Documente Academic
Documente Profesional
Documente Cultură
Abstract
The optimization of turning operations based on the Taguchi method with multiple performance characteristics is proposed in this paper.
The orthogonal array, multi-response signal-to-noise ratio, and analysis of variance are employed to study the performance characteristics
in turning operations. Three cutting parameters namely, cutting speed, feed rate, and depth of cut, are optimized with considerations of
multiple performance characteristics including tool life, cutting force, and surface nish. Experimental results are provided to illustrate the
effectiveness of this approach. # 1999 Elsevier Science S.A. All rights reserved.
Keywords: Analysis of variance; Orthogonal array; Cutting speed; Feed rate; Depth of cut; Tool life; Cutting force; Surface nish
1. Introduction
The Taguchi method [13] is a systematic application of
design and analysis of experiments for the purpose of
designing and improving product quality. In recent years,
the Taguchi method has become a powerful tool for improving productivity during research and development so that
high quality products can be produced quickly and at low
cost. A lot of applications of the Taguchi method have been
reported in a world-wide range of industries and nationalities [4]. This is because the Taguchi method is universally
applicable to all engineering elds. However, most published Taguchi applications to date have been concerned
with the optimization of a single performance characteristic.
Handling the more demanding multiple performance characteristics is seldom considered in the literature [5]. In this
paper, the application of the parameter design of the Taguchi
method for improving the multiple performance characteristics in turning operations is reported.
In the past, several optimization methods for turning
operations have been documented [69]. To determine the
optimal cutting parameters, reliable mathematical models
based on a large amount of machining data have to be
*Corresponding author. Tel.: +886-2-2737-6456; fax: +886-2-27376460
E-mail address: ystarng@mail.ntust.edu.tw (Y.S. Tarng)
formulated to associate the cutting parameters with machining performance. Sophisticated optimization algorithms are
then applied to the mathematical models for solving the
optimal cutting parameters. It is shown by this study that the
use of the parameter design of the Taguchi method can
greatly simplify the optimization procedure for determining
the optimal cutting parameters in turning operations. As a
result, from the practical viewpoint, the parameter design of
the Taguchi method seems to be the most suitable approach
to determine the optimal cutting parameters for turning
operations in a machine shop.
The paper is organized in the following manner. An
overview of the parameter design based on the Taguchi
method is given rst. Then, the parameter design with the
multiple performance characteristics is introduced. The
experimental details of using the parameter design to determine and analyze the optimal cutting parameters in turning
operations is described next. Finally, the paper concludes
with a summary of this study.
2. Parameter design based on the Taguchi method
The objective of the parameter design [10] is to optimize
the settings of the process parameter values for improving
performance characteristics and to identify the product
parameter values under the optimal process parameter
0924-0136/99/$ see front matter # 1999 Elsevier Science S.A. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 9 9 ) 0 0 2 7 1 - X
91
Lij
;
Li
(1)
where Sij is the normalized loss function for the ith performance characteristic in the jth experiment, Lij the loss
function for the ith performance characteristic in the jth
experiment and Li is the average loss function for the ith
performance characteristic.
A weighting method is then used to determine the importance of each normalized loss function. Based on the
weighting method, the total loss function TLj in the jth
experiment is dened as
TLj
m
X
wi Sij ;
(2)
i1
(3)
92
meters, i.e., cutting speed, feed rate, and depth of cut, must
be determined in a turning operation. Common methods of
evaluating machining performance in a turning operation are
based on the following performance characteristics: tool life,
cutting force, and surface roughness. Basically, tool life,
cutting force, and surface roughness are strongly correlated
with cutting parameters such as cutting speed, feed rate, and
depth of cut [12]. Proper selection of the cutting parameters
can obtain a longer tool life, a lower cutting force, and better
surface roughness. Hence, optimization of the cutting parameters based on the parameter design of the Taguchi method
is adopted in this paper to improve the tool life, cutting force,
and surface roughness in a turning operation.
4.1. Selection of cutting parameters and their levels
The cutting experiments were carried out on an engine
lathe using tungsten carbide with the grade of P-10 for
the machining of S45C steel bars. The initial cutting parameters were as follows: cutting speed of 210 m/min, a feed
rate of 0.20 mm/rev, and a depth of cut of 1.1 mm. The
feasible range for the cutting parameters was recommended
by a machining handbook, i.e., cutting speed in the range
135285 m/min, feed rate in the range 0.080.32 mm/rev,
and depth of cut in the range 0.61.6 mm. Therefore, three
levels of the cutting parameters were selected as shown in
Table 1.
4.2. Machining performance measure
Tool life is dened as the period of cutting time at which
the average ank wear land VB of the tool is equal to 0.3 mm
or the maximum ank wear land VBmax is equal to 0.6 mm.
This tool life criterion is recommended by the International
Standard Organization (ISO). In the experiments, the ank
wear land was measured by using a toolmaker's microscope
(Isoma). The cutting force acting on the cutting tool in the X,
Y, and Z directions was measured by a three-component
piezo-electric dynamometer (Kistler 5257A) under the tool
holder. The resultant cutting force is then calculated to
evaluate the machining performance in this study. The
machined surface roughness was measured by a prole
meter (3D-Hommelewerk). The average surface roughness
Ra, which is the most widely used surface nish parameter in
industry, is selected in this study, being the arithmetic
average of the absolute value of the heights of roughness
Table 1
Cutting parameters and their levels
Symbol
Cutting
parameter
Unit
Level 1
Level 2
Level 3
A
B
C
Cutting speed
Feed rate
Depth of cut
m/min
mm/rev
mm
135
0.08
0.6
210a
0.20a
1.1a
285
0.32
1.6
93
Table 2
Experimental layout using an L9 orthogonal array
Table 4
Multi-response signal-to-noise ratio with different weighting factors
Experiment
number
Experiment number
1
2
3
4
5
6
7
8
9
Case 1
Case 2
Cutting speed
Feed rate
Depth of cut
Error
1
1
1
2
2
2
3
3
3
1
2
3
1
2
3
1
2
3
1
2
3
3
1
2
2
3
1
1.807
4.464
11.715
4.840
5.606
10.501
4.351
8.703
16.402
0.194
7.752
13.199
6.696
5.457
11.102
4.037
10.173
14.549
1
2
3
4
5
6
7
8
9
optimal machining performance, the higher-the-better performance characteristic for tool life must be taken. On the
other hand, the lower-the-better performance characteristic
for cutting force and surface roughness should be taken for
obtaining optimal machining performance. For the higherthe-better performance characteristic, the loss function can
be expressed as
Lij
n
1X
1
n k1 y2ijk
(4)
where Lij is the loss function of the ith performance characteristic in the jth experiment, n the number of tests, and yijk
is the experimental value of the ith performance characteristic in the jth experiment at the kth test.
The loss function Lij for the lower-the-better performance
characteristic can be expressed as
Lij
n
1X
y2 :
n k1 ijk
(5)
A
B
C
Cutting
parameter
Level 2
Cutting speed
Feed rate
Depth of cut
4.79
2.46
6.73
6.98
6.26
6.44
Level 3
9.82
12.87
8.42
Maxmin
5.03
10.41
1.98
Tool
life (s)
Cutting
force (N)
Surface
roughness (mm)
Table 6
Multi-response signal-to-noise table for w13, w25, w32
1
2
3
4
5
6
7
8
9
2645
2060
1733
1310
1198
734
854
765
216
263
704
1198
593
389
854
335
857
464
1.239
1.921
9.443
2.641
4.513
7.490
0.908
4.184
9.695
Symbol
A
B
C
Cutting
parameter
Level 2
Cutting speed
Feed rate
Depth of cut
6.84
3.51
6.60
7.75
7.72
7.55
Level 3
9.59
12.95
10.02
Max-min
2.74
9.44
3.42
94
p
X
j m 2 ;
(6)
j1
Table 7
Results of the analysis of variance for w15, w22, w33
Symbol
Cutting parameter
Degrees of freedom
Sum of squares
Mean square
Contribution (%)
A
B
C
Cutting speed
Feed rate
Depth of cut
2
2
2
38.13
166.55
6.85
19.06
83.28
3.43
3.31
14.47
0.06
17.10
74.67
3.07
Error
11.51
5.75
Total
223.04
5.16
100
95
Table 8
Results of the analysis of variance for w13, w25, w32
Symbol
Cutting parameter
Degrees of freedom
Sum of squares
Mean square
Contribution (%)
A
B
C
Cutting speed
Feed rate
Depth of cut
2
2
2
11.73
134.12
18.69
5.86
67.06
9.35
1.07
12.26
1.71
6.68
76.43
10.65
Error
10.94
5.47
Total
223.04
Level
A2B2C2
A1B1C2
Tool life (s)
1059
Cutting force (N)
622
Surface roughness (mm)
2.754
S/N ratio (dB)
5.73
0.06
Improvement multi-response S/N ratio4.91 dB
Experiment
A1B1C2
2604
454
1.084
0.82
100
Tool
life (dB)
Cutting
force (dB)
Surface
roughness (dB)
60.50
55.88
8.80
68.31
53.14
0.70
7.81
2.73
8.10
Table 11
Results of the confirmation experiment for w13, w25, w32
6.23
Level
Tool life (s)
Cutting force (N)
Surface roughness (mm)
S/N ratio (dB)
Initial cutting
parameters
Experiment
A2B2C2
1059
622
2.754
7.30
A1B1C1
A1B1C1
2645
263
1.239
0.19
0.07
96
Table 12
Improvement of the individual signal-to-noise ratio for w13, w25, w32
Initial cutting
parameters (A2B2C2)
Optimal cutting
parameters (A1B1C1)
Improvement S/N ratio
Tool
life (dB)
Cutting
force (dB)
Surface
roughness (dB)
60.50
55.88
8.80
68.50
48.40
1.86
8.00
7.48
6.94
6. Conclusions
This paper has presented an application of the parameter
design of the Taguchi method in the optimization of turning
operations with multiple performance characteristics. It is
found that the parameter design of the Taguchi method
provides a simple, systematic, and efcient methodology
for the optimization of the cutting parameters. Furthermore,
the multiple performance characteristics such as tool life,
cutting force, and surface roughness can be improved
simultaneously through this approach instead of using engineering judgement. Therefore, a useful technical tool for the
quality optimization of manufacturing systems with considerations of multiple performance characteristics has been
proposed and veried in this study.
Acknowledgements
Financial support from the National Science Council of
the Republic of China, Taiwan, under grant number NSC872216-E011-025 is acknowledged.
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