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.
Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation u...IJMER
Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchi’s L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis
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 Analysis of Material Removal Rate in Drilling of 41Cr4 by a Tagu...IJERA Editor
In manufacturing industries the largest amount of money spent on drills. Therefore, from the viewpoint of cost and productivity, modeling and optimization of drilling processes parameter are extremely important for the manufacturing industry this paper presents a detailed model for drilling process parameter. The detailed structure includes in the model, are three parameters such as such as Spindle Speed, feed and depth of cut on material removal rate in drilling of 41 Cr 4 material using HSS spiral drill .We an effect of this three parameters on material removal rate .The detailed mathematical model is simulated by Minitab14 and simulation results fit experiment data very well In this investigation, an effective approach based on Taguchi method, analysis of variance (ANOVA), multivariable linear regression (MVLR), has been developed to determine the optimum conditions leading to higher MRR. Experiments were conducted by varying Spindle Speed, feed and depth of cut using L9 orthogonal array of Taguchi method. The present work aims at optimizing process parameters to achieve high MMR. Experimental results from the orthogonal array were used as the training data for the MVLR model to map the relationship between process parameters and MMR the experiment was conducted on drilling machine. From the investigation It concludes that speed is most influencing parameter followed by feed and depth of cut on MRR
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation u...IJMER
Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchi’s L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis
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 Analysis of Material Removal Rate in Drilling of 41Cr4 by a Tagu...IJERA Editor
In manufacturing industries the largest amount of money spent on drills. Therefore, from the viewpoint of cost and productivity, modeling and optimization of drilling processes parameter are extremely important for the manufacturing industry this paper presents a detailed model for drilling process parameter. The detailed structure includes in the model, are three parameters such as such as Spindle Speed, feed and depth of cut on material removal rate in drilling of 41 Cr 4 material using HSS spiral drill .We an effect of this three parameters on material removal rate .The detailed mathematical model is simulated by Minitab14 and simulation results fit experiment data very well In this investigation, an effective approach based on Taguchi method, analysis of variance (ANOVA), multivariable linear regression (MVLR), has been developed to determine the optimum conditions leading to higher MRR. Experiments were conducted by varying Spindle Speed, feed and depth of cut using L9 orthogonal array of Taguchi method. The present work aims at optimizing process parameters to achieve high MMR. Experimental results from the orthogonal array were used as the training data for the MVLR model to map the relationship between process parameters and MMR the experiment was conducted on drilling machine. From the investigation It concludes that speed is most influencing parameter followed by feed and depth of cut on MRR
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Vibration control of newly designed Tool and Tool-Holder for internal treadi...IJMER
Machining processes are manufacturing methods for ensuring processing quality, usually within
relatively short periods and at low cost. Several machining parameters, such as cutting speed, feed rate, work
piece material, and cutting tool geometry have significant effects on the process quality. Many researchers have
studied the impact of these factors. The cutting tool overhang affects the surface quality, especially during the
internal turning process, but this has not been reviewed much [9].
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.
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.
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
“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.
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
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.
Vibration control of newly designed Tool and Tool-Holder for internal treadi...IJMER
Machining processes are manufacturing methods for ensuring processing quality, usually within
relatively short periods and at low cost. Several machining parameters, such as cutting speed, feed rate, work
piece material, and cutting tool geometry have significant effects on the process quality. Many researchers have
studied the impact of these factors. The cutting tool overhang affects the surface quality, especially during the
internal turning process, but this has not been reviewed much [9].
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.
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.
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
“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.
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
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.
Characteristics analysis of silicon carbide based 1-D Photonic crystal with 2...IOSR Journals
Abstract: Silicon carbide based 1-D Photonic crystals with 2 layered unit cell are analyzed in this paper. The transmission characteristics of photonic crystals are computed by transfer matrix method and performance of such photonic crystals of different material combinations are also compared, and after comparison some one able to know the characteristics such as pass band width, stop band width, centre band gap of a light wave of a particular wave length traveling through this 2 layered unit cell photonic crystal in nano meter range where one layer of this unit cell must be made of semiconductor material named silicon carbide (SiC). Key word: 1-D photonic crystal, transmission coefficient, light wave
Evaluation of titanium in hydrochloric acid solutions containing corrosion in...IOSR Journals
Currently, the use of titanium alloys components and coating (clad) in petroleum subsea production systems continues to increase. Titanium alloys are lightweight, very flexible; have greater mechanical resistance relationship showing excellent resistance to corrosion and fatigue in ambient seawater and marine environments. The rate of corrosion of titanium alloys are low for hydrochloric acid (3%), however, in the acidification operations from petroleum well is necessary the use of corrosion inhibitors, because the concentration of hydrochloric acid varies from 10 to 28%. A corrosion inhibitor for acidification can be defined as a substance or mixture of substances which are added to the corrosive medium aim inhibit or minimize the action of the corrosive medium. This paper presents the laboratory tests made with titanium coupons subjected to hydrochloric acid solution 10% (weight %), in temperatures of 50° C and 70° C, and additions of phenylamine (aniline), thiocarbamide and β-naphthol as corrosion inhibitors. The results showed that the corrosion protection inhibitors exerted by varies from 50 to 80% depending on the concentration of inhibitors and temperatures used in the tests.
Static and Dynamic Behavior of Reinforced Concrete Framed Building: A Compara...IOSR Journals
Reinforced concrete frame buildings are most common type of construction in urban India, which is subjected to several types of forces during their life time such as static forces and dynamic forces due to wind and earthquakes. The static loads are constant with time, while dynamic loads are time varying, causing considerable inertia effects .It depends mainly on location of building, importance of its use and size of the building. Its consideration in analysis makes the solution more complicated and time consuming and its negligence may sometimes becomes the cause of disaster during earthquake.
So it is growing interest in the process of designing civil engineering structures capable to withstand dynamic loads . The behavior of building under dynamic forces depends upon its mass and stiffness properties, whereas the static behavior is solely dependent upon the stiffness characteristics.
Taguchi Method for Optimization of Cutting Parameters in Turning OperationsIDES Editor
Surface roughness an indicator of surface quality is
one of the prime customer requirements for machined parts.
For efficient use of machine tools, optimum cutting
parameters are required. The turning process parameter
optimization is highly complex and time consuming. In this
paper taguchi parameter optimization methodology is applied
to optimize cutting parameters in turning. The turning
parameters evaluated are, cutting velocity, feed rate, depth of
cut, and nose radius of tool and hardness of the material each
at two levels. The results of analysis show that feed rate,
cutting velocity and nose radius have present significant
contribution on the surface roughness and depth of cut and
hardness of material have less significant contribution on the
surface roughness.
Optimization of Turning Parameters Using Taguchi MethodIJMER
Abstract: Today in manufacturing and metal industries customer satisfaction is very important to
make own place in competitive market and also to make mirror image with faith in the heart of
customer, because customer gives preference to buy good quality product. In the metal and
manufacturing industries for the product low surface roughness is very important. Lowest surface
roughness assures not only good quality but also reduces manufacturing cost. In this paper the main
objective is to study effect of cutting speed, feed rate and depth of cut on surface roughness of mild steel
in turning operation and as a result of that the combination of optimum level of factors was obtained to
get lowest surface roughness. Experiments have been conducted using Taguchi’s experimental design
technique. An orthogonal array, signal to noise ratio, and analysis of variance are employed to
investigate cutting characteristics of mild steel using high speed steel. Experimental results show that
among the cutting parameter cutting speed is the most significant machining parameter for surface
roughness followed by feed rate and depth of cut.
Full factorial method for optimization of process parameters for surface roug...Editor IJMTER
Quality and productivity play significant role in today’s manufacturing market.In
machining operations, achieving desired surface quality features of the machined product, is really a
challenging job on cnc machine. Because, these quality features are highly correlated and are
expected to be influenced directly or indirectly by the direct effect of process parameters. There are a
number of parameters like cutting speed, feed and depth of cut etc. which must be given
consideration during the machining of SS 316L. The prediction of optimal machining conditions for
good surface roughness and material removal rate plays a very important role in process planning.
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.
optimization of process parameters for cnc turning using taguchi methods for ...INFOGAIN PUBLICATION
Coated and uncoated tool inserts offers certain degrees of control on the desired rate of tool wear and surface roughness to an extent. This work pursues the quest for realizing the optimal values for the significant process parameters that bears an influence on the response parameters. Experiments were conducted on the samples of EN 24 alloy steel material with the help of PVD coated TiAlN insert and uncoated carbide insert. The experimental runs carried out with proper variation in the levels. Levels are selected with the help of manufacturing catalogue and by pilot experimentation and results are recorded for further analysis. For this study, 9 runs designed using L9 orthogonal array of Taguchi Design of Experiment. Surface roughness was measured using a Mitutoyo surface tester at test lab and material removal rate is calculated by mathematical equation. The data was compiled into Minitab 17 software for analysis. The relationship between the machining parameters and the response variables were analyzed using the Taguchi Method. Optimization of process parameters is carried out by Grey Relational Analysis method (GRA). GRA method is a powerful and most versatile tool which can manipulate the input data as per requirement and comes with results that can be used to have best multi-objective in respective concerns
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
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Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
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• Remote control system for accessing CCR and allied system over serial or TCP.
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Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
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• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
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Process Parametric Optimization of CNC Vertical Milling Machine Using Taguchi Technique in Varying Condition
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 6, Issue 5 (May. - Jun. 2013), PP 34-42
www.iosrjournals.org
www.iosrjournals.org 34 | Page
Process Parametric Optimization of CNC Vertical Milling
Machine Using Taguchi Technique in Varying Condition
Piyush pandey*, Prabhat kumar sinha, Vijay kumar, Manas tiwari
Mechanical Engineering Department, Sam Higginbottom Institute of Agriculture Technology and sciences,
Allahabad
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.
I. Introduction
The Taguchi‟s method for optimization has been used as the principle of the process. It helps in the
selection of experiment process, selection of orthogonal array, process of reducing variation, tolerance design,
analysis and confirmation test [1]. The Taguchi‟s design is an efficient method which can optimize given
various control and noise factor using fewer resources and factorial design. This study includes feed rate spindle
speed and depth of cut as a control factor and as a noise factors were the operating chamber temperature and the
usage the different tool insert in the same specification which introduce tool condition and dimensional
variability [2]. The optimization of feed rate is essential in terms of providing high precision and efficient
machining. The surface roughness is very sensitive to the feed rate. The effect of insert run out error and the
variation of feed rate on the surface roughness and the dimensional accuracy in milling operation using a surface
roughness model. The estimated surface roughness value, the optimal feed rate that give a maximum material
removal rate under given surface roughness constraint could be selected by bisectional method [3]. By
validating the result and performance of Taguchi Method a group of researchers study the role of parameter
design and Taguchi‟s methodology for implementing it. It include the importance of variation reduction, the use
of noise factors, the role of interaction, selection of quality characteristic, signal to noise ratios, experimental
strategy dynamic systems, and applications [4]. A design of experiment (DOE) has been implemented to select
manufacturing process parameter for quality of the work piece. There use of two different parameter Dependent
and independent has been considered for optimization. The Dependent parameters were material removal rate
and surface roughness. The independent parameters used were Rake Angle, Helix Angle, Cutting Speed and
Depth of cut. The experiment was conducted in various steps by selection of quality characteristics, noise
factors, control factors, orthogonal array and then conducting and confirming experiment. The L18 was used
since it has seven three level column and one two level column [5]. The deviation of quality characteristics from
the target causes loss. The uncontrollable factor which causes the characteristics to deviate from the target
values are called noise factors. Signal-to-noise (S/N) ratio was used as a measurable value instead of standard
deviation because as the mean decreases, the standard deviation decreases and vice versa [6]. To increase the
process efficiency, flexibility and robustness, Taguchi dynamic approach couple with a proposed ideal function
model for high dimensional quality. To increase the robustness of the manufacturing process, the experiment
was design to consider the effect of manufacturing noise and to compound them as to extreme condition for
assessing the quality characteristics of the work piece [7]. To maintain stable machining much attention was
given to the formation of desired chip and chip control to facilitate its easy removal, Chip formation and
breaking aspect perform significant role in machining. Problem with surface finish, work piece accuracy and
tool life can be caused by minor changes in the chip formation process [8]. Quality improvement program in
milling industry central composite designs and classical fractional factorial design were used in conjunction
with the philosophy given by Taguchi [9]. ANOVA or analysis of variance used for analyzing and interpreting
the experimental results, It include the F-Test and percentage contribution method which helps in the statistical
test of comparison of result. ANOVA was applied to the orthogonal array types of designed experiment [1]. In
end milling operation to assure product quality and increased production rate Artificial Neural Networks (ANN)
model was developed. In this system the accelerometer and a proximity sensor were used during cutting to
collect the vibration and rotation data respectively. Using Spindle Speed, Feed rate and Depth of cut which has a
accuracy rate of (96-99%) [10]. The Orthogonal array which was the systematic tabulated arrangement made
from the combination of factor and levels helps the result to interpret properly. The uses of MINITAB made it
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possible to analyze and simulate the result in short span of time, MINITAB assist in analyze the work piece
optimization‟s result.
II. Experimental Setup
There are 3 Solid Carbide Tools which are to be placed on to the CNC Milling machine as
per the signified table of trials
Tool Specification
Rake angle
Rake angle is used for better surface finish. The formal definition of a rake angle is "the angle between the
leading edge of a cutting tool and a perpendicular to the surface being cut".
Rake Angle Representation
Rake angles come in two varieties, positive and negative
If the leading edge of the blade is ahead of
the perpendicular, the angle is, by
definition, negative.
Examples of negative rake instruments are
reamers, K-files, K-Flex files, diamond
burs, most NiTi-files, and burnishing burs
or regular burs run backwards.
Tool Diameter (mm) Helix Angle (°) Rake Angle (°)
8 35 4
10 30 7
12 45 10
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III. Rake Angle Importance
Work piece Material
We are using mild steel as a work piece. In this study mild steel having composition (0.16–0.29%
carbon is used. The density of mild steel is approximately 7.85 g/cm3, Young's modulus is 210,000 MPa
(30,000,000 psi). Mild steel work piece having dimension L, B, W in mm. (respectively 39.4, 35, and 11.7) is
used. Mild steel has a relatively low tensile strength, but it is cheap and malleable; surface hardness can be
increased through carburizing.
Control Parameters
Coolant:A coolant is a fluid which flows through a device to prevent its overheating,
transferring the heat produced by the device to other devices that use or dissipate it.
Cutting Oil arrangement have to be made in the machine. Cutting oil is water soluble with refractive index of
1.534 (Coolage SL non EP-Type). When a 10 ml of oil is mixed with 50ml water a change of 0.1 comes in the
refractive index.
e.g. for a cutting speed of 100 ft/min (a plain HSS steel cutter on mild steel) and diameter of 10 inches (the
cutter or the work piece)
Following Steps Have to Be Undertaken-
There are 3 Solid Carbide Tools which are to be placed on to the CNC Milling machine as per the signified table
of trials.
Tool Diameter (mm) Helix Angle(°) Rake Angle (°)
8 35 4
10 30 7
12 45 10
Tool Specification
Cutting Oil arrangement has to be made in the machine. Cutting oil is water soluble with refractive index of
1.534(Cool age SL non EP-Type).When a 10 ml of oil is mixed with 50ml water a change of 0.1 comes in the
refractive index.
Defined levels are being made-
Defined Levels Of factors
Below we have taken the response table of the material removal rate(MRR) and the surface roughness(SR).
Now out of 8 factors we have taken the factors from A to E because one of them which is A(coolant) is having
Controllable Factors Level 1 Level 2 Level 3
Cutting Speed (rpm) 800 900 1000
Depth of cut (mm) 0.6 0.7 0.8
Feed Rate (mm/min) 100 110 150
Tool Diameter (mm) 8 10 12
Coolant C1 C2 C3
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just 2 levels and as prescribed in the Minitab software the minimum factor table which could accommodate 1
factor of 2 levels is L18 TABLE as in Taguchi designs.
The S/N ratio can be calculated as a logarithmic transformation of the loss function as shown below.
S/N ratio for MRR =
S/N ratio for SR =
The experimental results (or data) are further transformed into a signal-to-noise (S/N) ratio. There are several
S/N ratios available depending on the type of characteristic; lower is better (LB), Normal is best (NB) and
higher is better (HB)
The characteristic that higher value represents better machining performance, such as MRR, is called
„Higher is better (HB)‟. The characteristic that lower value represents better machining performance such as
„surface roughness, is called „Lower is better (LB)‟. Therefore, “HB” for MRR and “LB” for SF were selected
for obtaining optimum machining performance characteristics
Experimental Values
MRR (SECTION)
1. Average effect response table for raw data (MRR)
LEVELS A B C D
1 0.097 0.136 0.098 0.196
2 0.198 0.042 0.205 0.157
3 0.149 0.271 0.141 0.123
MAX-MIN 0.101 0.229 0.107 0.073
RANK 3 1 2 4
n
i MRRyn 1
2
11
log10
n
i
SRy
n 1
21
log10
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Average Effect Response Table for MRR
2. Average effect response table for S/N ratios (MRR)
LEVELS A B C D
1 -26.82 -20.84 -24.60 -18.90
2 -16.70 -27.24 -9.95 -20.89
3 -20.70 -12.43 -20.90 -24.40
MAX-MIN 10.12 14.81 14.65 5.50
RANK 3 1 2 4
Average Effect Response Table for S/N Ratios (MRR)
SR (SECTION)
1. Next table shows the response values of the surface roughness (SR) column.
S.NO Response values Average
Value (µm)
S/N ratio
1 2 3
1
1.13 1.02 0.77
0.97 0.26
2 0.93 0.86 1.53 1.10 -0.82
3 2.12 1.12 1.43 1.55 -3.80
4 2.01 1.1 1.05 1.38 -2.79
5 1.5 2.09 2.06 1.88 -5.48
6 1.01 1.1 0.97 1.02 -0.17
7 1.96 1.42 1.48 1.62 -4.19
8 1.39 0.98 1.91 1.42 -3.04
9 2.22 2.42 1.57 2.07 -6.31
10 1.35 1.24 0.94 1.17 -1.36
11 0.92 0.82 1.01 0.91 0.81
12 0.94 0.98 2.01 1.31 -2.34
13 1.3 1.69 1.57 1.52 -3.63
14 1.14 1.58 1.35 1.35 -2.60
15 1.43 2.7 1.25 1.79 -5.05
16 3.05 1.44 1.53 2.00 -6.02
17 1.87 2.81 2.31 2.33 -7.34
18 1.98 2.69 3.09 2.58 -8.23
Response Values for SR
1. Average effect response table for raw data (SR)
LEVELS A B C D
1 1.16 1.44 1.24 1.40
2 1.49 1.49 1.66 1.50
3 2.00 1.72 1.41 1.75
MAX-MIN 0.84 0.28 0.42 0.35
RANK 1 4 2 3
Average Effect Response Table for SR
2. Average effect response table for S/N ratios (SR)
LEVELS A B C D
1 -1.20 -2.95 -3.40 -2.62
2 -3.28 -3.07 -4.11 -3.34
3 -5.58 -4.31 -2.28 -4.23
MAX-MIN 4.38 1.36 1.83 1.61
RANK 1 4 2 3
Average Effect Response Table for S/N Ratios (SR)
4.2. Plotting methods
The plotting of experimental results should be done in as many ways as are meaningful:
1. By levels of influential factors
2. By levels of combinations of influential factors to assess interaction possibilities
3. By order of actual test
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The column effects, and later ANOVA, indicate what to plot. To plot the effect of influential factors, the
average result for each level must be calculated first. The sum of the data associated with each level in the OA
column divided by the number of tests (data points) for that level will provide the appropriate averages. This
applies to factors two or more levels.
Plot may be made with equal increments between levels on the horizontal axes of the graphs to show
the relative strengths of the factors. The factors strength is directly proportional to the slope of the graph. An
actual scale may also be used for the horizontal axes of continuous factors to graphically interpolate or
extrapolate for prediction of other levels. With the actual scale, however the relative comparison of slopes is not
meaningful.
The analysis was made using the popular software specifically used for design of experiment
applications known as MINITAB 14. Before any attempt is made to use this simple model as a predictor for the
measures of performance, the possible of interactions between the factors must be considered. Thus factorial
design incorporates a simple means of testing for the presence of the interaction effects.
MeanofSR
0.80.70.6
2.0
1.8
1.6
1.4
1.2
1000900800
120110100
2.0
1.8
1.6
1.4
1.2
12108
DEPTH OF CUT CUTTING SPEED
FEED RATE TOOL DIAMETER
Main Effects Plot (data means) for SR
Main Effects Plot For SR
DEPTH OF CUT
Mean
0.80.70.6
2.2
2.0
1.8
1.6
1.4
1.2
1.0
FEED
120
RATE
100
110
Interaction Plot (data means) for SR
Interaction Plot For SR
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DEPTH OF CUT (A)
Mean
0.80.70.6
2.2
2.0
1.8
1.6
1.4
1.2
1.0
TOOL
12
DIAMETER
8
10
Interaction Plot (data means) for SR
Interaction Plot For SR
MeanofMRR
0.80.70.6
0.25
0.20
0.15
0.10
0.05
1000900800
120110100
0.25
0.20
0.15
0.10
0.05
12108
DEPTH OF CUT CUTTING SPEED
FEED RATE TOOL DIAMETER
Main Effects Plot (data means) for MRR
Main Effect Plot For MRR
DEPTH OF CUT
Mean
0.80.70.6
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
CUTTING
1000
SPEED
800
900
Interaction Plot (data means) for MRR
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DEPTH OF CUT
Mean
0.80.70.6
0.30
0.25
0.20
0.15
0.10
0.05
0.00
FEED
120
RATE
100
110
Interaction Plot (data means) for MRR
Interaction Plot for MRR
DEPTH OF CUT
Mean
0.80.70.6
0.30
0.25
0.20
0.15
0.10
0.05
0.00
TOOL
12
DIAMETER
8
10
Interaction Plot (data means) for MRR
Interaction Plot for MRR
IV. Conclusion
This experimental study described the development of process in terms of MRR and Surface finish,
using Taguchi‟s L18 orthogonal array. It was fond that the S/N ratio with Taguchi‟s parameter design is a simple,
systematic, reliable and more efficient tool for optimizing multiple performance characteristics of CNC milling
process parameters. Factors like depth of cut, feed rate, cutting speed, tool diameter and there interactions have
been found to play a significant role in rough cutting operations for maximization of MRR and surface finish.
Interestingly, the optimal levels of the selected control factors for both objectives differ widely. In order to
optimize for both objectives, mathematical models are developed using the non-linear regression method.
Analysis of variance (ANOVA) is also employed to identify the level of importance of the machining
parameters on the multiple performance characteristics namely material removal rate and surface roughness.
Assumptions of ANOVA are tested using residual analysis. After careful testing, none of the assumptions was
violated. ANOVA results showed that CUTTING SPEED AND FEED RATE are the powerful control
parameters for the material removal rate and DEPTH OF CUT AND FEED RATE calculated as powerful
factors for controlling the surface finish of Mild Steel. In case of MRR analysis, percent contribution for
residual error is 4.166% is very small (less than 15%), it is proved that no important factors were omitted during
the experiment and there is no opportunity for the further improvement while surface roughness analysis result
interprets that percent contribution of residual error is -5% is small (less than 50%), it is acceptable that no
important factors were omitted during the experiment but there may be very small opportunity for the further
improvement.
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