
2 **
E 8 5598 699.7 9.98
Fig 2 Main effect plot for means of Ra
T 17 56064 100
Here,
Table 6 Response Table for means of MRR V-Variable, CS-Cutting Speed,
Level CS F DOC F-Feed Rate, D-Depth Of Cut,
1 361.2 436.0 416.2 SR-Surface Roughness, E-Error,
2 403.4 428.5 433.4 T-Total, DF-Degree of Freedom,
3 423.7 450.7 465.7 SS-Sum of Squares, MS-Mean of Squares,
4 488.9 F-a statistical parameter, P-Percentage,
5 497.9 C-% Contribution.
6 455.5 Here *** & ** represents most significant and
Delta 136.8 22.2 49.5 significant parameters and * as less significant.
Rank 1 3 2
6. Grey Relational Analysis
In the Grey relational analysis the quality
characteristics are first normalized, ranging from zero
to one. This process is known as Grey Relational
Generation. Then the Grey Relational Coefficient
based on normalized experimental data is calculated
to represent the correlation between the desired and
the actual experimental data. Then overall Grey
Relational Grade (GRG) is determined by averaging
the Grey relational coefficient corresponding to
Fig 1 Main effect plot for means of MRR selected responses.
Table 7 ANOVA Table for means of Ra The overall performance characteristic of the
V D SS MS F P C multiple response process depends on the calculated
F GRG. This Grey relational approach converts a
C 5 0.0826 0.016 1.77 0.226 22.35 multiple response process optimization problem into
S 5 * a single response optimization problem. The optimal
F 2 0.0954 0.047 5.10 0.037 25.82 parametric combination is then evaluated, which
7 ** would result in the highest Grey relational grade. The
D 2 0.1166 0.058 6.23 0.023 31.56 optimal factor setting for maximizing the overall
2 *** Grey relational grade can be performed using the
E 8 0.0749 0.009 20.27 Taguchi method.
3 In Grey relational generation, the normalized MRR
T 17 0.3695 100 should follow the larger-the-better (LB) criterion,
which can be expressed as:
max yi k – yi k
Table 8 Response Table for means of Ra xi k =
Level CS F DOC max yi k – min yi k
1 0.8567 0.8217 0.8200 The normalized Ra should follow the smaller-the-
2 0.8800 0.9533 0.9300 better (SB) criterion which can be expressed as:
3 0.8533 0.9917 1.0167 yi k − min yi k
xi k =
4 0.9167 max yi k – min yi k
5 1.0067 Where, xi(k) and xj(k) are the value after Grey
6 1.0200 Relational Generation for LB and SB criteria. Max
Delta 0.1667 0.1700 0.1967 yi(k) is the largest value of yi(k) for kth response and
Rank 3 2 1 min yi(k) is the minimum value of yi(k) for the kth
response.
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Vol. 3, Issue 2, March -April 2013, pp.429-436
The Grey relational coefficient ξi(k) can be calculated Table 10: Grey Relational Analysis Calculations
as: S. GRGC RSDC GRCC
ξi(k) = Δmin + Ψ Δmax N.
Δ oi(k) + Ψ Δmax MR Ra MR Ra MR Ra
R R R
And Δ oi = ║ xo(k) – xi(k) ║ xo 1.000 1.000 1.000 1.000 1.000 1.000
1 0.000 1.000 1.000 0.000 0.333 1.000
Where Δ oi is the difference between absolute value 2 0.148 0.250 0.852 0.750 0.369 0.400
xo(k) and xi(k). Ψ is the distinguishing coefficient 0 ≤ 3 0.697 0.096 0.303 0.904 0.622 0.356
Ψ ≥ 1. Δ min and Δ max are the minimum and 4 0.431 0.962 0.569 0.038 0.467 0.929
maximum value among the Δ oi for corresponding kth 5 0.438 0.250 0.562 0.750 0.470 0.400
response. 6 0.605 0.000 0.395 1.000 0.558 0.333
Now the Grey Relational Grade (GRG) can be 7 0.669 0.519 0.331 0.481 0.601 0.509
calculated as : 8 0.642 0.404 0.358 0.596 0.582 0.456
9 0.472 0.442 0.528 0.558 0.486 0.472
γi =
10 0.988 0.231 0.012 0.769 0.976 0.394
Where n is the number of process responses. 11 0.896 0.481 0.108 0.519 0.822 0.490
The higher value of the GRG corresponds to a 12 0.878 0.288 0.122 0.712 0.803 0.412
relational degree between the Reference Sequence 13 0.949 0.327 0.051 0.673 0.907 0.426
xo(k) and the given sequence xi(k). The Reference 14 1.000 0.058 0.000 0.942 1.000 0.346
Sequence xo(k) represents the best process sequence. 15 0.951 0.096 0.049 0.904 0.910 0.356
Therefore, a higher GRG means that the 16 0.896 0.058 0.104 0.942 0.827 0.346
corresponding parameter combination is closer to the 17 0.589 0.135 0.411 0.865 0.548 0.366
optimal. The mean response for the GRG and the 18 0.775 0.212 0.225 0.788 0.689 0.388
main effect plot of the GRG are very important
because the optimal process condition can be Where,
evaluated from this plot. GRGC- Grey Relational Generation Calculation,
RSDC- Reference Sequence Definition Calculation,
Table 9 S/N Ratio Calculation for MRR and Ra GRCC- Grey Relational Coefficient Calculation
S. No. Mean Values S/N Ratios
Table 11 GRG calculation
Xo MRR Ra MRR Ra S. No. GRG Rank
1 304.85 0.57 49.681 4.882 Mean S/N Ratio
2 334.53 0.96 50.488 0.354 1 0.6665 -3.5240
3 444.14 1.04 52.950 -0.340 2 0.3845 -8.3020
4 391.91 0.59 51.863 4.582 3 0.4890 -6.2138
5 392.40 0.96 51.874 0.354 4 0.6980 -3.1228
6 425.77 1.09 52.583 -0.748 5 0.4350 -7.2302
7 438.65 0.82 52.842 1.723 6 0.4455 -7.0230
8 433.14 0.88 52.732 1.110 7 0.5550 -5.1141
9 399.22 0.86 52.024 1.310 8 0.5190 -5.6966
10 502.37 0.97 54.020 0.264 9 0.4790 -6.3932
11 483.87 0.84 53.694 1.514 10 0.6850 -3.2861
12 480.36 0.94 53.631 0.537 11 0.6560 -3.6619
13 494.41 0.92 53.881 0.724 12 0.6075 -4.3290
14 504.57 1.06 54.058 -0.506 13 0.6665 -3.5240
15 494.82 1.04 53.888 -0.340 14 0.6730 -3.4397
16 483.99 1.06 53.696 -0.506 15 0.6330 -3.9719
17 422.59 1.02 52.518 -0.172 16 0.5865 -4.6346
18 459.82 0.98 53.251 0.175 17 0.4570 -6.8016
Max. 304.85 0.57 49.681 -0.748 18 0.5385 -5.3762
Min. 504.57 1.09 54.058 4.882
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Vol. 3, Issue 2, March -April 2013, pp.429-436
Table 12: ANOVA calculations for means of GRG
V D SS MS F P C
F
C 5 0.0706 0.0141 3.50 0.05 41.29***
S
F 2 0.0546 0.0273 6.78 0.01 31.93**
D 2 0.0135 0.0067 1.68 0.24 7.89*
E 8 0.0323 0.0040 18.89
T 17 0.1710 100 Fig 4Main effect plot for S/N Ratio of GRG
Table 13: ANOVA calculations for S/N ratio of
GRG
V D SS MS F P C
F
C 5 17.65 3.531 3.15 0.07 40.30
S 3 ***
F 2 13.75 6.878 6.14 0.02 31.40
6 **
D 2 3.430 1.715 1.53 0.27 7.83*
E 8 8.965 1.121 20.47
T 17 43.80 100 Fig 5 Interaction plot for means of GRG
4
7. Determination of Optimum Condition:
Table 14 Response Table for means of GRG Both the response and S/N ratio are used to derive the
Level CS F DOC optimum conditions. Since for quality characteristic,
1 0.5133 0.6429 0.5983 Grey Relational Grade larger the better approach is
2 0.5262 0.5207 0.5312 desirable, the largest is the ideal level for a
3 0.5177 0.5321 0.5663 parameter. The S/N ratio is always highest at the
4 0.6495 optimum condition. The graphs of Figures 2 and 3
5 0.6575 are used to determine the optimum process
6 0.5273 parameters combination. The optimum combination
Delta 0.1442 0.1222 0.0671 is therefore V5-F1-D1.
Rank 1 2 3
7.1 Predictive Equation and Verification:
Table 15 Response Table for S/N Ratio of GRG The predicted values of GRG, MRR and Ra at the
Level CS F DOC optimal levels are calculated by using the relation:
1 -6.013 -3.868 -4.579
2 -5.792 -5.855 -5.646
3 -5.735 -5.551 -5.049
4 -3.759 Where,
5 ñ - Predicted response value after optimization,
-3.645
6 -5.604 - Total mean value of quality characteristic,
Delta 2.368 1.988 1.067 - Mean value of quality characteristic at
Rank 1 2 3 optimum level of each parameter and
o - Number of main machining parameters that affect
the response parameter.
Applying this relation, predicted values of GRG,
MRR and Ra at the optimum conditions are
calculated as:
1. ñGRG = 0.5652 + [ (0.6575 - 0.5652) + (0.6429 –
0.5652) + (0.5983 - 0.5652) ]
= 0.7683
2. ñRa = 0.9222 + [ (1.0067 – 0.9222) + (0.8217 –
0.9222) + (0.8200 – 0.9222 ]
Fig 3 Main effect plot for means of GRG = 0.8040 µm.
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Vol. 3, Issue 2, March -April 2013, pp.429-436
OL-Optimum Levels of Parameters
3. ñMRR = 438.4 + [ (497.9 – 438.4) + (436.0 – POV-Predicted Optimum value
438.4) + (416.2 – 438.4) ] EOV-Experimental Optimum Value
= 473.3 mm³/sec. OR-Optimum Range of MRR and Surface
Roughness
The robustness of this parameter optimization is
verified experimentally. This requires the 9. Conclusions
confirmation run at the predicted optimum In this study, the Grey relational based Taguchi
conditions. The experiment is conducted twice at the method was applied for the multiple performance
predicted optimum conditions. characteristics of turning operations.
A grey relational analysis of the Material removal
Verifications rate and the surface roughness obtained from the
1. For Material Removal Rate (MRR) Taguchi method reduced from the multiple
The calculated value of MRR at the optimum performance characteristics to a single performance
condition (V5-F1-D1) is 488.8 mm³/sec. The error in characteristic which is called the grey relational
the predicted optimum value (473.3) and the grade. Therefore, the optimization of the complicated
calculated value (488.8) is only 3.2%. multiple performance characteristics of the processes
can be greatly simplified using the Grey relational
2. For Surface Roughness (Ra) based Taguchi method. It is also shown that the
The average of two measured values (0.82, 0.86) of performance characteristics of the turning operations,
the response at the optimum condition (V5-F1-D1) is such as the material removal rate and the surface
0.84 μm. The error in the predicted optimum value roughness are greatly enhanced by using this method.
(0.8040) and experimental value (0.84) is only 4.4%.
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