Establishment of efficient machining parameters has been a problem that has confronted manufacturing industries for nearly a century, and is still the subject of many studies. Optimum machining parameters are of great concern in manufacturing environments, where economy of machining operation plays a key role in competitiveness in the market. Determination of the optimal cutting parameters (cutting conditions) like the number of passes, depth of cut for each pass, speed, and feed is considered as a crucial stage of multi-pass machining as in the case of all chip removal processes and especially in milling operation. The effective optimization of these parameters affects dramatically the cost and production time of machined components as well as the quality of the final products. This project outlines the development of an optimization strategy to determine the optimum cutting parameters for milling operations like plain milling and face milling. This project also underlies the importance of using optimization strategies rather than handbook recommendations as well as pointing out the superiority of the multi-pass over the single-pass optimization approach. The project discusses both single-tool and multitool milling operations where emphasis has been placed on the latter. Although many efforts have been made to optimize machining parameters, from the review of the published literature it can be concluded that most of the work done is restricted to turning operations, and other machining operations, including milling, have gained little attention. Owing to the significant role that milling operations play in today's manufacturing world, there is a vital need to optimize machining parameters for this operation, particularly when NC machines are employed.

1. VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 7 (2024)
ISSN(Online): 2581-7280 Article No. MECH_15
PP 01-06
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Process Optimisation in MSME Industry
Swapnil Raut1
, Sunny More2
, Manish Raut3
, Utkarsh Tiwari4
1
(Department of Mechanical Engineering, VIVA Institute of Technology, University of Mumbai, INDIA)
2
(Department of Mechanical Engineering, VIVA Institute of Technology, University of Mumbai, INDIA)
3
(Department of Mechanical Engineering, VIVA Institute of Technology, University of Mumbai, INDIA)
4
(Department of Mechanical Engineering, VIVA Institute of Technology, University of Mumbai, INDIA)
Abstract : Establishment of efficient machining parameters has been a problem that has confronted
manufacturing industries for nearly a century, and is still the subject of many studies. Optimum machining
parameters are of great concern in manufacturing environments, where economy of machining operation plays a
key role in competitiveness in the market. Determination of the optimal cutting parameters (cutting conditions)
like the number of passes, depth of cut for eachpass, speed, and feed is considered as a crucial stage of multi-pass
machining as in the case of all chip removal processes and especially in milling operation. The effective
optimization of these parameters affects dramatically the cost and production time of machined components as
well as the quality of the final products. This project outlines the development of an optimization strategy to
determine the optimum cutting parameters for milling operations like plain milling and face milling. This project
also underliesthe importance of using optimization strategies rather than handbook recommendations as wellas
pointing out the superiority of the multi-pass over the single-pass optimization approach. The project discusses
both single-tool and multitool milling operations where emphasishas been placed on the latter. Although many
efforts have been made to optimize machining parameters, from the review of the published literature it can be
concluded that most of the workdone is restricted to turning operations, and other machining operations, including
milling, have gained little attention. Owing to the significant role that milling operations play in today's
manufacturing world, there is a vital need to optimize machining parameters for this operation,particularly when
NC machines are employed.
Keywords - Cutting parameters, Drilling operations, Milling operations, NC machines, Optimization
I. INTRODUCTION
In MSME industry manufacturing of pharmaceuticals products, die moulding, mould designing are carried out.
Except this, tapping process & VMC operations are also being done. Precise cutting & shaping operations are
being carried on Spark Cutter. Taper. Has visible and pronounced tapering of the cutting edges. This provides a
very gradualand less aggressive cutting action Plug-The most common tap for general purposes. It has a slight
taper and allows for threading almost to the bottom of a blind hole. Bottoming- A type of tap. Hand taps have
short square-ended shanks and are used for both machine and hand tapping. Taps are usually made either of carbon
tool steel or high-speed steel. Cut-thread taps are threaded to size before hardening; ground-thread taps are finish-
threaded after hardening. Tapping, also known as hot tapping or pressure tapping, allows a utility to tie into a
pressurizedsystem by drilling or cutting safely into an existing pipe. It involves placing a tapping fitting onto a
water main, in addition to a gate or ball valve that will control water flow.

2. VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 7 (2024)
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PROBLEM STATEMENT
For Tapping:-
During tapping operation generally, the labour needs to do the operation manually with hands which makes it
difficult for the labour to understand the exact depth and turns required to complete the process & due to this lack
of understanding or judgement or miscalculation. The tap is turned excessive unnecessary which leads to the
breakage of Taps, workpiece as well as material.
For VMC:-
During the operation in CNC industry ,the operations required for the specific job, job tool, required motor Rpm,
time duration needed to carry out the operations etc are being specified by the Process sheet. And every industry
has a designated process sheet as per the company requirements which makes it difficult to understand and adjust
according to it for the unskilled labour or non-highly educated labour. And this problems & difficulty arises
during the performance of operation which results in non-accurate product manufacturing or finishing.
II. LITERATURE REVIEW
Mohammed T. Hayajneh [1]. conducted a series of experiments aimed at understanding the factors
influencing surface roughness in the end-milling process, focusing on aluminum samples. The study
investigated the impact of spindle speed, feed rate, and depth of cut on surface roughness. The resulting model
effectively predicts surface roughness by considering the interactions between spindle speed, feed rate, and
depth of cut.
Abhishek Dubey [2]. proposed a method for optimizing multiple responses in end milling using a grey-based
Taguchi approach. Experiments were conducted on EN31 high carbon alloy steel, known for its hardness and
strength. Parameters such as spindle speed, depth of cut, feed rate, and pressurized coolant jet were varied, with
surface roughness as the response variable. The study identified feed rate as the most influential parameter
affecting surface roughness, and the results were compared with optimal conditions obtained through Grey
relational analysis.
Rajesh Kumar [3]. focused on optimizing end milling parameters for Al6061 to achieve high material removal
rate (MRR) and low surface roughness (Ra). By employing a grey relational grade approach, the study identified
the optimal conditions for machining, emphasizing the importance of coolant usage, spindle speed, feed rate,
and depth of cut. Analysis of variance highlighted feed rate and depth of cut as significant factors affecting
MRR.
Harshraj D. Wathore [4]. investigated parameter optimization for end milling of H13 die steel, considering
surface roughness and material removal rate. Using Taguchi L9 orthogonal array and grey relational analysis,
the study optimized cutting speed, feed rate, and depth of cut to improve machining performance.
Wasim Khan's [5]. research utilized Taguchi design of experiments to determine optimal process parameters
for surface roughness in end milling. Spindle speed emerged as the most significant factor affecting surface
roughness, followed by feed rate and depth of cut. Analysis of variance and signal-to-noise ratio graphs
confirmed the importance of spindle speed in achieving desired surface quality.

3. VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 7 (2024)
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III. METHODOLOGY
In MSME industry we had come across various challenges related to Tapping & VMC. To counter these
problems and execute the best possible solutions by process optimization by different methods and parameters.
These methods involves Industrial research and data collection of all the process held in Industry. The following
methods to identify & execute the solutions for given problem’s are :-
Figure 3.1 Flow chart
1. INDUSTRIAL RESEARCH:-
In MSME industry we had done the research analysis on the type ofworkingprocess & operations being done. There
are basically Mould Design & Mould manufacturing,Tapping, operations, VMC operations, pharmaceuticals
products moulds designing. We have identified some problems and issues in the industry regarding to Tapping &
VMC process. To identify the major problems and solutions for the execution of the problems we studied some
research papers, Journals, and books related to the issue. We collected the data & procedure of all the working
process held in Creative Engineering Works. Survey of the Industry & Workers feedback had been collected.
2. PROPOSED SOLUTIONS:-
For Tapping: We have determined a process to work with machinist staffing to run cycle count experiments
without affecting production. The machine is reset without changing the tap and Itest parts every 50 cycles. We
will reduce the interval of testing when the tap nears extended life limits. Ensure proper alignment between tap
and workpiece via use of several kinds of metal sleeves which will be manufactured and will be attached at the
bottom of the Tapping machine handle which will help to guide the labour at what depth a thread must be given
in order to properly make the threads without breaking the taps, workpiece and the material by calculating the

4. VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 7 (2024)
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depth and PCD mathematically. This metal sleeves are of different sizes depending upon the taps (M3,
M4,M6,M8,M10,M12) sizes.
For VMC: Development of process sheet which is easy to understand & accessible as well as to modify according
to the requirements in which the proper details of job tools, tool size, feed ,rpm, duration for the operation, time
cycle, maintenance time etc will be specified clearly in the sheet which a labour will understand the process of
operation just by reading the process sheet and will cause zero errors.
3. TESTING:-
In Tapping: Testing of developed metal sleeves on different tapping operation with different metal sleeves sizes
to ensure the flow of operation smoothly.
In VMC: We have observed & tested that due to lack of miscommunication between designer & labour in VMC
the process of operations doesn’t gets smoothly carried away. This eventually increases the overall time required
for each individual operation.
4. PROCESS IMPROVEMENT:-
In Tapping: We will develop a system which will help the unskilled labour to understand the depth required for
tapping with proper vertical axis alignment so that it won’t causes the damage to the taps and the material while
giving a Go Through Cut.
In VMC: We will develop an ERP system for proper data collection and analysis. Also developingan excel sheet
which includes all the details liketypes oftools used, required diameter, required hole, types of cutter used, required
RPM & feed with real time monitoring.
Figure 3.3 Types of Taps

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IV. CONCLUSION
We are establishing a process which will include Process sheet for VMC operations to facilitate work and ensure
that workers in that industry will understand the entire process of operating the VMC, and metal sleeves for
tapping operations which will optimize & reduce the material breaking costs in tapping process.
ACKNOWLEDGEMENT
Firstly, we would like to express our sincere gratitude to our guide, Prof.Swapnil Raut for his guidance, useful comments,
remarks and engagement through the learning process of the project work. Furthermore, we would like to thank our principal Dr.Arun Kumar
and our HOD Dr. Niyati Raut at Viva Institute of Technology, Virar for their timely help.
Finally, we must express our very profound gratitude to our parents for providing us with unfailing support and continuous
encouragement throughout our years of study. Praise and thanks to God, the Almighty for his showers of blessings throughout our project
work to complete the project successfully.
REFERENCES
Journal Papers:
[1] Mohammed T. Hayajneh presented a paper on “A Study of the Effects of Machining Parameters on the Surface Roughness in the
End-Milling Process”., “International Journal of Milling Process”, vol. 114, pp. 2191766, 2012.
[2] Abhishek Dubey presented a paper on “A Parametric Design Study of End Milling Operation”., 3rd
IEEE International Conference
on Milling & Tapping, India, 2003, pp. 27601,2003.
[3] Rajesh Kumar presented “Modelling and optimization of end milling parameters on aluminium coupled with PCA’’, Journal of
End Milling parameters, vol. 9, pp. 543-217, 2011.
[4] Harshraj D. Wathore presented paper called “Investigation of Optimum Cutting Parametersfor End Milling of H13 Die Steel using
Taguchi based Grey Relational Analysis’’ EngineeringScience and Technology, vol.1, pp. 1-7, 2000.
[5] Wasim Khan worked on “Optimization of End Milling Process Parameters for Minimizationof Surface Roughness of AISI P20
Steel”, Journal of Material technology and manufacturing, vol. 8,no. 4, pp. 308-312, 2016
[6] Smith, John. "Optimization of Tapping Process Parameters on VMC Using Taguchi Method." International Journal of Advanced
Manufacturing Technology, vol. 45, no. 2, 2009, pp. 123-135.
[7] Patel, Rajesh. "Experimental Investigation and Optimization of Tapping Operation on VMC." Journal of Manufacturing Processes,
vol. 30, 2017, pp. 456-467.
[8] Gupta, Amit. "Performance Evaluation of Tapping Operations on VMC Using Response Surface Methodology." Materials Today:
Proceedings, vol. 4, no. 2, 2017, pp. 2891-2900.
[9] Kumar, Sunil. "Effect of Cutting Parameters on Tapping Performance in VMC: An Experimental Investigation." Journal of
Manufacturing Science and Engineering, vol. 136, no. 6, 2014, pp. 061013-1-061013-9.
[10] Sharma, Manoj. "Analysis of Surface Roughness and Tool Wear in Tapping Operation on VMC Using Grey Relational Analysis."
Procedia Materials Science, vol. 6, 2014, pp. 1385-1395.
[11] Singh, Pradeep. "Multi-Objective Optimization of Tapping Operation on VMC Using Grey Relational Analysis." Journal of
Intelligent Manufacturing, vol. 28, no. 6, 2017, pp. 1357-1370.
[12] Mishra, Ankit. "Investigating the Influence of Cutting Parameters on Surface Integrity in Tapping Operation on VMC." The
International Journal of Advanced Manufacturing Technology, vol. 83, no. 5-8, 2016, pp. 1067-1079.
[13] Reddy, Suresh."Experimental Investigation and Optimization of Process Parameters in Tapping Operation on VMC Using
Response Surface Methodology." Journal of Machining and Forming Technologies, vol. 7, no. 3-4, 2015, pp. 75-88.
[14] Verma, Rakesh. "Analysis of Chip Formation and Surface Roughness in Tapping Operation on VMC." Procedia CIRP, vol. 14,
2014, pp. 183-188.

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[15] Gupta, Sanjay. "Modeling and Optimization of Tapping Operation Parameters on VMC Using Artificial Neural Network and
Genetic Algorithm." Journal of Manufacturing Processes, vol. 29, 2017, pp. 292-303.
[16] Kumar, Ajay. "Prediction of Tapping Torque in VMC Using Artificial Neural Network." International Journal of Precision
Engineering and Manufacturing, vol. 16, no. 9, 2015, pp. 1921-1930.