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.
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.
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.
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.
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.
Experimental investigation of tool wear in turning of inconel718 material rev...EditorIJAERD
This document summarizes an experimental investigation into tool wear during turning of Inconel718 material. It reviews the effects of various cutting conditions, tool geometries, and tool treatments on tool wear and other output parameters like cutting force, temperature, vibration, power consumption, surface roughness, and material removal rate. The goal is to analyze tool wear based on literature to optimize machining of Inconel718 using a CNC machine. Various studies investigating factors like cutting speed, feed rate, depth of cut, tool material, and cooling conditions are summarized to reduce tool wear during machining of this difficult-to-cut alloy.
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.
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.
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.
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.
Experimental investigation of tool wear in turning of inconel718 material rev...EditorIJAERD
This document summarizes an experimental investigation into tool wear during turning of Inconel718 material. It reviews the effects of various cutting conditions, tool geometries, and tool treatments on tool wear and other output parameters like cutting force, temperature, vibration, power consumption, surface roughness, and material removal rate. The goal is to analyze tool wear based on literature to optimize machining of Inconel718 using a CNC machine. Various studies investigating factors like cutting speed, feed rate, depth of cut, tool material, and cooling conditions are summarized to reduce tool wear during machining of this difficult-to-cut alloy.
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.
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
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
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.
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.
Turning Parameter Optimization for Material Removal Rate of AISI 4140 Alloy S...IRJET Journal
1. The document analyzes the optimization of turning parameters for material removal rate when machining AISI 4140 alloy steel.
2. Experiments were conducted using different levels of spindle speed, feed rate, and depth of cut. Material removal rate was calculated and analyzed using Taguchi methods.
3. Analysis of variance found feed rate to be the most influential parameter on material removal rate, followed by depth of cut and then spindle speed. The optimal combination for maximum material removal rate was found to be a spindle speed of 2100 rpm, feed rate of 0.3 mm/rev, and depth of cut of 0.6 mm.
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.
IRJET- A Review on: Parametric Study for Optimization of CNC Turning Process ...IRJET Journal
This document reviews research on optimizing CNC turning process parameters to minimize surface roughness. It summarizes 10 research papers that studied the effects of cutting speed, feed rate, depth of cut, cutting tool type, and cooling conditions on surface roughness when turning various materials like steel, aluminum, and titanium. The document finds that feed rate typically has the largest effect on surface roughness, followed by cutting speed, while depth of cut has a smaller impact. It recommends using techniques like Taguchi methods, response surface methodology, and ANOVA to determine the optimal process parameters that achieve the minimum possible surface roughness.
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
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.
Determining the Influence of Various Cutting Parameters on Surface Roughness ...IOSR Journals
The document describes an experimental investigation that analyzed the effect of various cutting parameters on surface roughness during wet CNC turning of AISI 1040 medium carbon steel. The parameters tested included cutting speed, feed rate, depth of cut, cutting fluid concentration, and two different cutting fluids. Custom experimental design and statistical analysis using JMP software revealed that feed rate had the most significant influence on surface roughness, and that there was no significant difference in surface roughness between the two cutting fluids tested.
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].
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.
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.
This document summarizes an experimental study on optimizing surface roughness and material removal rate during turning of AISI D2 steel. 27 experiments were conducted using a full factorial design varying cutting speed, feed rate, and depth of cut. Cutting speed had the greatest effect on surface roughness, while feed rate and depth of cut most influenced material removal rate. Analysis of variance found cutting speed contributed 79.8% to surface roughness. Grey relational analysis identified the optimal condition for low surface roughness as low feed rate, low depth of cut, and high cutting speed.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
OPTIMIZATION OF MACHINING PARAMETERS WITH TOOL INSERT SELECTION FOR S355J2G3 ...AVINASH JURIANI
The key goal of modern manufacturing industries is increased productivity & high quality
Surface Roughness is major concern for quality aspects affecting performance.
Speed, Feed & Depth of cut mainly influences SR & MRR in Turning
Taguchi & Grey Relational Technique is used for optimization followed by ANOVA for contribution
MADM is the need for better Tool Insert Selection to get requisite surface finish
Optimizing of High Speed Turning Parameters of Inconel 625 (Super Alloy) by u...IRJET Journal
This document discusses optimizing cutting parameters for high speed turning of Inconel 625 super alloy using the Taguchi technique. Inconel 625 is difficult to machine due to its properties. The study aims to determine optimal cutting speed, feed rate, and depth of cut to minimize surface roughness and maximize material removal rate. Experiments are conducted on a CNC turning machine using tungsten carbide tools and Taguchi's L9 orthogonal array. The cutting forces and responses of surface roughness and material removal rate are measured. Regression and Taguchi design of experiments methods are used for analysis to determine the optimal cutting parameters for high speed machining of Inconel 625 super alloy.
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.
IRJET- A Review on Optimization of Cutting Parameters in Machining using ...IRJET Journal
This document reviews optimization of cutting parameters in machining using the Taguchi method. It summarizes previous research that has investigated the effects of cutting speed, depth of cut, and feed rate on surface finish in end milling processes using the Taguchi method. The document also provides background on end milling, Taguchi methods, design of experiments, and reviews several previous studies that optimized cutting parameters for different materials using Taguchi methods and found that cutting speed typically has the greatest influence on surface finish, while depth of cut tends to have the smallest effect.
The document discusses prototyping and provides examples of different types of prototypes including paper prototypes, digital prototypes, storyboards, role plays, and space prototypes. It explains that prototyping is used to make ideas tangible and test reactions from users in order to gain insights. Prototypes should be iterated on and fail early to push ideas further and save time and money. Both low and high fidelity prototypes are mentioned as ways to test ideas at different stages of the design process.
10 Insightful Quotes On Designing A Better Customer ExperienceYuan Wang
In an ever-changing landscape of one digital disruption after another, companies and organisations are looking for new ways to understand their target markets and engage them better. Increasingly they invest in user experience (UX) and customer experience design (CX) capabilities by working with a specialist UX agency or developing their own UX lab. Some UX practitioners are touting leaner and faster ways of developing customer-centric products and services, via methodologies such as guerilla research, rapid prototyping and Agile UX. Others seek innovation and fulfilment by spending more time in research, being more inclusive, and designing for social goods.
Experience is more than just an interface. It is a relationship, as well as a series of touch points between your brand and your customer. Here are our top 10 highlights and takeaways from the recent UX Australia conference to help you transform your customer experience design.
For full article, continue reading at https://yump.com.au/10-ways-supercharge-customer-experience-design/
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.
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
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
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.
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.
Turning Parameter Optimization for Material Removal Rate of AISI 4140 Alloy S...IRJET Journal
1. The document analyzes the optimization of turning parameters for material removal rate when machining AISI 4140 alloy steel.
2. Experiments were conducted using different levels of spindle speed, feed rate, and depth of cut. Material removal rate was calculated and analyzed using Taguchi methods.
3. Analysis of variance found feed rate to be the most influential parameter on material removal rate, followed by depth of cut and then spindle speed. The optimal combination for maximum material removal rate was found to be a spindle speed of 2100 rpm, feed rate of 0.3 mm/rev, and depth of cut of 0.6 mm.
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.
IRJET- A Review on: Parametric Study for Optimization of CNC Turning Process ...IRJET Journal
This document reviews research on optimizing CNC turning process parameters to minimize surface roughness. It summarizes 10 research papers that studied the effects of cutting speed, feed rate, depth of cut, cutting tool type, and cooling conditions on surface roughness when turning various materials like steel, aluminum, and titanium. The document finds that feed rate typically has the largest effect on surface roughness, followed by cutting speed, while depth of cut has a smaller impact. It recommends using techniques like Taguchi methods, response surface methodology, and ANOVA to determine the optimal process parameters that achieve the minimum possible surface roughness.
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
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.
Determining the Influence of Various Cutting Parameters on Surface Roughness ...IOSR Journals
The document describes an experimental investigation that analyzed the effect of various cutting parameters on surface roughness during wet CNC turning of AISI 1040 medium carbon steel. The parameters tested included cutting speed, feed rate, depth of cut, cutting fluid concentration, and two different cutting fluids. Custom experimental design and statistical analysis using JMP software revealed that feed rate had the most significant influence on surface roughness, and that there was no significant difference in surface roughness between the two cutting fluids tested.
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].
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.
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.
This document summarizes an experimental study on optimizing surface roughness and material removal rate during turning of AISI D2 steel. 27 experiments were conducted using a full factorial design varying cutting speed, feed rate, and depth of cut. Cutting speed had the greatest effect on surface roughness, while feed rate and depth of cut most influenced material removal rate. Analysis of variance found cutting speed contributed 79.8% to surface roughness. Grey relational analysis identified the optimal condition for low surface roughness as low feed rate, low depth of cut, and high cutting speed.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
OPTIMIZATION OF MACHINING PARAMETERS WITH TOOL INSERT SELECTION FOR S355J2G3 ...AVINASH JURIANI
The key goal of modern manufacturing industries is increased productivity & high quality
Surface Roughness is major concern for quality aspects affecting performance.
Speed, Feed & Depth of cut mainly influences SR & MRR in Turning
Taguchi & Grey Relational Technique is used for optimization followed by ANOVA for contribution
MADM is the need for better Tool Insert Selection to get requisite surface finish
Optimizing of High Speed Turning Parameters of Inconel 625 (Super Alloy) by u...IRJET Journal
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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.
IRJET- A Review on Optimization of Cutting Parameters in Machining using ...IRJET Journal
This document reviews optimization of cutting parameters in machining using the Taguchi method. It summarizes previous research that has investigated the effects of cutting speed, depth of cut, and feed rate on surface finish in end milling processes using the Taguchi method. The document also provides background on end milling, Taguchi methods, design of experiments, and reviews several previous studies that optimized cutting parameters for different materials using Taguchi methods and found that cutting speed typically has the greatest influence on surface finish, while depth of cut tends to have the smallest effect.
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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.
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This document summarizes an experiment to optimize surface roughness and material removal rate during dry turning of SAE52100 steel. The experiment varied cutting speed, feed rate, and depth of cut using a Taguchi L9 orthogonal array. Surface roughness increased with increasing feed rate and decreasing cutting speed. Material removal rate models were developed that showed it increases with cutting speed and depth of cut but decreases with feed rate. Analysis found feed rate has the greatest influence on surface roughness, while depth of cut most influences material removal rate. The goal of the experiment was to determine optimal machining parameters that minimize surface roughness and maximize material removal rate and productivity during dry turning of SAE52100 steel.
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
Milling machining GFRP composites using grey relational analysis and the resp...IRJET Journal
This document summarizes research on optimizing the milling machining process for glass fiber reinforced polymer (GFRP) composites. The researchers used a Taguchi experimental design and Grey Relational Analysis (GRA) to determine the optimal machining parameters that minimize machining force and surface roughness. Their results showed that at optimal levels for spindle speed, feed rate, depth of cut, and cutting tool type, machining force decreased from 17.19N to 15.92N and surface roughness improved. Analysis of variance found that cutting tool type had the greatest influence on machining force. The researchers concluded that Taguchi and GRA methods can effectively optimize composite machining outcomes.
IRJET- Review Paper Optimization of Machining Parameters by using of Taguchi'...IRJET Journal
This document summarizes a research paper that used the Taguchi method to optimize machining parameters for turning operations on EN-31 alloy steel. The paper conducted experiments using various cutting speeds, feed rates, and depths of cut. The Taguchi design of experiments approach was used to determine the optimal machining parameters that maximize material removal rate. Analysis with MINITAB statistical software found that feed rate had the greatest influence on surface roughness, while cutting speed most significantly impacted cutting forces. The optimized parameters can improve the efficiency and cost-effectiveness of turning EN-31 alloy steel.
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.
IRJET- Determining the Effect of Cutting Parameters in CNC TurningIRJET Journal
This document discusses a study that aims to determine the effect of cutting parameters in CNC turning. The study analyzes the effects of spindle speed, feed rate, depth of cut, and material type on surface roughness and material removal rate during CNC turning operations. Experiments were designed using Taguchi's orthogonal array and analyzed using ANOVA. The results showed that spindle speed and feed rate significantly affect surface roughness, while depth of cut significantly affects material removal rate. Optimal parameters were identified for minimum surface roughness and maximum material removal rate.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presentswork of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This document summarizes a study that optimized surface roughness and material removal rate when dry turning the steel alloy EN-31. Experiments were conducted using carbide inserts with cutting speed, feed rate, and depth of cut as controllable variables. Taguchi's design of experiments and Grey relational analysis were used to optimize surface roughness. The literature review found that feed rate is often the most influential factor on surface roughness in hard turning steel alloys like EN-31. The goal of the study was to determine optimal machining parameters in dry turning of EN-31 to improve productivity for small and medium industries in India.
ANALYSIS OF PROCESS PARAMETERS IN DRY MACHINING OF EN-31 STEEL by GREY RELATI...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth o f cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presents work of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
IRJET- Review Paper Optimizationof MachiningParametersbyusing of Taguchi'...IRJET Journal
This document summarizes an experimental study that used the Taguchi method to optimize machining parameters for turning AA6063 alloy steel. The study aimed to maximize the material removal rate (MRR) by investigating the effects of cutting speed, depth of cut, and feed rate. A number of turning experiments were conducted using an L9 orthogonal array with different combinations of the machining parameters. Analysis of the experimental results found that feed rate had the greatest influence on MRR, followed by depth of cut. The Taguchi method was effective for determining the optimal machining parameters for maximizing the material removal rate during turning of AA6063 alloy steel.
This document summarizes a study that used the Taguchi method to optimize the material removal rate (MRR) when turning mild steel 1018 on a CNC lathe. The document describes the experimental setup including the workpiece material, CNC machine, tool material, and selection of cutting parameters (speed, feed, depth of cut). An L16 orthogonal array was used to conduct the experiments. Analysis of variance was performed on the signal-to-noise ratios to determine the optimal cutting conditions for maximizing MRR. The analysis found cutting speed to be the most influential parameter, followed by feed and then depth of cut. Validation experiments confirmed the optimal settings achieved the predicted maximum MRR.
IRJET- Review on Cutting Process Parameter for Surface Roughness During Turni...IRJET Journal
This document reviews the effects of cutting parameters like cutting speed, feed rate, nose radius, and depth of cut on surface roughness during turning operations. It discusses previous research that has investigated these effects on various materials like steel, aluminum alloys, and cast iron. The key findings of previous studies are that feed rate often has the greatest influence on surface roughness, while depth of cut and cutting speed also significantly affect results. Response surface methodology and Taguchi experimental design approaches have been used to optimize cutting parameters and predict surface roughness. Overall, controlling cutting parameters is important for achieving the desired surface quality during turning.
Optimization of Machining Parameters Affecting Surface Roughness of Al6082 in...IRJET Journal
The document discusses optimizing machining parameters to minimize surface roughness in dry end milling of Al6082 aluminum alloy. It reviews previous research, describes the experimental setup using Taguchi methods, and reports results from 27 experiments with varying spindle speed, feed rate, and depth of cut. Analysis found that feed rate had the greatest influence on surface roughness, with higher feed rates increasing roughness. The optimal parameters to minimize roughness were determined.
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 Surface Roughness and MRR in CNC Turni...IRJET Journal
This document summarizes an experiment that optimized cutting parameters for surface roughness and material removal rate (MRR) in CNC turning of 16MnCr5 steel. The experiment used a Taguchi design of experiments with cutting speed, feed rate, and depth of cut as parameters. An L9 orthogonal array was used to test combinations of the parameters at three levels each. The experiments measured surface roughness and MRR, which were analyzed using signal-to-noise ratios to determine the optimal settings for each response. Analysis of variance was also used to determine the effect of each parameter. The results showed that depth of cut had the highest effect on surface roughness, while feed rate had the lowest effect.
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 summarizes an investigation into flank wear on minimal cutting fluid application during turning of OHNS steel. Seven input parameters were varied at three levels in a 27-run Taguchi experiment. Analysis found that feed rate had the greatest influence on flank wear, cutting temperature, and chip thickness based on ANOVA. Optimal cutting and fluid application parameters were determined to be a cutting speed of 168.23 m/min, feed of 0.04 mm/rev, depth of cut of 1 mm, pressure of 100 bar, frequency of 900 pulses/min, application rate of 3 ml/min, and fluid composition of 20%. The study provides optimized parameters for improved tool performance during turning of OHNS steel with minimal cutting fluid application.
This document presents a comparative analysis of surface roughness and material removal rate during milling of AISI 410 steel and aluminum 6061. Experiments were conducted using a CNC milling machine varying spindle speed, feed rate, and depth of cut. Response surface methodology was used to optimize surface roughness. The results showed that for AISI 410 steel, spindle speed had the greatest effect on material removal rate and surface roughness, while for aluminum 6061, no parameters significantly affected the responses. Overall, different milling parameters impacted the materials differently in terms of surface finish and productivity.
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Welcome to UiPath Test Automation using UiPath Test Suite series part 6. In this session, we will cover Test Automation with generative AI and Open AI.
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What will you get from this session?
1. Insights into integrating generative AI.
2. Understanding how this integration enhances test automation within the UiPath platform
3. Practical demonstrations
4. Exploration of real-world use cases illustrating the benefits of AI-driven test automation for UiPath
Topics covered:
What is generative AI
Test Automation with generative AI and Open AI.
UiPath integration with generative AI
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
UiPath Test Automation using UiPath Test Suite series, part 6
G045063944
1. Vijaykumar H.K et al Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 5( Version 6), May 2014, pp.39-44
www.ijera.com 39 | P a g e
Optimization of Turning Parameters Using Taguchi Technique
for MRR and Surface Roughness of Hardened AISI 52100 Steel
Vijaykumar H.K1
, Aboobaker Siddiq1
and Muhammed Sinan1
1
Department of Mechanical Engineering, Bearys Institute of Technology, Mangalore, Karnataka-574153, India.
ABSTRACT
In this paper, Taguchi technique is used to find optimum process parameters for turning of hardened AISI 52100
steel under dry cutting conditions. A L9 orthogonal array, signal-to-noise(S/N) ratio and analysis of variances
(ANOVA) are applied with the help of Minitab.v.16.2.0 software to study performance characteristics of
Machining parameters namely cutting speed, feed rate and depth of cut with consideration of Material Removal
Rate (MRR) and surface roughness. The results obtained from the experiments are changed into signal-to-noise
ratio(S/N) ratio and used to optimize the value of MRR and surface roughness. The ANOVA is performed to
identify the importance of parameters. The final results of experimental study are presented in this paper. The
conclusions arrived at are significantly discussed at the end.
Keywords: ANOVA, Hardened, MRR, Surface roughness, Taguchi technique
I. INTRODUCTION
In metal cutting industries the foremost
drawback is not operating the machine tool to their
optimum operating conditions and the operating
conditions continue to be chosen solely on the basis
of the handbook values or operator’s experience. In
metal cutting industries turning is the majorly used
process for removing the material from the
cylindrical work piece. In turning that to turning of
hardened steels such as AISI52100 is a challenging
process. Turning of hardened material is a process, in
which materials in the hardened state (above 45HRC)
are machined with single point cutting tools. This has
become possible with the availability of the new
cutting tool materials (cubic boron nitride and
ceramics). The traditional method of machining the
hardened materials includes rough turning, heat
treatment followed by the grinding process. Turning
of hardened material eliminates a series of operations
required to produce the component and thereby
reducing the cycle time and hence resulting in
productivity improvement [1,2]. Turning of hardened
material is an alternative to conventional grinding
process; it is a flexible and economic process for
hardened steels [3]. The advantages of tuning of hard
materials are higher productivity, reduced set up
times, surface finish closer to grinding and the ability
to machine complex parts. Rigid machine tools with
adequate power, very hard and tough tool materials
with appropriate tool geometry, tool holders with
high stiffness and appropriate cutting conditions are
some of the prerequisites for hard turning
[4].Material Removal Rate (MRR) is a vital factor to
be considered in hard turning of steels since it is
directly affects the machining time. It also had been
reported that the resulting machining time reduction
is as high as 60% in hard turning compared to
grinding [5]. Surface properties such as roughness are
critical to the function ability of machine
components. Increased understanding of the surface
generation mechanisms can be used to optimize
machining process and to improve component
function ability.
Numerous investigators have been
conducted to determine the effect of parameters such
as feed rate, tool nose radius, cutting speed and depth
of cut on surface roughness in hard turning operation
[6,7].Taguchi’s Parameter design suggests an
efficient approach for optimization of various
parameters with regard to performance, quality and
cost [8,9]. Taguchi recommends the use of S/N ratio
for the determination of the quality characteristics
implemented in engineering design problems. The
addition to S/N ratio, a statistical analysis of variance
(ANOVA) can be employed to indicate the impact of
process parameters on MRR and surface roughness.
In this paper Taguchi’s DOE approach is used to
analyze the effect of turning process parameters-
cutting speed, feed and depth of cut while machining
for hardened AISI52100 steel and to obtain an
optimal setting of the parameters that results in
optimizing MRR and Surface roughness.
II. DETAILS OF EXPERIMENT
2.1Workpiece Material, Cutting Tool and
Machine
The AISI 52100 steel work piece material is
selected for the present work and the chemical
composition of work piece material includes
C-0.93%,Cr-1.43%,Mn-0.43%,Si-0.2%,P-0.08%,S-
0.0047% and balance Fe. The work pieces of
RESEARCH ARTICLE OPEN ACCESS
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diameter 18mm and 100mm length has been used for
trials. For all the work pieces heat treatment was
carried out. Initially before the heat treatment average
hardness of the work piece was 22HRC. The heat
treatment includes Hardening at 8500
C for two hours
and quenched with oil and also Tempering at 2000
C
for one hour. After heat treatment the average
hardness value of 48HRC was obtained. The cutting
tool insert used for machining AISI 52100 was
carbide insert of ISO number: CCMT 32.52 MT
TT8020 of TaeguTec make under dry cutting
conditions. The Cutting Tool holder used was of
Specification SCLCR1212H09 D 4C of WIDIA
make.
The machine used for turning was all geared
Head Precision lathe (Preci-Turnmaster -350) of OM
JINA MACHINE TOOLS make. The instrument
used for measuring weight of the specimen and
surface roughness was weighing balance and
Mitutoyo surface roughness tester respectively.
Machining time is noted by stopwatch and measured
final weight of all jobs. Material removal rate (MRR)
is calculated by using relation MRR = (Wi.–Wf) ÷
Machining Time, where Wi is the initial weight of the
workpiece and Wf is the final weight of the work
piece. The Taguchi method developed by Genuchi
Taguchi is a statistical method used to improve the
product quality. It is commonly used in improving
industrial product quality due to the proven success
[10].With the Taguchi method it is possible to
significantly reduce the number of experiments. The
Taguchi method is not only an experimental design
technique, but also a beneficial technique for high
quality system design [11].
2.2 Taguchi Method
The Taguchi technique includes the
following steps:
• determine the control factors,
• determine the levels belonging to each control
factor and select the appropriate orthogonal
array,
• assign the control factors to the selected
orthogonal matrix and conduct the experiments,
• analyze data and determine the optimal levels of
control factors,
• perform the confirmation experiments and obtain
the confidence interval,
• improve the quality characteristics.
The Taguchi method uses a loss function to
determine the quality characteristics. Loss function
values are also converted to a signal-to-noise (S/N)
ratio (η). In general, there are three different quality
characteristics in S/N ratio analysis, namely
“Nominal is the best”, “Larger is the better” and
“Smaller is the better”. For each level of process
parameters, signal-to-noise ratio is calculated based
on S/N analysis.
2.3 Selection of Control factors and orthogonal
array
In this study Cutting speed, Feed rate and
Depth of cut (DOC) was selected as control factors
and their levels were determined as shown in the
Table 1.
Table 1Turning Parameters and their levels
Factors Level 1 Level 2 Level 3
Cutting Speed(rpm) 450 710 1120
Feed rate(mm/rev) 0.05 0.12 0.18
Depth of cut(mm) 0.2 0.3 0.4
The first step of the Taguchi method is to
select an appropriate orthogonal array. The most
appropriate orthogonal array (L9) was selected to
determine the optimal turning parameters based on
the total degree of freedom (DOF) and to analyze the
effects of these parameters. The L9 orthogonal array
has eight DOF and can handle three level design
parameter. The L9 orthogonal array is as shown in
the Table2.
Table 2 Orthogonal L9 array of Taguchi
III. ANALYSIS AND DISUSSION OF
EXPERIMENTAL RESULTS
Table 3 shows the experiment results for the
average Surface roughness (SR) and
MRR and corresponding S/N ratios were obtained
with the help of Minitab.v.16.2.0 software.
3.1 Cause of Cutting speed, feed rate and Depth of
cut on MRR
From the response Table 4 and Fig.1 it is
clear that cutting speed is the most influencing factor
followed by depth of cut and feed rate for MRR. The
optimum for MRR is cutting speed of 1120rpm, feed
rate of 0.12mm/rev and depth of cut of 0.4mm.
Experiment
No.
P1 P2 P3
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 2
5 2 2 3
6 2 3 1
7 3 1 3
8 3 2 1
9 3 3 2
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3.2 Cause of Cutting speed, feed rate and Depth of
cut on Surface roughness
From the response Table 5 and Fig. 2 it is
clear that cutting speed is the most influencing factor
followed by feed rate and depth of cut for surface
roughness. The optimum conditions for Surface
roughness are cutting speed of 450rpm feed rate of
0.05mm/rev and depth of cut of 0.4mm.
3.3 Analysis of variances (ANOVA)
Taguchi method cannot judge and determine
effect of individual parameters on entire process
while percentage contribution of individual
parameters can be well determined using
ANOVA.Using Minitab.v.16.2.0 software ANOVA
module can be employed to investigate effect of
parameters. It is clear from the Table6 cutting speed
(rpm) it is contributing of about 28.33%, depth of
cut 24.3% and feed rate 19.55% on Material Removal
Rate (MRR). It is evident from Table 7 cutting speed
(rpm) is the most significant factor contributing of
about 56.75%, followed by feed rate 32.7% and depth
of cut 8.37% on surface roughness.
Table 3 Experimental results for the surface roughness, MRR and corresponding S/N ratios
Sl.No
SPEED
(rpm)
FEED
(mm/rev)
DOC
(mm)
Average
SR(µm)
S/N Ratio
for SR MRR(g/min)
S/N Ratio
for MRR
1 450 0.05 0.2 10.33 -20.28 0.008 -41.89
2 450 0.12 0.3 11.33 -21.08 0.296 -10.55
3 450 0.18 0.4 11.33 -21.08 0.086 -21.23
4 710 0.05 0.3 12.7 -22.07 0.012 -38.061
5 710 0.12 0.4 13.2 -22.41 0.113 -18.87
6 710 0.18 0.2 14.22 -23.057 0.067 -23.37
7 1120 0.05 0.4 11.36 -21.10 0.542 -5.30
8 1120 0.12 0.2 13.3 -22.47 0.089 -21.00
9 1120 0.18 0.3 15.2 -23.63 0.233 -12.63
Table 4 Response Table for Signal to Noise Ratios (Larger is better)
Level 1 Speed(rpm) Feed(mm/rev) DOC(mm)
1 -24.56 -28.42 -28.76
2 -26.77 -16.81* -20.42
3 -12.98* -19.08 -15.41*
Delta 13.79 11.61 13.62
Rank 1 3 2
* indicates optimum level
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1120710450
-15
-20
-25
-30
0.180.120.05
0.40.30.2
-15
-20
-25
-30
SPEED(rpm)
MeanofSNratios
FEED(mm/rev)
DOC(mm)
Main Effects Plot for SN ratios
Data Means
Signal-to-noise: Larger is better
Figure 1 Main effects plots for MRR
Table 5 Response Table for Signal to Noise Ratios (Smaller is better)
Level 1 Speed(rpm) Feed(mm/rev) DOC(mm)
1 -20.82* -21.61* -21.94
2 -22.52 -21.99 -22.27
3 -22.41 -22.59 -21.53*
Delta 1.70 1.44 0.73
Rank 1 2 3
* indicates optimum level
1120710450
-21.0
-21.5
-22.0
-22.5
0.180.120.05
0.40.30.2
-21.0
-21.5
-22.0
-22.5
SPEED(rpm)
MeanofSNratios
FEED(mm/rev)
DOC(mm)
Main Effects Plot for SN ratios
Data Means
Signal-to-noise: Smaller is better
Figure 2 Main effects plots for Surface roughness.
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Table 6 ANOVA for S/N ratio for MRR
Source DOF SS MS F P % contribution
Speed(rpm) 2 329.2 164.6 1.02 0.495 28.33%
Feed(mm/rev) 2 227.2 113.6 0.70 0.587 19.55%
DOC(mm) 2 282.8 141.4 0.88 0.533 24.3%
Error 2 322.5 161.2 - - 27.7%
Total 8 1161.7 - - - 100%
Table 7 ANOVA for S/N ratio for Surface roughness
Source DO
F
SS MS F P % contribution
Speed(rpm) 2 5.42 2.71 27.17 0.036 56.75%
Feed(mm/rev) 2 3.12 1.56 15.67 0.060 32.67%
DOC(mm) 2 0.80 0.40 4.03 0.199 8.37%
Error 2 0.19 0.09 - - 1.98%
Total 8 9.55 - - - 100%
IV. VALIDATION OF EXPERIMENTS
After obtaining optimum conditions from
Taguchi method of both MRR and Surface roughness
the prediction was made for MRR and Surface
roughness. The predicted value of MRR for optimum
conditions of cutting speed 1120rpm feed
rate0.12mm/rev and depth of cut 0.4mm is
0.782g/min and when the actual experiment was done
using these optimum conditions the MRR obtained is
0.807g/min therefore the error obtained 2.5% as
shown in Table8. The predicted value of surface
roughness for optimum conditions of cutting speed
450rpm feed rate0.05mm/rev and depth of cut 0.4mm
is 9.63µm and when the actual experiment was done
using these optimum conditions the surface
roughness obtained is 9.85µm therefore the error
obtained 2.23% as shown in Table 9..From these
confirmation tests, good agreement between the
predicted machining performance and the actual
performance were observed.
V. CONCLUSION
The optimum conditions obtained from Taguchi
method for optimizing Material Removal Rate
(MRR) during turning of hardened AISI52100
steel under dry condition are cutting speed of
1120rpm Feed rate of 0.12mm/rev and depth of
cut of 0.4mm.
From response table for S/N ratio of MRR it is
clear that cutting speed is the most significant
factor influencing MRR followed by Depth of
cut and Feed rate is the least significant factor.
Analysis of Variances (ANOVA) for S/N ratio
for MRR clearly indicates that the cutting speed
is majorly contributing of about 28.33% in
obtaining optimal MRR followed by depth of cut
24.3% and feed rate 19.55%.
Optimum conditions for optimizing Surface
roughness are cutting speed of 450rpm Feed rate
of 0.05mm/rev and depth of cut of 0.4mm
From response table for S/N ratio of surface
roughness it is clear that cutting speed is the
most significant factor influencing MRR
followed by Feed rate and depth of cut is the
least significant factor.
Analysis of Variances (ANOVA) for S/N ratio
for surface roughness clearly indicates that the
cutting speed is majorly contributing of about
56.75% in obtaining optimal surface roughness
followed by feed rate of 32.67%.and depth of cut
of 8.37 %.
Table 8 Confirmation test for MRR
Optimum Values S/N ratio obtained Predicted MRR(g/min) Actual MRR(g/min) obtained Error%
Speed:1120rpm
Feed:0.12mm/rev
DOC:0.4mm
-2.05574 0.782 0.807 2.5%
Table 9 Confirmation test for Surface roughness (SR)
Optimum Values S/N ratio obtained Predicted SR(µm) Actual SR(µm) obtained Error%
Speed:450rpm
Feed:0.05mm/rev
DOC:0.4mm
-19.68 9.638 9.85 2.23%
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