The document discusses optimizing parameters for boring operations. It aims to achieve a surface finish less than 2 micrometers and bore diameter of 70 mm. Experiments were conducted varying speed, feed rate, and depth of cut. Analysis of variance and response surface methodology were used to analyze results. The optimal parameters were found to be a speed of 1000 rpm and feed rate of 100 mm/min, predicted to achieve a surface roughness of 1.843 micrometers and bore diameter of 70.005 mm. Validation experiments confirmed the predicted results were within acceptable ranges.
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 Cylindrical Grinding Process Parameters on C40E Steel Using T...IJERA Editor
Surface finish and dimensional accuracy play a vital role in the today’s engineering industry. There are several methods used to achieve good surface finish like burnishing, honing and lapping, and grinding. Grinding is one of these ways that improves the surface finish and dimensional accuracy simultaneously. C40E steel has good industrial application in manufacturing of shafts, axles, spindles, studs, etc. In the present work the cylindrical grinding of C40E steel is done for the optimization of grinding process parameters. During this experimental work input process parameters i.e. speed, feed, depth of cut is optimized using Taguchi L9 orthogonal array. Analysis of variance (ANOVA) concluded that surface roughness is minimum at the 210 rpm, 0.11mm/rev feed, and 0.04mm depth of penetration.
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.
Optimization of Cylindrical Grinding Process Parameters on C40E Steel Using T...IJERA Editor
Surface finish and dimensional accuracy play a vital role in the today’s engineering industry. There are several methods used to achieve good surface finish like burnishing, honing and lapping, and grinding. Grinding is one of these ways that improves the surface finish and dimensional accuracy simultaneously. C40E steel has good industrial application in manufacturing of shafts, axles, spindles, studs, etc. In the present work the cylindrical grinding of C40E steel is done for the optimization of grinding process parameters. During this experimental work input process parameters i.e. speed, feed, depth of cut is optimized using Taguchi L9 orthogonal array. Analysis of variance (ANOVA) concluded that surface roughness is minimum at the 210 rpm, 0.11mm/rev feed, and 0.04mm depth of penetration.
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.
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
Experimental Analysis & Optimization of Cylindirical Grinding Process Paramet...IJERA Editor
As per the modern Industrial requirements, higher surface finish mechanical components and mating parts with close limits and tolerances, is one of the most important requirement. Abrasive machining processes are generally the last operations performed on manufactured products for higher surface finishing and for fine or small scale material removal. Higher surface finish and high rate of removal can be obtained if a large number of grains act together. This is accomplished by using bonded abrasives as in grinding wheel or by modern machining processes. In the present study, Taguchi method or Design of experiments has been used to optimize the effect of cylindrical grinding parameters such as wheel speed (rpm), work speed, feed (mm/min.), depth of cut and cutting fluid on the surface roughness of EN15AM steel. Ground surface roughness measurements were carried out by Talysurf surface roughness tester. EN15AM steel has several industrial applications in manufacturing of engine shafts, connecting rods, spindles, studs, bolt, screws etc. The results indicated that grinding wheel speed, work piece speed, table feed rate and depth of cut were the significant factors for the surface roughness and material removal rate. Surface roughness is minimum at 2000 r.p.m. of grinding wheel speed , work piece speed 80 rpm, feed rate 275 mm/min. and 0.06 mm depth of cut.
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].
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.
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.
“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.
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
Experimental Analysis & Optimization of Cylindirical Grinding Process Paramet...IJERA Editor
As per the modern Industrial requirements, higher surface finish mechanical components and mating parts with close limits and tolerances, is one of the most important requirement. Abrasive machining processes are generally the last operations performed on manufactured products for higher surface finishing and for fine or small scale material removal. Higher surface finish and high rate of removal can be obtained if a large number of grains act together. This is accomplished by using bonded abrasives as in grinding wheel or by modern machining processes. In the present study, Taguchi method or Design of experiments has been used to optimize the effect of cylindrical grinding parameters such as wheel speed (rpm), work speed, feed (mm/min.), depth of cut and cutting fluid on the surface roughness of EN15AM steel. Ground surface roughness measurements were carried out by Talysurf surface roughness tester. EN15AM steel has several industrial applications in manufacturing of engine shafts, connecting rods, spindles, studs, bolt, screws etc. The results indicated that grinding wheel speed, work piece speed, table feed rate and depth of cut were the significant factors for the surface roughness and material removal rate. Surface roughness is minimum at 2000 r.p.m. of grinding wheel speed , work piece speed 80 rpm, feed rate 275 mm/min. and 0.06 mm depth of cut.
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].
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.
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.
Parametric Analysis and Optimization of Turning Operation by Using Taguchi Ap...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Optimization and Process Parameters of CNC End Milling For Aluminum Alloy 6082 ijiert bestjournal
he study aims at optimization of cutting parameters in CNC End milling of Aluminum Alloy 6082. CNC milling is a versatile and most widely used operation in present industry. Sur face quality affects fatigue life of components and influences various mechanical properties and has receive d serious attention for many years. In this work,experiments are conducted to analyze the surface roughnes s using various machining parameters such as Spindle speed,feed rate and depth of cut . The data was used to devel op surface roughness prediction models as a function of the machining parameters. In the present study,CNC machining centre with Cemented carbide end mill of 25mm diameter and 30� helix angle was used. A multiple regression analysis is used to correlate the relationship between the machining parameters and surface roughnes s. RS methodology was selected to optimize the surface roughness resulting minimum values of surface roughness and their r espective optimal conditions. Key words:CNC end milling,Aluminum alloy 6082,Taguchi,ANOVA
An Experimental Study of the Effect of Control Parameters on the Surface Roug...IOSR Journals
Surface quality is one of the specified manufacturer requirements for machined parts. There are
many parameters that have an effect on surface roughness, but those are difficult to quantify adequately in
finish turning operation such as cutting speed, feed rate, and depth of cut are known to have a large impact on
surface quality. The Taguchi method is one of the statistical tools, to investigate influence of surface roughness
by cutting parameters such as cutting speed, feed and depth of cut. The Taguchi process helps to select or to
determine the optimum cutting conditions for turning process. Many researchers developed many mathematical
models to optimize the cutting parameters to get lowest surface roughness by turning process. The Taguchi
design of experiments was used for optimizing quality and performance output of manufacturing processes.
Evaluation of cutting and geometric parameter of single point cutting tool fo...AM Publications
Evaluation of cutting and geometric parameter is one of the most important elements for quality and
productivity which play significant role in today’s manufacturing market. From customers’ viewpoint quality is very
important because the extent of quality of the procured item (or product) influences the degree of satisfaction of the
consumers during usage of the procured goods. Therefore, every manufacturing or production unit should concern
about the quality of the product. Apart from quality, there exists another criterion, called productivity which is directly
related to the profit level and also goodwill of the organization. Turning is the first most common method for cutting
and especially for the finishing machined parts. In a turning operation, it is important task to select cutting and
geometric parameters for achieving high cutting performance. In this paper,particle swarm optimization technique is
used efficiently to optimize cuttingand geometric parameter like cutting speed,feed,depth of cut and rake angle due to
complexity of cutting and geometric parameter optimization. The overall objective of this study is to predict the tool
wear evolution and tool life in orthogonal cutting
Implementation of Response Surface Methodology for Analysis of Plain Turning ...IJERD Editor
This paper investigates the effect of cutting speed, feed rate and depth of cut on the surface roughness of mild steel material with turning process. The response surface methodology (RSM) was employed in the experiment. The investigated turning parameters were cutting speed (CS) (1150, 850m/min), feed rate (FR) (1 and 0.5 mm/rev) and depth of cut (DOC) (1.0 and 0.5 mm) and no. of cuts(NOC) (2 and 1). The results showed that the interaction between the feed rate and depth of cut, was the primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The optimum condition required for minimum surface roughness(SR) include cutting speed of 1150 m/min, feed rate of 1 mm/rev, axial depth of cut of 0.5 mm and no. of cut 1. With this optimum condition, a surface roughness of 0.280μm was obtained. The methodology for above experimentation is presented in this paper along with results and interpretation.
Optimization of cutting strategies for forging die manufacturing on cnc milli...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Optimization of Process Parameters of Tool Wear in Turning OperationIJERA Editor
Tool Wear is of great apprehension in machining industries since itaffects the surface quality, dimensional accuracy and production cost of the materials / components. In the present study twenty seven experiments were conducted as per 3 parameter 3 level full factorial design for turning operation of a mild steel specimen with high speed steel (HSS) cutting tool. An experimental investigation on cutting tool wear and a mathematical model for tool wear estimation is reported in this paper where the model was simulated by computer programming and it has been found that this model is capable of estimating the wear rate of cutting tool and it provides an optimum set of process parameters for minimum tool wear.
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Optimization of Process Parameters of Tool Wear in Turning Operation
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1. Optimization of Boring Parameters
V Sai Nitish
Amit Shiva Kumar
Chiranjeevi Chennu
UNDER THE GUIDANCE OF
Dr. BADARI NARAYANA KANTHETI
2. BUCKET ORIELS SPECIFICATIONS AND IMPORTANCE
• Bucket oriels are welded supports
which act as a connection between the
arm of the earth moving machine and
the bucket which carries the load.
• Bucket oriels bear huge amounts of
load, which makes it one of the most
crucial components of the earth moving
machine.
• Minute changes in diameter and surface
finish might result in excess friction,
vibrations, wear and tear.
3. BUCKET ORIELS ARE ATTACHED AT THE BACK OF THE
BUCKET BY METAL INERT GAS WELDING
4. Objectives
• To obtain surface finish of the bore to be less
than 2 micro meters
• To achieve a dimensional conformance of
diameter of the hole of 70 mm.
• To find the parameters influencing the boring
operation.
5. • In many manufacturing organizations experiments are performed to increase the
understanding and knowledge of various manufacturing processes. For continuous
improvement in product/process quality, it is fundamental to understand the process
behaviour, the amount of variability and its impact on product / processes. The present work
being optimization of boring parameters, the literature related to this subject area is briefly
covered.
• The study of cutting forces of boring process is important for selecting appropriate proper
cutting conditions. A predictive cutting force model has been developed and influence of
cutting parameters on force components has been studied by Alwarsamy et al., 2011. In their
work a new analytical cutting force model obtain from the information related to the work
piece and tool signature for a boring operation.
• The optimization work done by Gaurav Vohra et al 2013, of the boring parameters for a CNC
turning centre such as speed, feed rate and depth of cut on aluminium to achieve the highest
possible Material removal rate and at minimum surface roughness by using the Taguchi
method. In their work it was found that the depths of cut and cutting speed to be the most
influencing parameter, followed by the feed rate.
• Kanase Sandip et al 2013 proposed an innovative method to reduce tool chatter and enhance
surface finish in boring operation. Their results showed the use of passive damping technique
has vast potential in the reduction of tool chatter.
Literature Review
6. • The optimum conditions to obtain better damping in boring process for chatter reduction
is identified for various cutting conditions by Prasanna venkadesan et al, 2015.
• Lee and Tarng 2001 used computer vision techniques to inspect surface roughness of a
work piece under a variation of turning operations and developed a relationship between
the feature of the surface image and the actual surface roughness under a variation of
turning operations for predicting surface roughness with reasonable accuracy.
• Davim 2003 studied the influence of cutting condition and cutting time on turning metal
matrix composites and used Taguchi method and (ANOVA) for the analyses. They
obtained a correlation between cutting velocity, feed and cutting time with tools wear, the
power required and the surface roughness of the job.
• Balamuruga and Sugumaran 2013 developed a Gaussian process regression model to
predict the surface roughness based on tool post vibration and cutting conditions. In their
work the data obtained from their experiments and collected from previous studies, have
been used to validate the model.
• Badadhe et. al., 2012, optimized combination of cutting parameters to achieve the
minimum value of surface roughness. In their work, the experimentation was carried out
with the help of lathe machine, with three machining parameters such as spindle speed,
feed and depth of cut taken as control factors. During the machining, the boring bar is
subjected vibrations in different directions; the impact of these vibrations on the surface
roughness which is an important quality parameter of the bored surface was estimated.
7. Analysis and Optimization of Parameters Affecting Surface
Roughness in a Boring Process using DOE
• Manufacturing industries are continuously demanding for
higher production rate and improved machinability as
quality and productivity play significant role in the
manufacturing environment.
• Higher production rate can be achieved at high cutting
speed, feed and depth of cut
• The quality of the final product is limited by capability
of tooling and surface finish.
• Over all performance of the operation depends on the
selection of right cutting parameters and is generally a
compromise between several variables.
8. • Depth of cut at 1 mm (1 level)
• Feed rate is varied at 40, 80, 120, 160, 200 and 240 in mm/min ( 6
levels)
• Speed of cut 800, 900 and 1200 rpm ( 3 levels)
• The number of possible iteration using a full factorial will be 6*3 =
18. In the present program, as iterations required are small all
possible combinations are used.
• The responses measured for each iteration are:
a) surface roughness (RA) and b) hole diameter.
• To analyse the data , a statistical tool DESIGN OF
EXPERIMENTS (Mini TAB Ver 16) is used to arrive at proper
improvement plan of the manufacturing process parameters. The
experimentation plan is designed using design of experiment
(DOE).
• It is possible to determine these parameters using ANOVA,
Response Surface Methodologies including optimization.
THE PLAN
9. A sample data of inputs and response parameters is shown below
Sl. No Factor 1
Depth of
cut , mm
Factor 2
Feed rate
mm/min
Factor 3
Speed of cut
RPM
Surface
finish RA
µ m
Diameter of
hole, mm
1 1 40 800 2.320 70.025
2 1 40 900 2.306 70.010
3 1 80 900 1.618 70.015
4 1 80 1200 1.968 70.000
. . . . . .
. . . . . .
18 1 120 1200 2.306 69.999
10. EQUIPMENT USED FOR BORING
Tool holder
TOOLS
JIGS & FIXTURES
MX-5 MACHINE
CONTROL
UNIT
11. EQUIPMENT USED FOR BORING
TOOL HOLDER
AUTOMATIC TOOL CHANGER
CONTROL UNIT
12. Calibration of surface tester
Surface Roughness
Tester LC : 1 nm
MEASURING INSTRUMENT USED
A Mitutoyo SJ-201P
apparatus was used. For
each specimen three
readings were taken at
approximately 1200 angles
apart and the average value
was used for the
subsequent analysis.
BORE GAUGE
LC: 1 MICRON
14. DOE ANALYSIS IS DONE USING MINITAB VER
16.0
Steps involved in statistical analysis:
1. Statistical analysis -> DOE -> Factorials -Table of influencing factors will be
generated
2. Statistical analysis -> ANOVA -> Balanced ANOVA
-> Main Effect plot and Interaction Effect Plot
3. Statistical analysis -> DOE -> Response Surface
-> Surface and Contour plots
4. Statistical analysis -> DOE -> Selection of optimal design
-> Response optimization
5. Model validation -> Use optimal factors, repeat the boring operation and measure
the respective hole diameter and surface roughness
15. Full Factorial Design
• Full factorial designs include all possible combinations of every
level of every factor.
• Full factorial designs can require a lot of trials, which can take a lot
of time and cost.
• Requires at least one observation for every combination of factors
and levels.
• Allows for the measurement of all possible interactions.
• Ex1. a design of 4 factors with 3 levels each would be: 3 x 3 x 3 x 3
= 3^4 = 81 observations.
• Ex 2. 4 factors (A=3, B = 2, C=5, D= 4 levels). 3 x 2 x 5 x 4 = 120
observations.
34. Conclusion
In this project, we have selected the combination of optimum cutting
parameters which will result in better surface finish and diameter of the
bore. Three parameters viz. spindle speed, feed and depth of cut of the MX-5
machine were taken as control factors. The cutting trials were performed as
per full factorial method to deal with the response from multi-variables.
Carbon steel was used as a job material which was cut by using
carbide tool. DOE and Analysis of Variance (ANOVA) was carried out to
find the significant factors and their individual contribution in the response
function i.e. surface roughness and diameter accuracy of the bore.
After the validation, we have determined that the most optimal values for
our given machining conditions of speed, feed rate and depth of cut are 1000
rpm, 100 mm/min and 1 mm respectively.
35. Future scope of study
The selection of optimal cutting parameters to obtain specified surface roughness is very
difficult for any work piece material. In the current scenario, desired surface roughness can
be achieved by trial and error method. But it is time consuming and material is
unnecessarily wasted for this purpose. So, there is a need to find a technique that can
predict cutting parameters for the desired surface roughness.
Following are the recommendations for continuing the research work in this area.
1. Improved method for surface roughness measurement with higher sampling rate can be
helpful to locate the principal frequencies of boring vibrations in the surface roughness
spectrum.
2. In depth study of dynamic cutting force can be carried out regards to frequency content.
3. An intelligent machine controller can be developed as per the technique proposed in the
present work for automatic adjustment of the machining parameters.
4. Detail analysis of time delays in control action and stability analysis of the control
system can be carried out.
36. • S. Vetrivel et al., “Theoretical Cutting Force Prediction and Analysis of Boring Process Using
Mathcad”, World Applied Sciences Journal 12 (10): 1814-1818, 2011
• Gaurav Vohra et al., “Analysis and Optimization of Boring Process Parameters by Using
Taguchi Method”, International Journal of Computer Science and Communication
Engineering IJCSCE Special issue on “Recent Advances in Engineering & Technology”
NCRAET-2013.
• Kanase Sandip et. al., “Improvement Of Ra Value Of Boring Operation Using Passive
Damper”, The International Journal Of Engineering And Science (IJES), Vol. 2, Iss 7, P 103-
108, 2013.
• V. Prasanna Venkadesan, et al., “Chatter Suppression in Boring Process Using Passive
Damper”, International Journal of Mechanical, Aerospace, Industrial, Mechatronic and
Manufacturing Engineering Vol: 9, No: 11, 2015.
• Yang WH, Tarng YS ,1998, “Design optimization of cutting parameters for turning
operations based on the Taguchi method”, J. of Materials Processing Technology 84:122-
129.
REFERENCES
37. • Davim, J.P., 2001, "A Note on the Determination of Optimal Cutting Conditions for Surface
Finish Obtained in Turning Using Design of Experiments", Journal of Materials Processing
Technology, Vol. 116, Iss. 23, pp. 305-308.
• Lee B.Y., Tarng Y.S., 2001, “Surface roughness inspection by computer vision in
turning operations”, International Journal of Machine Tools & Manufacture 41 (2001): 1251
• Davim J. P., “Design of optimization parameters for turning metal matrix composites
based on the orthogonal arrays”, Journal Processing Technology, 132, 2003, pp. 340
• Balamuruga Mohan Raj. G, Sugumaran. V, 2013, “Developing Gaussian Process Model to
Predict the Surface Roughness in Boring Operation”, International Journal of Engineering
Trends and Technology- Vol. 4 Iss.3, 2013
• A. M. Badadhe et. al., 2012, “Optimization of Cutting Parameters in Boring Operation”,
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), P 10-15.
38. PUBLICATION
This work has been accepted to be presented as a
paper at International Conference on Recent
Advances in Engineering Sciences (ICRAES) in
MS Ramaiah Institute of Technology, Bangalore
on 8th of September 2016.