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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882

Volume 4, Issue 8, August 2015

Optimization of Machining Parameters in


Drilling of Stainless Steel
Kunal Sharma, Mr. Abhishek Jatav
Suresh Gyan Vihar Unversity, Jaipur Rajasthan
Assistant Professor, Suresh Gyan Vihar University
Jaipur, Rajasthan

ABSTRACT
Almost half of the worlds industrial and production is
done by using stainless steel. It is not easy to machine
materials like austenitic stainless steel because of their
high strength, high ductility and low thermal
conductivity. This paper discusses the experimental
study on performance characteristics of AISI 304
stainless steel during CNC drilling process.Factors like
spindle speed, feed rate and point angle affect the
performance parameters such as the surface roughness
and ovality in drilling process. To get minimum surface
roughness and minimum ovality, the best optimal level
of parameters has to be chosen carefully. This paper
presents the multi-objective optimization of drilling
process parameters using Taguchi method in machining
of AISI304 stainless steel. The experiments are
conducted based on Taguchi L16 orthogonal array by
taking point angle, drill diameter, feed rate and spindle
speed at two levels. The Taguchi based signal-to-noise
ratio analysis is used to obtain the relation between the
machining parameters and performance characteristics.
The complete experimental results are discussed and
presented in this paper.
Keywords: CNC drilling, AISI stainless steel, surface
roughness, ovality, signal-to-noise ratio, Taguchi
method, AISI304.

1. INTRODUCTION
Drilling is one of the oldest metal removal processes.
Also, 40% of metal removal processes in industries,
majorly aerospace and automobile are done by drilling.
Bottlenecks were major problem in the drilling of
material using conventional method. However, the use
of CNC, NC machines has made it very easy to drill
without any kind of problem or bottlenecks. Also, the
use of drills all over the industry shows the significance
of drilling of material in each industry. AL-6061, Al6351 and AL-7075 were machined with feed rate,
cutting speed and point angle as the parameters to
optimize the effect on the diameter error and thrust
force. And results showed that the cutting speed and
feed rate both will help in minimising the thrust force
and diameter accuracy [1]. Al-2014 was selected as the
work piece and L18 of the orthogonal array was
selected for several experiments. Control factors were
the spindle speed, feed rate and cutting tool. Not much

difference was found in the predicted values and the


measured ones (feed was most effective) [3]. L27
orthogonal array was selected with the process
parameters such as cutting environment, cutting speed,
step angle and feed rate. The analysis of variance
showed that the feed rate has the maximum influence
when it comes to best optimum drilling conditions [4].
The drilling of fibre is not an easy task as it is not as
strong as the metal. ANOVA and Taguchi are used to
maximise tensile strength and minimise delamination.
Cutting speed as well as feed rate is responsible for the
delamination and tensile strength of the fibre [5]. The
orthogonal array L18 was selected for the optimization
of parameters using grey rational analysis and Taguchi
method of Hybrid metal matrix AL-356/Sic- mica
composites and feed and drill type are the most
influential deciding factors [6]. Taguchis (L25) 5-level
orthogonal array was selected. ANOVA (analysis of
variance) was chosen for the optimization of parameters
like spindle speed and feed rate. All this was done to
decrease the amount of delamination in the drilling of
GFRP. Variation in the parameters showed that the
delamination can be reduced if the proper values and
conditions are applied [10]. One of the most important
factor in machining of any material is surface
roughness. It has to be perfect as this part is usually the
core reason behind the wear rate and performance of
any machine or product. It is one of the deciding factor
in the selection of a material also, mainly metal [11].
Surface roughness was highly affected by spindle speed
and MRR was highly affected by the feed rate when L9
orthogonal array is established with ANOVA in drilling
of mid steel [14].OHNS has a lot of potential in the
industry as it is quite superior and mostly used to make
tools. During experiments parameters that were
controlled extensively tool diameter, feed and cutting
speed to get the maximum performance of tool wear,
MRR, diameter error and surface roughness.
Orthogonal array L18 was used for the experimentation
on CNC with a tool of high speed steel and design of
spiral drill [15].The whole drilling operation of the
composites was done to check the delamination (DF)
factor and un-cut fibre (UCFF) factor. The results
showed that the UCFF was highly affected by the feed
but the diameter and feed rate were not very effective
on the DF. Feed was found to be directly proportional
to the factors as any increase or decrease showed the
same for the factors [16].

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902

International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015

feed that can be attained in this specific machine is


2000mm/min.

Fig: Drilling process


Fig: VMC400 machine

2. TAGUCHI METHOD
Dr.Genichi Taguchi introduced an optimization method
that helped in making calculations of experiments
easier and rapid. It was originally made to make the
improvement in the quality of goods that were being
made in japan. This technique helped in introducing a
method that only require a specific set of experiments
to find the effectiveness on the response parameters.
Orthogonal Array represents the data structure and the
matrix that it shows contains the data for the
experiments. In addition, the number of runs during
experiment is defined by orthogonal array. In order to
reach maximum quality of product three steps are very
important in Taguchi method which is System Design,
Parameter Design and tolerance design. Taguchi
analysis was done using MINITAB17 software and the
results and graphs were plotted with that. MINITAB17
is software which a brilliant tool for the calculations
and researches using several algorithm. The
experiments were designed using Taguchi orthogonal
array and both the design of experiment follow the
same methodology. The DOE is a L16 orthogonal array
with four process parameters having two levels.

3. EXPERIMENTAL WORK
Table: Selected Parameters with levels
Sr.
Parameters
Level -1
no.
1.
Spindle Speed(rpm) 300
2.
Feed(mm/min)
20
3.
Point Angle
90
4.
Depth of Hole(mm) 15mm

Level +1

CUTTING TOOL

Fig: HSS tool used in drilling


Stainless steel is a material that cannot be machined
easily because of its properties. Therefore, the cutting
tool need to be the right one in order to get optimum
results. The cutting tool used here for drilling is HSS
(High Speed Steel) drill bits. HSS drills are easily
available and are cost effective as compared to the
other.

WORKPIECE MATERIAL

500
50
118
18mm

4. MACHINE USED
The experiments were conducted on the VMC-400. It is
a vertical milling/drilling machine, which is
manufactured by HMT. This vertical machining center
is equipped with the Fanuc India series O-M controller
for the execution of programs. The machine is capable
of running at 4000rpm of spindle speed. The maximum

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Fig. The drilling process

903

International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015

Stainless steel is better than other type of steel as it


doesnt corrode or rust. Stainless steel is found in many
grades but the one that was selected for this dissertation
was AISI 304 also known as DIN 1.4301. Sometimes it
is known by another name that is 18/8 which means the
composition of the material is 8% nickel and 18%
chromium.
Table: Chemical composition of material
ELEMENT
CONTENT (%)
Chromium (Cr)

Ovaliy is measured using the Coordinate measuring


machine (CMM). CMM has a vertical probe which
moves up and down and along edges of the holes. The
workpiece is placed flat on the table and the probe
measures the ovality of the drilled hole. The machine
used is Mitutoyo CRT-A C544 three-dimensional
coordinate measuring machine (CMM) device.
Minimum 10 points weremeasured to obtain the ovality
of drilled hole.

5. DESIGN MATRIX

17.50-19.50

Table: Design of Experiments using Taguchi L16


orthogonal Array

Nickel (Ni)

8.00-10.50

Manganese (Mn)

0.0-2.00

Silicon (Si)

0.0-1.00

Sr. No.

Nitrogen (N)

0.0-0.11

Point
Angle

Depth
Of
Hole

Spindle Speed

Feed

1.

90

15

300

20

0.0-0.07

2.

90

15

300

50

3.

90

15

500

20

4.

90

15

500

50

Carbon
Phosphorus (P)

0.0-0.05

Sulphur (S)

0.0-0.03

5.

90

18

300

20

Iron (Fe)

Balance

6.

90

18

300

50

7.

90

18

500

20

8.

90

18

500

50

9.

118

15

300

20

10.

118

15

300

50

11.

118

15

500

20

12.

118

15

500

50

13.

118

18

300

20

14.

118

18

300

50

15.

118

18

500

20

16.

118

18

500

50

SURFACE ROUGHNESS MEASUREMENT


Surface roughness is defined as the finer irregularities
of the surface texture that usually result from the
inherent action of the machining process or material
condition.A portable surface roughness tester (Model
No TR 210 manufactured by Beijing TIME High
Technology Ltd. Beijing City, China) has been used to
measure surface roughness indicators of finished work
pieces.

RESULTS FOR SURFACE ROUGHNESS

Fig: surface roughness tester

OVALITY MEASUREMENT

Fig: Coordinate Measuring Machine

In this experiment, the surface roughness for each hole


was measured and noted as response. The result of the
surface roughness (SR) is represented along with
parameters in the given table 4.11. S/N (SR) represents
the signal-to-noise ratio for surface roughness. For all
the tables and models, A, B, C, and D are point angle,
depth of hole, spindle speed and feed.
Sr.
no.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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SR

S/N (SR)

90
90
90
90
90
90
90
90
118
118

15
15
15
15
18
18
18
18
15
15

300
300
500
500
300
300
500
500
300
300

20
50
20
50
20
50
20
50
20
50

3.672
5.662
4.561
5.83
4.013
6.124
4.825
6.94
4.31
5.827

-11.29805345
-15.0593973
-13.18120144
-15.3133711
-12.06938319
-15.74070364
-13.66994635
-16.82718941
-12.6895454
-15.30890036

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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015

11.
12.
13.
14.
15.
16.

118
118
118
118
118
118

15
15
18
18
18
18

500
500
300
300
500
500

20
50
20
50
20
50

4.868
5.521
4.469
6.448
5.145
6.583

-13.74701139
-14.84035494
-13.00420709
-16.18850058
-14.22770758
-16.3684771

ANOVA
ANOVA means the disintegration of complete
variability into its constituents. Using ANOVA, we can
find the most effective parameters in the study and
name the significant ones very easily and performance
parameter can be optimized successfully. It helps in
understanding the means of groups and the chances of
them being equal. It is a very helpful method in finding
the significance when we have two or more means to
analyse.

Level
1
2
Delta
Rank

A
B
C
D
A*B
A*C
A*D
B*C
B*D
C*D
Residual
error
Total

SS

DF

MS

0.6462
2.7708
2.9041
29.5932
0.0040
0.5012
0.8484
0.1164
0.4056
1.3881
0.2289

1
1
1
1
1
1
1
1
1
1
5

0.6462
2.7708
2.9041
29.5932
0.0040
0.5012
0.8484
0.1164
0.4056
1.3881
0.0458

39.4068

15

RESPONSE
TABLE
ROUGHNESS

Fvalue
14.11
60.51
63.43
646.32
0.09
10.95
18.53
2.54
8.86
30.32

FOR

Pvalue
0.013
0.001
0.001
0.000
0.780
0.021
0.008
0.172
0.031
0.003

Significant
Significant
Significant
Significant
Insignificant
Significant
Significant
Insignificant
Significant
Significant

SURFACE

The given table shows the response and their


significance in the variation in response which is
surface roughness at the moment. It is clear from the
table that the feed is most effective of them and the
point angle is the least effective on the response. While
the spindle speed is second to the most significant.
Response Table for SURFACE ROUGHNESS Smaller
is better

B
-13.93
-14.76
0.83
3

C
-13.92
-14.77
0.85
2

D
-12.99
-15.71
2.72
1

RESULTS FOR OVALITY


The results were recorded and then analysed using the
MINITAB software. The following table shows the
response and its signal-to-noise ratio along with
ANOVA in separate tables.

ANOVA FOR SURFACE ROUGHNESS


The amount of variation can be indicated by S/N ratio
in the given process. The variations in surface
roughness can be calculated by using the S/N ratio and
it is shown in the table below. The table shows the
ANOVA result surface roughness which is taken at
95% confidence interval. According to the table all
factors are significant and the interactions A*C, A*D,
B*D, C*D are also significant while the other
interactions are insignificant.
Analysis of Variance for Surface Roughness-SN ratio
Source

A
-14.14
-14.55
0.40
4

Sr.
no.
1.

Ovality

S/N (OV)

90

15

300

20

14.235

-23.06714943

2.

90

15

300

50

14.185

-23.0365868

3.

90

15

500

20

14.237

-23.0683697

4.

90

15

500

50

14.343

-23.13279997

5.

90

18

300

20

14.286

-23.09821292

6.

90

18

300

50

14.217

-23.05615927

7.

90

18

500

20

14.457

-23.20156362

8.

90

18

500

50

14.512

-23.23454539

9.

118

15

300

20

14.017

-22.93310147

10.

118

15

300

50

14.147

-23.01328707

11.

118

15

500

20

14.164

-23.02371836

12.

118

15

500

50

14.379

-23.15457367

13.

118

18

300

20

14.082

-22.9732868

14.

118

18

300

50

14.103

-22.98623012

15.

118

18

500

20

14.377

-23.15336545

16.

118

18

500

50

14.414

-23.17569035

ANOVA FOR OVALITY


The amount of variation can be indicated by S/N ratio
in the given process. The table shows the ANOVA
result for S/N ratio for ovality which is taken at 95%
confidence interval. According to the table all factors
are significant and the interactions A*C, A*D, B*C,
B*D, C*D are also significant while A*B is an
interaction which is insignificant.
Analysis of Variance for Ovality- SN ratio
Source

SS

MS

0.014528

D
F
1

0.014528

Fvalue
32.17

Pvalue
0.002

Significant

0.012626

0.012626

27.96

0.003

Significant

0.060100

0.060100

133.10

0.000

Significant

0.004594

0.004594

10.17

0.024

Significant

A*B

0.000925

0.000925

2.05

0.212

Insignifica
nt

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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015
A*C

0.003088

0.003088

6.84

0.047

Significant

A*D

0.003067

0.003067

6.79

0.048

Significant

B*C

0.006478

0.006478

14.35

0.013

Significant

B*D

0.002990

0.002990

6.62

0.050

Significant

C*D

0.003309

0.003309

7.33

0.042

Significant

Residu
al
error

0.002258

0.000452

Total

0.113962

15

RESPONSE TABLE FOR OVALITY


The given table shows the response and their
significance in the variation in response which is
ovality at the moment. It is clear from the table that the
spindle speed is most effective of them and the feed is
the least effective on the response. The point angle and
depth of hole are respectively at the IInd and IIIrd place.
Response Table for OVALITYSmaller is better
Level

-23.11

-23.05

-23.02

-23.05

-23.11

-23.14

Delta

0.06

0.06

0.12

23.06
23.10
0.03

Rank

Fig. Main effect plot for of surface roughness

Fig. Main effect plot of Ovality

INTERACTION PLOT

6. RESULTS AND DISCUSSION


The surface roughness and ovality was recorded and
analysed using MINITAB software which helped us in
creating graphs and plots for the results which makes it
easier to understand the effect of the parameters on the
responses.

MAIN EFFECT PLOT


According to the main effect plot for means the value of
surface roughness increases rapidly with the slightest
change in feed.Surface roughness values (Ra) were
found decreasing with increasing spindle speed.
According to the slope the least influential factor is
point angle as the variation is relatively very low.With
the increase in the values of the parameter the surface
roughness is decreasing.With the increase in the values
of the parameters the ovality is decreasing while in the
case of point angle the values are increasing. The
spindle speed is the most effective of all the process
parameters.

For surface roughness, it shows the decrease in the


response values which are on the x-axis with the
variation in the parameters values which are on the yaxis. Here, with the increase in feed the values are
decreasing. As in this interactions the value of the
ovality increases rapidly with the increase in the spindle
speed.It shows the decrease in the response values other
than the interactions of point angle in which case the
values are increasing, which are on the x-axis with the
variation in the parameters values which are on the yaxis.

Fig. Interaction plot surface roughness


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906

International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015

Fig. Interaction plot of Ovality

7. CONCLUSION
In this paper, the research has been done to find out the
best optimal conditions for the drilling of AISI 304
stainless steel using HSS twist drills. The analysis of
variance and Signal-to-Noise ratio showed the effect of
factors over the responses in various forms like one
way or with the interaction. Now, we have following
conclusions from our research study:
i.
The feed is the most effective parameter and
that the small variation in feed will show large
increase in surface roughness.
ii.
For better or minimum surface roughness the
feed need to be kept low along with the spindle
speed and depth of hole.
iii.
The surface roughness increases with increase
in feed, depth of hole.
iv.
The ovality increases with the increase in depth
of hole, spindle speed and feed.
v.
The ovality decreases with the increase in point
angle. So, for minimum ovality, point angle
should be high.

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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 4, Issue 8, August 2015

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