This document describes an experimental study that optimized cutting parameters during machining of stainless steel SS 310 to minimize cycle time using Taguchi methodology and analysis of variance (ANOVA). The experiments were carried out using a CNC turning machine with coated carbide inserts. An L9 orthogonal array was used to test the effects of cutting speed, feed rate, and depth of cut on surface roughness and cycle time. ANOVA results showed that feed rate was the most significant factor for minimizing surface roughness, with higher feed rates providing higher surface roughness. The optimal cutting parameters for minimizing cycle time were also identified.
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 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
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 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
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.
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Parametric analysis and multi objective optimization of cutting parameters in...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
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Journals
Abstract Modern manufacturers, seeking to remain competitive in the market, rely on their Manufacturing engineers and production personnel to quickly and effectively set up manufacturing processes for new products. This paper presents the multi response optimization of turning parameters for Turning on AISI 4340 Alloy Steel. Experiments are designed and conducted based on Taguchi’s L27 Orthogonal array design. This paper discusses an investigation into the use of Taguchi parameter Design and Regression analysis to predict and optimize the Surface Roughness, Metal Removal Rate and Power Consumption in turning operations using CVD Cutting Tool. The Analysis of Variance (ANOVA) is employed to analyze the influence of Process Parameters during Turning. This paper also remarks the advantages of multi-objective optimization approach over the single-objective one. The useful results have been obtained by this research for other similar type of studies and can be helpful for further research works on the Tool life and Vibration of tools etc. Keywords: Turning, Ra, MRR, PC, Taguchi, Anova etc…
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.
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Parametric analysis and multi objective optimization of cutting parameters in...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
Parametric analysis and multi objective optimization of cutting parameters in...eSAT Journals
Abstract Modern manufacturers, seeking to remain competitive in the market, rely on their Manufacturing engineers and production personnel to quickly and effectively set up manufacturing processes for new products. This paper presents the multi response optimization of turning parameters for Turning on AISI 4340 Alloy Steel. Experiments are designed and conducted based on Taguchi’s L27 Orthogonal array design. This paper discusses an investigation into the use of Taguchi parameter Design and Regression analysis to predict and optimize the Surface Roughness, Metal Removal Rate and Power Consumption in turning operations using CVD Cutting Tool. The Analysis of Variance (ANOVA) is employed to analyze the influence of Process Parameters during Turning. This paper also remarks the advantages of multi-objective optimization approach over the single-objective one. The useful results have been obtained by this research for other similar type of studies and can be helpful for further research works on the Tool life and Vibration of tools etc. Keywords: Turning, Ra, MRR, PC, Taguchi, Anova etc…
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.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
Experimental Investigation and Parametric Studies of Surface Roughness Analys...IJMER
The modern machining industries are focused on achieving high quality, in terms of
part/component accuracy, surface finish, high production rate and increase in product life. Surface
roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter.
The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other
parameters such as cutting force and power consumption in different conditions.
INVESTIGATION AND OPTIMIZATION OF TURNING PROCESS PARAMETER IN WET AND MQL SY...IAEME Publication
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
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.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 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) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
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.
Impact of Mechanical System in Machining Of AISI 1018 Using Taguchi Design o...IJMER
The imperative objective of the science of metal cutting is the solution of practical problems
associated with the efficient and precise removal of metal from work piece. Optimization of process
parameters is done to have great control over quality, productivity and cost aspects of the process.
Taguchi method stresses the importance of studying the response variation using the signal–to–noise
(S/N) ratio, resulting in minimization of quality characteristic variation due to uncontrollable
parameter. Orthogonal array was adopted in order to planning the (L9) experimental runs in turning of
AISI 1018 by taking the help of software Minitab 16. The MRR and time
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
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Optimization of Cutting Parameters for Minimizing Cycle Time in Machining of SS 310 using Taguchi Methodology and Anova.
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 1 Ver. IV (Jan- Feb. 2015), PP 31-39
www.iosrjournals.org
DOI: 10.9790/1684-12143139 www.iosrjournals.org 31 | Page
Optimization of Cutting Parameters for Minimizing Cycle Time
in Machining of SS 310 using Taguchi Methodology and Anova.
K. Ramesh1
1
Assistant Professor, Mechanical Engineering, Karpagam college of Engineering coimbatore
Abstract: This paper presents an experimental study to optimize cutting parameters during machining of SS
304 for simultaneous minimization and maximization of Surface roughness (Ra), machining time, geometrical
tolerance of Stainless Steel affect the aesthetical aspect of the final product and hence it is essential to select the
best combination values of the CNC turning and CNC Milling process parameters to minimize as well as
maximize the responses. An orthogonal array, Signal to noise(S/N) ratio and analysis of variance(ANOVA) were
employed to analyze the effects and contributions of depth of cut, feed rate and cutting speed on the response
variable. The experiments were carried out on a CNC turning and CNC machining, using coated carbide insert
for the machining of Stainless Steel. The experiments were carried out as per L9 orthogonal array with each
experiment performed under different conditions of such as cutting speed, depth of cut, and feedrate. te analysis
of variance (ANOVA) was employed to identify the level of importance of the machining parameters on Surface
roughness (Ra), machining time and geometrical tolerance. The result of this research work showed that feed
rate is the most significant factor for minimizing surface roughness. Higher feed rate provides higher surface
roughness.
I. Introduction
1.1 Cnc Machines - An Overview
It has long been recognized that conditions during cutting, such as feed rate, cutting speed and depth of
cut, should be selected to optimize the economics of machining operations, as assessed by productivity, total
manufacturing cost per component or some other suitable criterion. Since long researchers showed that an
optimum or economic cutting speed exists, this could maximize material removal rate. Manufacturing industries
have long depended on the skill and experience of shop-floor machine-tool operators for optimal selection of
cutting conditions and cutting tools. Considerable efforts are still in progress on the use of handbook based
conservative cutting conditions and cutting tool selection at the process planning level. The most adverse effect
of such a not-very scientific practice is decreased productivity due to sub-optimal use of machining capability.
The need for selecting and implementing optimal machining conditions and the most suitable cutting tool has
been felt over the last few decades. Despite early works on establishing optimum cutting speeds in CNC
machining, progress has been slow since all the process parameters need to be optimized.
Furthermore, for realistic solutions, the many constraints met in practice, such as low machine tool
power, torque, force limits and component surface roughness must be overcome. The non-availability of the
required technological performance equation represents a major obstacle to implementation of optimized cutting
conditions in practice. This follows since extensive testing is required to establish empirical performance
equations for each tool coating work material combination for a given machining operation, which can be quite
expensive when a wide spectrum of machining operations is considered.
The F8 large, vertical machining center is designed to provide the power, speed, precision and
versatility to attack both large production part applications as well as big die and mold components. The F8 is
designed to provide stiffness and rigidity for chatter-free, heavy cutting, roughing and finishing on the same
machine, agility for high-speed / hard-milling and accuracies for tight-tolerance blends and matches typical of
complex, 3-D contoured geometry associated with die/mold and medical production. The unique machine
design provides unparalleled access to ease setup and changeover reducing WIP and overall lead time.
2. Optimization of Cutting Parameters for Minimizing Cycle Time in Machining of SS 310 using ….
DOI: 10.9790/1684-12143139 www.iosrjournals.org 32 | Page
1.2 Cnc Machining Center
Fig 1The F8 large, MAKINO vertical machining center
1.3 Experimental Setup
To attain the main objectives of the present investigation, the experimental work has been planned in the
following sequences
• Selection of material for CNC Machining operation
• Studying the effect of process parameter on mechanical properties of SS304
• Establishing relationship between material properties and CNC process parameters
• Manufacturing process of CNC turning operation of selected materials based on the design of experiments.
• Developing mathematical model using DOE, ANOVA, and Regression analysis.
Table 1.Material Properties of STAINLESS STEEL AISI 304
Stainless steel is used for jewellery and watches. The most common stainless steel alloy used for this is
316L. It can be re-finished by any jeweller and will not oxidize or turn black
Exhaustive literature survey was carried out and the available relevant information was presented under the
following headings. It is the conceptual framework of a methodology for quality improvement and process
robustness that needs to be emphasized
• Gilbert(2010) studied the optimization of machining parameters in turning with respect to maximum
production rate and minimum production cost as criteria
• Armarego&Brown (2013) investigates unconstrained machine – parameter optimization using differential
calculus.
• Carmitacamposeco – negrete(2013) Optimization of cutting parameter for minimize energy consumption
inturning of AISI 6061 T6 using taguchi methodology .
• jihongyan,lin li (2013) Multi-objective optimization of milling parameters- the off between energy ,
production rate and cutting quality
• Shortening cycle times in multi-product , capacitated production environment through quality level
improvements and setup reduction(2013) moustaphadiaby , josevruzaaron.
• YingguangLi, WeiWang,WeimingShenWeimingShen 16 November 2012 Afeaturebasedmethod for NC
machining time estimation Changqing.
COMPOSITION REPORT
CARBON% 0.08
SILICON% Max 1
MANGANESE% 2
CHROMIUM% 19
NICKEL% 9
IRON% BALANCE
3. Optimization of Cutting Parameters for Minimizing Cycle Time in Machining of SS 310 using ….
DOI: 10.9790/1684-12143139 www.iosrjournals.org 33 | Page
• Fabrício José Pontes, Anderson Paulo de Paiva , Pedro Paulo Balestrassi, João Roberto Ferreira , Messias
Borges da Silva b 2012 Elsevier Ltd. Optimization of Radial Basis Function neural network employed for
redaction of surface roughness in hard turning process using Taguchi’s orthogonal arrays .
• EmelKurama, Babur Ozcelik , MahmutBayramoglu, ErhanDemirbas c, BilginTolgaSimsek Available
online 15 November 2012 Optimization of cutting fluids and cutting parameters during end milling by
using D-optimal design of experiments .
• B. MoetakefImania, M. Pourb, A. Ghoddosianb, M. Fallah accepted 14 February 2012. Improved dynamic
simulation of end-milling process using time series analysis .
• R. Venkata Rao, V.D. Kalyankar accepted 27 October 2012 Multi-pass turning process parameter
optimization usingteaching–learning-based optimization algorithm.
• Rajarshi Mukherjee, Shankar Chakraborty, SumanSamanta Available online 3 April 2012 Selection of wire
electrical discharge machining process parameters using non-traditional optimization algorithms .
• K. Schützera, E. Uhlmannb, E. Del Contea, J. Mewisb 2012, Improvement of surface accuracy and shop
floor feed rate smoothing through open cnc monitoring system and cutting simulation.
• SubramaniamJayantia, KalyanMavuletia, Brian Beckera, Ethan Ericksona, Jon Wadella, Troy D.
Marusicha,ShujiUsuia, Kerry Marusicha 2012 Modeling of Cutting Forces
• Arunkumarpandey, Ainashkumardubey 1 Dec 2011,Taguchi based fuzzy logic optimization of multiple
quality, characteristics in laser cutting of Duralumin sheetand Cycle Times for Micromachined Components
• Anil Gupta, Harisingh, Amanaggarwal 2010Taguchi-fuzzy multi output optimization(MOO) in high speed
cnc turning of AISI P-20 tool steel.
• Firmanridwan, Uun-xu.17- JUNE 2012.Advanced CNC system with in-process feed-rate optimization.
• Chanquingliu,YingguangLi,Weiwang,Weiming shen.16-nov-2012.A feature-based method for NC
machining time estimation.
• Rajarshi Mukherjee, Shankar Chakraborty, SumanSamanta 3rd
APRIL 2012. Selection of wire electrical
discharge machining process parameters using non-traditional optimization algorithms
II. Optimization Of Multiple Performance Characteristics
2.1 Introduction
Optimization of process parameters is the key step in the Taguchi method in achieving high quality
without increasing the cost. This is because optimization of process parameters can improve performance
characteristics and the optimal process parameters obtained from the Taguchi method are insensitive to the
variation of environmental conditions and other noise factors. Basically, classical process parameter design is
complex and not easy to use. Especially, a large number of experiments have to be carried out when the number
of the process parameters increases.
2.2Taguchi method for optimization of process parameters
Analysis of the S/N ratio
The Taguchi method uses S/N ratio instead of the average value to infer the trial results data into a
value for the evaluation characteristics in the optimum setting analysis. This is because S/N ratio can reflect
both average and variation of the quality characteristics. In the present work, the optimization of CNC
TURNING and CNC MACHINING process parameters using Taguchi’s robust design methodology with
multiple characteristics is proposed. In order to optimize the multi performance characteristics, namely Cycle
Timeand Surface roughness (Ra) while machining in CNC of Stainless Steel304material. Here performances
namely Ra and cycle time are to be minimized .Most of the investigations presented in section2 employed
Taguchitechniques, such as orthogonal arrays and S/N ratio analysis to optimize values of cutting parameters
that minimize the response variable.Taguchi methodology allows obtaining results using fewer experimental
runs than other techniques.
2.2.1analysis Of Cnc Process Parameters
Introduction
The statistical procedure used most often to analyze data is known as the analysis of variance
(ANOVA). This technique determines the effects of the treatments, as reflected by their means, through an
analysis of their variability.
In statistics, analysis of variance (ANOVA) is a collection of statistical model, and their associated
procedures, in which the observed variance in a particular variable is partitioned into components attributable to
different sources of variation. In its simplest form, ANOVA provides a statistical test of whether or not the
means of several groups are all equal, and therefore generalizes t-test to more than two groups. Doing multiple
two-sample t-tests would result in an increased chance of committing type-1 error. For this reason, ANOVAs
are useful in comparing two, three, or more means
4. Optimization of Cutting Parameters for Minimizing Cycle Time in Machining of SS 310 using ….
DOI: 10.9790/1684-12143139 www.iosrjournals.org 34 | Page
III. Machining process:experimental procedure
Table 2 Machining parameters
Fig 2 Existing Taguchi Methods
Fig 3 Machining parameters vs Processparameters
Table 3machining parameters and their levels
Fig 4 Methodology
I SPEED
II FEED
III DEPTH OF CUT
IV MATERIAL AISI STAINLESS STEEL 304
V Insert/TOOL XNMU 0906 ANTRMTT9080
Symbols
Used
Process
parameter
Unit Level- I Level-2 Level-3
A Spindle
Speed
RPM 477 488 500
B Feed rate mm/rev 143 150 155
C Depth of cut Mm 0.25 0.30 0.35
5. Optimization of Cutting Parameters for Minimizing Cycle Time in Machining of SS 310 using ….
DOI: 10.9790/1684-12143139 www.iosrjournals.org 35 | Page
Table 4Taguchi L9 Orthogonal Array
Job No
Spindle
Speed (rpm)
Feed Rate
(mm/rev) Depth of Cut (mm)
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
Fig 5 Part Drawing For Minimum Cycle Time and
Surface Roughness Component
Operation Breakup
There are 18 options in this component. We are using Taguchi method for Optimising Cutting Parameters in
Operation Number 01.
01.Face Milling Maintain the Height 58.0 and Flange Thickness 9.0mm.
IV. Results And Data Analysis
Three Categories of Performance Characteristics,
The lower-the-better,
The higher –the-better, and
The nominal-the-best
To obtain the optimal machining performance, the lower- the- better performance characteristic for surface
roughness and cycle time have been taken for obtaining optimal machining performances.
Analysis of S/N Ratio:
=-10log10[ra2
]
=-10log10[cycle time]2
where =multi response signal to noise ratio
The results obtained from the experimental runs carried out, according to the orthogonal array shown in
Table 4.Table 5 contains data for cycle time, surface roughness and S/N ratio for each Response and Data.The
main effect plots are used to study the trend of the effects of each of the factors. Main effects plots for the three
factors for Spindle speed, feed rate and Depth of cut versus surface roughness and cycle time have been shown
in Figs.
6. Optimization of Cutting Parameters for Minimizing Cycle Time in Machining of SS 310 using ….
DOI: 10.9790/1684-12143139 www.iosrjournals.org 36 | Page
Table 5 Experimental Result and Corresponding S/N Ratio
Fig 6 Surface Roughness graph
Fig 7 Surface Roughness graph
Analysis Of Variance(ANOVA) And main effects plots
Table 6General Linear Model: Surface Roug, Cycle Time versus Spindle spee, Feed Rate,
Factor Type Levels Values
Spindle speed random 3 477, 488, 500
Feed Rate random 3 143, 150, 155
Depth Of Cut random 3 0.25, 0.30, 0.35
Spindle
speed
(rpm)
Feed
rate
(mm/r
ev)
Depth
of cut
(mm)
Surfac
e
rough
ness
(Ra)
Cycle
time
(Secs)
S/N
Ratio1 S/N Ratio2
477 143 0.25 1.85 108 -5.34343 -40.6685
477 150 0.3 1.9 102 -5.57507 -40.172
477 155 0.35 1.9 99 -5.57507 -39.9127
488 143 0.3 1.7 97 -4.60898 -39.7354
488 150 0.35 1.85 95 -5.34343 -39.5545
488 155 0.25 1.75 93 -4.86076 -39.3697
500 143 0.35 1.7 91 -4.60898 -39.1808
500 150 0.25 1.9 90 -5.57507 -39.0849
500 155 0.3 1.95 87 -5.80069 -38.7904
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Table 7Analysis of Variance for Surface Roughness, using Adjusted SS for Tests
Source DF Seq SS Adj SS Adj MS F P
Spindle speed 2 0.021667 0.021667 0.010833 1.44 0.409
Feed Rate 2 0.031667 0.031667 0.015833 2.11 0.321
Depth Of Cut 2 0.001667 0.001667 0.000833 0.11 0.900
Error 2 0.015000 0.015000 0.007500
Total 8 0.070000
S = 0.0866025 R-Sq = 78.57% R-Sq(adj) = 14.29%
Table8Analysis of Variance for Cycle Time, using Adjusted SS for Tests
Source DF Seq SS Adj SS Adj MS F P
Spindle speed 2 282.889 282.889 141.444 79.56 0.012
Feed Rate 2 48.222 48.222 24.111 13.56 0.069
Depth Of Cut 2 6.889 6.889 3.444 1.94 0.340
Error 2 3.556 3.556 1.778
Total 8 341.556
S = 1.33333 R-Sq = 98.96% R-Sq(adj) = 95.84%
Table 9 Percentage of influence of factors spindle speed, feed rate and depth of cut.
Factor case 1 case 2
_________________________________________
Spindle speed 39.39% 83.69%
Feed Rate 57.57% 14.27%
Depth Of Cut 3.03% 2.04
Case 1 : surface roughness
Case 2 : cycle time
Fig 8 cycle Time Graph
8. Optimization of Cutting Parameters for Minimizing Cycle Time in Machining of SS 310 using ….
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Fig 9 cycle Time Graph
V. Confirmation test
In order tovalidate conclusions obtainedin thissection, an experimental run was done with the optimum
cutting parameters according to main effects and S/N ratio analysis.
VI. Conclusions
Taguchi methodology was employed for optimizing a finish machining process, involving AISI SS 304
as the material to be machined and a T-max Cutter of dia100 with coated inserts. Optimum values of cutting
parameters were found out in order to minimize cycle time and Surface roughness during the machining process.
The cycle time is the response variable that should be analysed. According to the analysis showed in
table 9,Spindle speed is the most significant factor (83.69%)followed by feed rate(14.27%) and depth of
cut(2.04%).The most optimal results for cycle time were found when the spindle speed was set at 500rpm,feed
rate of 155mm/rev and depth of cut of 0.35mm.Higher spindle speed, feed rate and depth of cut leads to
minimum cycle time.
For minimising surface roughness, feed rate is the most significant factor(57.57%).The most optimal
results for this response variable were found when the spindle speed was set at 488rpm,feed rate143mm/rev,and
depth of cut 0.35mm.In order to increase accuracy and find the values that lead to a reduction of the response
variables studied, it is necessary to conduct in machining operations.
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