Measurement 93 (2016) 108116

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Measurement
journal homepage: www.elsevier.com/locate/measurement

Optimization of surface roughness and tool wear in hard turning of

austempered ductile iron (grade 3) using Taguchi method
D. Manivel , R. Gandhinathan
Department of Production Engineering, PSG College of Technology, Coimbatore 641004, India

a r t i c l e i n f o a b s t r a c t

Article history: In this work, the cutting parameters are optimized in hard turning of ADI using carbide inserts based on
Received 19 February 2016 Taguchi method. The cutting insert CVD coated with AL2O3/MT TICN. Experiments have been carried out
Received in revised form 9 June 2016 in dry condition using L18 orthogonal array. The cutting parameters selected for machining are cutting
Accepted 23 June 2016
speed, feed rate and depth of cut with each three levels, nose radius in two levels maintaining other cut-
Available online 24 June 2016
ting parameters constant. The ANOVA and signal to noise ratio are used to optimize the cutting param-
eters. The cutting speed is the most dominant factor affecting the surface roughness and tool wear. In
Keywords:
optimum cutting condition, the confirmation tests are carried out. The optimum cutting condition results
Austempered ductile iron
Surface roughness
are predicted using signal to noise ratio and regression analysis. The predicted and experimental values
Taguchi for surface roughness and tool wear adhere closer to 9.27% and 1.05% of deviations respectively.
Tool wear 2016 Elsevier Ltd. All rights reserved.

1. Introduction and literature review
Hard Turning is a turning of hard material with a hardness
range from 45 to 68 HRC. Generally, coated carbide, cubic boron
nitride (CBN), Ceramic and polycrystalline cubic boron nitride
(PCBN) inserts are used to turn the hard materials in CNC lathe.
The machining of hardened materials using CBN, PCBN and cera-
mic tools are generally used and it is a good alternative to expen-
sive grinding operations [1]. Hard turning has many advantages
other than the cost advantage such as faster metal removal rate,
reduced cycle time, good surface finish and environmental free [2].
ADI materials have been used in many engineering applications
because of their high strength, high hardness, ductility and tough-
ness. These materials have been widely used for many applications
such as automotive, agricultural, railroad, construction and mining
industries due to their excellent mechanical properties, such as
high strength to weight ratio, high wear resistance and inexpensive
material compared to other materials [3]. Austempered ductile
iron (ADI) is a comparatively latest material for industrial applica-
tions. ADI is a heat treated form of as cast Ductile Iron. The
Austempering process consists of three stages they are austenitiz-
ing, isothermal quenching and cooling to room temperature.
Abbreviations: CVD, Chemical Vapor Deposition; ADI, Austempered ductile iron;
HRC, Rockwell hardness measured on C scale.
Corresponding author.
E-mail address: manivelpsg@yahoo.co.in (D. Manivel).
Austempering results the microstructure consists of ferrite in high
carbon austenite matrix [4].
ADI is difficult to machine compared to ductile cast irons in the
austempered condition, because of relatively high hardness and
high strength. In machining, the material is strained hardening
takes place due to the presence of retained austenite. The strain
hardening of retained austenite increases mechanical loads and
reduces the contact length on the cutting insert tools edge [5].
The higher cutting tool wear was observed in machining of ADI
in austempered condition, when compared to other hardened
material. The higher tool wear occurs at the cutting tools edge
due to high temperature, adhesion resting on the cutting tool
and higher ductility of ADI [6]. In turning of ADI, the cutting tools
edge subjected thermal softening due to higher cutting tempera-
tures and low thermal diffusivity of ADI [7]. The aim of the new
machining industries is to produce components at low product
cost with good quality in minimum time. To achieve a good cutting
performance in turning, selection of optimum cutting parameters
is important. Machinability of hardened materials is evaluated by
cutting force, surface roughness and tool wear.
Turning the hard material to get a minimum surface roughness
with minimum tool wear is difficult. The following literature sur-
vey indicates that most of the hard material is turned by CBN,
PCBN and ceramic inserts. Katuku et al. [8] conducted experimen-
tal work in dry cutting condition on austempered ductile iron
(ASTM grade 2). The cutting forces, chip characteristics and tool
wear were analyzed with PcBN cutting tools. The result revealed

http://dx.doi.org/10.1016/j.measurement.2016.06.055
0263-2241/ 2016 Elsevier Ltd. All rights reserved.
 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116
that the optimum cutting speed for better tool life and flank tool
wear is 150500 m/min. In another work Marcelo Vasconcelos de
Carvalho et al. [3] investigated machinability of ADI (ASTM grades
2 and 3). It has been reported that minimum surface roughness and
higher tool wear observed when turning ADI grade 3 with higher
tool nose radius. In another work, zel and Karpat [9] developed
the prediction model using regression and neural networks in hard
turning for surface roughness and tool wear by CBN inserts. Mini-
mum surface roughness was obtained at high work piece hardness
with high cutting speed. Higher tool wear were obtained with
higher cutting speed at lower feed rate. Lowered feed rate gives
the good surface finish.
Hessainia et al. conducted experimental work on hard turning.
The surface roughness was predicted with the use of cutting
parameters and tool vibrations. The mixed ceramic cutting tool
Al2O3/TiC was used. They found that feed rate was the most dom-
inating factor than the tool vibration in affecting the surface rough-
ness. [10]. Gunay and Yuce applied Taguchi for cutting conditions
optimizing for surface roughness in turning of white cast iron (high
alloy). The hardness of the material was 50 HRC and 62 HRC. The
turning was carried out by ceramic and cubic boron nitride. The
Taguchi orthogonal array L18 was used. Optimum cutting condi-
tions were calculated using the signal-to-noise (S/N) ratio based
on the-smaller-the-better approach. It was noted that cutting
speed and feed rate was the dominant factor disturbing the surface
roughness [11]. Saini et al. [12] studied the Influence of cutting
parameters in hard turning. The AISI H11 tool steel material and
the ceramic inserts were selected for hard turning. The effect of
cutting parameters were analyzed by response surface methodol-
ogy on tool wear and surface roughness. They found that the depth
of cut had no effect on tool wear and surface roughness. Insert nose
radius and cutting speed have the maximum effect on surface
roughness. In higher cutting speed the tool nose radius subjected
to maximum pressure and temperature results in increased tool
wear. More et al. [13] have been conducted the experiments and
compared the performance of CBNTiN coated and PCBN inserts
on hardened AISI 4340 steel about HRC = 53. The performance of
cutting tools was compared in terms of tool wear, surface rough-
ness, and cutting forces. The result indicated that PCBN insert
has better tool life, lower cutting force, and minimum surface
roughness than the cBNTiN coated carbide inserts at given cutting
conditions. But the cBNTiN coated carbide tool has less cost than
the PCBN; therefore, it reduces the machining cost based on a sin-
gle cutting edge.
The surface quality of the machined part is significant. The sur-
face quality depends on the surface finish. The good surface finish
increases fatigue strength, wear resistance and minimizes the cor-
rosion attack of the finished parts. The surface finish depends on
various parameters like material hardness, type of inserts, type of
coating, heat transfer and cutting parameters. Therefore the opti-
mization of surface roughness and tool wear is important. The opti-
mized parameter gives a good surface finish in the first machining
itself, increases the production rate and decreases the production
cost. Some of the following literature survey about optimization.
Mandal et al. [14] investigated that optimization of cutting param-
eter for tool flank wear using newly developed cutting tool Zirconia
Toughened Alumina (ZTA). Taguchi method and regression analy-
sis were used to optimize the cutting parameters. It has been
observed that the tool wear was highly affected by the depth of
cut. Asiltrk and Neseli [15] conducted the experiment on austeni-
tic stainless steel. The cutting parameters were multi optimized by
Taguchi method and response surface analysis. It found that the
feed rate has the most effect on surface roughness. It was most
leading parameters affecting the surface roughness comparability
to other parameters. In another work Selvaraj et al. [16] applied
the Taguchi method for dry turning of nitrogen alloyed duplex
109
stainless steel by coated carbide cutting inserts. The cutting
parameters were optimized for surface roughness, tool wear and
cutting force. The results revealed that the surface roughness and
cutting force was mostly dominated by feed rate where as tool
wear was mostly dominated by the cutting speed. In another work,
Palanikumar [17] optimized the drilling parameters for glass
fiber-reinforced plastics, composites by Taguchi method with grey
relational study. The result indicated that feed rate was the most
dominant parameter than the spindle speed. Munawar et al. [18]
studied the effect of cutting parameters in internal turning.
Taguchi method was applied. Turning was carried out using L18
orthogonal array. It was noted that low cutting speed and high feed
rate developed minimum surface roughness.
The cost of the CBN, PCBN and ceramic inserts are very high
compared to coated carbide inserts. Turning of hard material by
coated carbide insert reduces the production cost. Some of the
researcher used carbide inserts for turning of hard material as fol-
lows, Ucun and Aslantas [19] studied the effects cutting speed,
depth of cut and feed rate on surface roughness in hard turning.
The hard material used for experimental was bearing steel with
the grade of AISI 52100. The hard material was turned by coated
carbide inserts. They observed that, in the hard turning process,
carbide cutting tools were not fit especially at high cutting speed.
Asilturk and Akkus applied the Taguchi method in the hard turning
process using coated carbide tools; the experimental result indi-
cated that the feed rate was the dominant factor effect on surface
roughness [20]. In another work, AISI D2 steel a hardness of 66 HRC
was machined with coated carbide insert decreases in surface
roughness with the increase in cutting speed and surface rough-
ness increased with increased feed rate and depth of cut [2]. Chou
and Song have investigated the effect of tool nose radius on hard-
ened steel (AISI 52100) in hard turning; the better surface finish
was obtained in larger tool nose radius [21].
The literature survey shows that CBN, PCBN, and ceramic tool
were widely used for turning of hardened materials, but the hard
turning using coated carbide insert is very limited. In this work,
the coated carbide tool is used for turning the hard material. It is
a cost effective method. In this experimental work, the surface
roughness and tool wear only were considered. In this study, the
effect of machining parameters such as nose radius, cutting speed,
feed rate and depth cut on the surface roughness and tool wear in
the turning of ADI (grade 3) with CVD coated carbide inserts was
investigated. Experiments were conducted using Taguchis L18
orthogonal array. Analysis of variance (ANOVA) and S/N ratio were
used to analysis, cutting conditions (Nose radius, cutting tool, cut-
ting speed and feed rate) for surface roughness and tool wear.
Analysis of variance (ANOVA) was used to find out the significant
factors. S/N ratio was used to calculate the optimum cutting factors
and their levels. In addition, the measured values were predicted
by using regression analysis. At the end, the confirmation experi-
ments were used to check the reliability of the developed models
reliability.
2. Experimental details
The experimental work details, measurements, calculations and
procedure for this experimental study are discussed in following
chapters.
2.1. Material
The work material used for experimental work is austempered
ductile iron ASTM grade 3. The material is austenitized at 880 C
for 2 h. After austenitizing the specimens were quenched in the
salt bath of 50% of sodium nitrate (NaNO3) and 50% potassium
110 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116

nitrate (KNO3) at 230 C for 2 h. The Tensile Strength 1241 MPa,

Yield Strength 893 MPa, Hardness 45 HRC and Elongation 4.88%
were obtained after the austempered heat treatment. The size of
the work piece materials was 35 mm diameter and 90 mm long.
The chemical composition of ADI grade 3 is given in Table 1.

2.2. Cutting conditions

The experiments were conducted in galaxy Midas 6 CNC lathe

under dry cutting conditions, which having the maximum spindle
power of 7.5 kW and the spindle speed from 40 to 4000 rpm. The
cutting tools used were carbide inserts CVD coated of TaeguTec
Company (TT7310) with a specification of CNMG 120408 RT, and Fig. 1. Turning of ADI experimental setup.
CNMG 120404 MT (with an ISO designation equal to K10K20),
having nose radius 0.8 mm and 0.4 mm respectively were used.
Fig. 1 shows the turning of ADI experimental set-up. Every exper-
iment a fresh cutting edge was utilized. The right hand style tool Table 2
holder PCLNR2020K12 RH designated by ISO is used to hold the Cutting parameters for turning and their levels.

inserts. The material 1 mm depth was removed to avoid oxidiza- Symbol Cutting parameter Unit Level 1 Level 2 Level 3
tion, decarburization and also to remove irregularities before test- r Nose Radius mm 0.8 0.4
ing. The cutting parameter ranges selected as per cutting tool V Cutting speed m/min 50 100 150
manufacturers recommendation, machine capability and litera- f Feed rate mm/rev 0.04 0.08 0.12
ture review [2,10,20]. The design involves the variation of four cut- d Depth of cut mm 0.2 0.3 0.4

ting parameters at different levels as shown in Table 2.

2.3. Tool wear measurement  Nominal is the best approach,

The Mitutoyo tool makers microscope (TM 505 series) is used
to measure the tool wear. It is used to measure the work piece con-
tours and examine the surface features. The magnification of the
instrument is 30
and least count is 0.001 mm.
2.4. Surface roughness measurement
The surface roughness is measured by using stylus type surface
roughness tester (surfcorder SE 1200 series). According to JIS-1994
standard [18], cut off length and sampling length are 0.8 mm and
4 mm respectively were selected to evaluate the surface texture.
The surface roughness were measured at three locations and then,
the average surface roughness (Ra) calculated.
3. Taguchi method and design of experiment
The Taguchi design is widely accepted and used in engineering
analysis and optimization. This design is developed by Dr. Genichi
[20]. It is a power full design. In Taguchi methods, the number of
experiments were reduced by orthogonal array and also reduce
the effects of uncontrollable factors [20]. The quality of the Taguchi
design is ensured in the design phase itself. The Taguchi method is
used to reduce no. of trails, decreased experimental time,
decreased the production cost, simple and precision are the most
advantages in this technique. This also used to determine the sig-
nificant factors in a minimum time [22]. The Taguchi method used
to calculate loss function. Loss function is the difference among the
experimental and desired values. Then the loss function is con-
verted in the form of signalnoise (S/N) ratio. Generally, three
types of quality S/N ratio characteristics written in Eqs. (1)(3),
when the characteristic is continuous [20]

=S2y
S=N 10 log y 1
 Smaller is the better approach,
S=N 10 log 1=nR y2 2
 Larger is the better approach,
S=N 10 log 1=nR 1=y2 3
This indicates that engineering systems perform in such
method. The manipulated production factors are divided into three

is the observed data average, S2y the variance of
categories: where, y
y, n is the observation number and y the observed data of each
characteristic. The S/N ratio calculated for each level of parameters
by S/N ratio analysis. The objective of this study is to achieve min-
imum surface roughness and minimum tool wear. Therefore the
smaller is the better characteristic was chosen and shown in
Eq. (2). The orthogonal array L18 ((21 37) was selected to anal-
ysis and optimize cutting parameters [11,23]. The experiments
were conducted using L18 mixed orthogonal array and it is shown
in Table 3.
4. Results and discussion
In this experimental work, the Taguchi method is used to deter-
mine the optimum cutting condition. The orthogonal array (OA) is
used to check the quality characteristics with minimum trial [15].
The experiments conducted based on the orthogonal array and
then the results are transformed to signal to noise ratio (S/N ratio)
to perform the characteristic analysis. The parameter design is per-
formed to get optimum conditions. The parameter design is also
called as robust design. Fig. 2 shows the Taguchi method flow
chart.

Table 1
Chemical composition of ADI ASTM grade 3.

Element %C %Si %Mn %Cu %Cr %P %S %Mg %Sn

wt% 3.42 2.47 0.415 0.458 0.027 0.029 0.005 0.020 0.079
 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116 111

Table 3 cut on surface roughness and tool wear. This analysis was done
L18 orthogonal array. with 95% confidence level and 5% significance level. The ANOVA
S.N Nose radius Cutting speed Feed rate Depth of table consists of degrees of freedom, mean square, sum of square,
(mm) (m/min) (mm/rev) cut (mm) F ratio and % of contribution. In ANOVA, the F values of each control
1 1 1 1 1 factor were compared to determine the significance each control
2 1 1 2 2 factors. The higher F contribution, the higher the influence a factor
3 1 1 3 3 has in the result. F ratio is the ratio between mean square and the
4 1 2 1 1
5 1 2 2 2
mean square of the experimental error. Table 4 shows the ANOVA
6 1 2 3 3 results for surface roughness and tool wear. The percentage contri-
7 1 3 1 2 butions of the nose radius 14.6%, cutting speed 49.1%, feed rate
8 1 3 2 3 21.6% and depth of cut 9.7% on the surface roughness is found.
9 1 3 3 1
The cutting speed (49.1%) is the most predominant factor affecting
10 2 1 1 3
11 2 1 2 1 the surface roughness. From the ANOVA results, the percentage
12 2 1 3 2 contribution of the nose radius 5%, cutting speed 50.2%, feed rate
13 2 2 1 2 30.2% and depth cut 11.3% on the tool wear is found. The cutting
14 2 2 2 3 speed (50.2%) is the most predominant factor affecting the tool
15 2 2 3 1
wear. The percent of error for surface roughness 5% and tool wear
16 2 3 1 3
17 2 3 2 1 3.3% is considerably low.
18 2 3 3 2
4.2. Analysis of the S/N ratio for surface roughness (Ra) and tool wear
(Vb)
4.1. Analysis of variance (ANOVA) for surface roughness (Ra) and tool
wear (Vb) As per Taguchi technique, the experiments were conducted for
every combination of all the control factors. The surface roughness
Analysis of variance (ANOVA) can be useful in calculating the and tool wear measured in off line. Signal to noise ratios was cal-
influence of given input parameters and also used to interpret culated using the condition of smaller is the better. Table 5
experimental data. In this work, ANOVA was used to analyze the shows the values of observed S/N ratios for every combination of
effect of cutting tool nose radius, cutting speed, feed rate and depth surface roughness and tool wear. The average surface roughness

Start

Objective

Definition of Problem
Factors & Levels

OA
Experimental Design
Conduct Experiment
ANOVA & S/N ratio
Results analysis
Contour Plot

No
Results Validated?

Yes

End

Fig. 2. Flow chart of Taguchi method.

Table 4
Analysis of variance results for surface roughness and tool wear.

Cutting parameter Degrees of freedom Sum of square Mean square F ratio P Contribution (%)
Surface roughness
Nose radius 1 0.11940 0.11940 29.46 0.000 14.6
Cutting speed 2 0.40080 0.20040 49.44 0.000 49.1
Feed 2 0.17605 0.08803 21.72 0.000 21.6
Depth of cut 2 0.07891 0.03946 9.73 0.005 9.7
Error 10 0.04053 0.00405 5
Total 17 0.81570 100
Tool wear
Nose radius 1 0.0001125 0.0001125 15.32 0.003 5
Cutting speed 2 0.0011254 0.0005627 76.62 0.000 50.2
Feed 2 0.0006774 0.0003387 46.12 0.000 30.2
Depth of cut 2 0.0002528 0.0001264 17.21 0.001 11.3
Error 10 0.0000734 0.0000073 3.3
Total 17 0.0022416 100
112 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116

Table 5
The experimental layout for the L18 orthogonal array and cutting condition.

S.N Nose radius Cutting speed Feed rate Depth of cut Surface roughness S/N for Ra Tool wear S/N for (Vb)
(mm) (m/min) (mm/rev) (mm) (Ra) (lm) (dB) (Vb) (mm) (dB)
1 0.8 50 0.04 0.2 0.274 11.2450 0.137 17.2656
2 0.8 50 0.08 0.3 0.324 9.7891 0.124 18.1316
3 0.8 50 0.12 0.4 0.438 7.1705 0.118 18.5624
4 0.8 100 0.04 0.2 0.364 8.7780 0.126 17.9926
5 0.8 100 0.08 0.3 0.340 9.3704 0.110 19.1721
6 0.8 100 0.12 0.4 0.508 5.8827 0.104 19.6593
7 0.8 150 0.04 0.3 0.803 1.9057 0.134 17.4579
8 0.8 150 0.08 0.4 0.470 6.5580 0.132 17.5885
9 0.8 150 0.12 0.2 0.704 3.0485 0.124 18.1316
10 0.4 50 0.04 0.4 0.338 9.4217 0.128 17.8558
11 0.4 50 0.08 0.2 0.421 7.5144 0.125 18.0618
12 0.4 50 0.12 0.3 0.709 2.9871 0.108 19.3315
13 0.4 100 0.04 0.3 0.585 4.6569 0.104 19.6593
14 0.4 100 0.08 0.4 0.446 7.0133 0.112 19.0156
15 0.4 100 0.12 0.2 0.614 4.2366 0.104 19.6593
16 0.4 150 0.04 0.4 0.836 1.5559 0.132 17.5885
17 0.4 150 0.08 0.2 0.636 3.9309 0.135 17.3933
18 0.4 150 0.12 0.3 1.106 0.8751 0.116 18.7108
Mean 0.550889 5.788311 0.120722 18.40208

Table 6 Main Effects Plot for SN ratios

S/N response for surface roughness and tool wear. Data Means
Nose Radius Cutting Speed
Levels Control factors 19.2
18.9
Nose radius Cutting speed Feed rate Depth of cut
Mean of SN ratios

18.6
Surface roughness 18.3
1 7.083 8.021 6.261 6.459 18.0

2 4.494 6.656 7.363 4.639 1 2 1 2 3

3 2.687 3.742 6.267 Feed Rate Depth of Cut
Delta 2.590 5.334 3.621 1.820 19.2
18.9
Tool wear 18.6
1 18.22 18.20 17.97 18.08 18.3
2 18.59 19.19 18.23 18.74 18.0
3 17.81 19.01 18.38 1 2 3 1 2 3
Delta 0.37 1.38 1.04 0.66
Signal-to-noise: Smaller is better

Fig. 4. The effect of cutting parameters on average S/N ratio for tool wears.
Main Effects Plot for SN ratios
Data Means
Nose Radius Cutting Speed The optimal level for each control factor was calculated based on
8
highest S/N and shown in Table 6 as bolded values for surface
6 roughness and tool wear. According to this, the factors giving
Mean of SN ratios

4 the minimum surface roughness were specified as nose radius

2 (r1, S/N = 7.083), cutting speed (v1, S/N = 8.021) feed rate (f2,
1 2 1 2 3 S/N = 7.363) and depth of cut (d1, S/N 6.459). In another way, a
Feed Rate Depth of Cut
8 good surface finish value was obtained with a nose radius
6
0.8 mm, at cutting speed 50 m/min at a feed rate 0.04 mm/rev
and at a depth of cut 0.2 mm. Similarly, factors giving the mini-
4
mum tool wear were specified as nose radius (r2, S/N = 18.59),
2 cutting speed (v2, S/N = 19.19) feed rate (f3, S/N = 19.01) and depth
1 2 3 1 2 3
of cut (d2, S/N = 18.74) based on factor level and S/N ratio. In
Signal-to-noise: Smaller is better
another way, the minimum tool wear was obtained with a nose
Fig. 3. The effect of cutting parameters on average S/N ratios for surface roughness. radius of 0.4 mm, at a cutting speed of 100 m/min at a feed rate
0.12 mm/rev and at a depth of cut 0.3 mm.

values were calculated as 0.550889 lm and the average values of
tool wear were calculated as 0.120722 mm during the end of the
turning tests. Similarly, the S/N ratio average values are calculated
for surface roughness is 5.788311 dB and the S/N ratio average
values are calculated for tool wear is 18.40208 dB.
The surface roughness and tool wear response table for S/N are
shown in Table 6. According to the Taguchi, to get optimum cutting
condition the S/N ratio should have a maximum value. In
Figs. 3 and 4 and Table 6 indicates the level of S/N response and
cutting parameters effect on surface roughness and tool wear.
4.3. Evaluation of experimental results
The variation in the surface roughness and flank wear were
obtained from experimental work as shown in Figs. 5 and 6 respec-
tively. The contour plot is a graphical representation of the rela-
tionships between three numeric variables in two dimensions.
From the contour plot, larger tool nose radius had the better finish
than the smaller nose radius in hard turning. However, in flank
wear, smaller nose radius showed better flank wear resistant than
larger tool nose radius. In both the nose radius, surface roughness
 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116 113

Contour Plot of Surface Roughness vs Nose Radius, Cutting Speed Contour Plot of Tool Wear vs Nose Radius, Cutting Speed
0.8 0.8
Surface Tool Wear
Roughness < 0.105
< 0.4 0.105 0.115
0.7 0.7
0.4 0.6 0.115 0.125

Nose Radius
Nose Radius

0.6 0.8 0.125 0.135

0.8 1.0 > 0.135
0.6 > 1.0 0.6

0.5 0.5

0.4 0.4
50 75 100 125 150 50 75 100 125 150

Cutting Speed Cutting Speed

Contour Plot of Surface Roughness vs Feed Rate, Cutting Speed

Contour Plot of Tool Wear vs Feed Rate, Cutting Speed
0.12 0.12
Surface Tool Wear
0.11 Roughness 0.11 < 0.105
< 0.4 0.105 0.115
0.10 0.10
0.4 0.6 0.115 0.125
0.6 0.8 0.125 0.135

Feed Rate
Feed Rate

0.09 0.09
0.8 1.0 > 0.135
0.08 > 1.0 0.08

0.07 0.07

0.06 0.06

0.05 0.05

0.04 0.04
50 75 100 125 150 50 75 100 125 150

Cutting Speed Cutting Speed

Contour Plot of Surface Roughness vs DoC, Cutting Speed Contour Plot of Tool Wear vs Nose Radius, Feed Rate
0.8
0.40 Tool Wear
Surface
< 0.105
Roughness
0.105 0.115
< 0.4 0.7
0.35 0.115 0.125
Nose Radius

0.4 0.6
0.125 0.135
0.6 0.8
> 0.135
0.8 1.0
0.6
DoC

0.30 > 1.0

0.5
0.25

0.4
0.20 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12
50 75 100 125 150
Feed Rate
Cutting Speed
Contour Plot of Tool Wear vs DoC, Cutting Speed
Contour Plot of Surface Roughness vs Nose Radius, Feed Rate 0.40
Tool Wear
0.8 < 0.105
Surface
0.105 0.115
Roughness 0.35
0.115 0.125
< 0.4
0.7 0.125 0.135
0.4 0.6
> 0.135
Nose Radius

0.6 0.8
DoC

0.30
0.8 1.0
0.6 > 1.0

0.25

0.5

0.20
50 75 100 125 150
0.4 Cutting Speed
0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12

Feed Rate Fig. 6. Effect of cutting parameters on tool wear.

Fig. 5. Effect of cutting parameters on surface roughness.

increase in the roughness values. This is due to material hardness

and flank wear increased with increase in cutting speed because of
the cutting tool was subjected to highest temperature and pressure
at the nose in hard turning. This leads to thermal softening of cut-
ting tool [6]. At lower cutting speed the wear rate is high when cut-
ting speed increases with the decrease in tool wear; this is due to
increased cutting speed decreases the friction between tool and
chip.
It was noted that the second most effective parameter affecting
surface roughness is feed rate. An increased feed rate caused the
and tendency of strain hardening [5]. However, the increasing feed
rate with the decrease in tool wear due to increased feed rate
decreases the contact time of tool and material. Higher feed rate
with cutting speed increases the surface roughness and tool wear.
Surface roughness is also affected by another parameter is the
depth of cut, increased depth of cut increases the surface rough-
ness. The contour plot shows (Figs. 5 and 6) the effects of control
factors obtained from Taguchi Method on the changes of roughness
and tool wear to verify the outcome obtained based on the exper-
imental work.
114 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116

4.4. Surface roughness and tool wear prediction R-Sq 99:59% R-Sq adj 98:25%
In Figs. 7 and 8 show the relationship between the predicted
The relationship between a one dependent and several indepen-
values by regression and experimental values. There is good adher-
dent variables were calculated and analyzed by Regression analysis
ence between regression predicted values and experimental val-
[24]. Surface roughness and tool wear is dependant variables and
ues. The R2 value was obtained by full quadratic regression
the independent variables are tool nose radius, cutting speed, feed
model for surface roughness was found 90.90% and tool wear
rate and depth cut. Regression analysis was used to calculate pre-
was found 98.25%.
dictive equations for surface roughness and tool wear. The predic-
tive equations were prepared with full quadratic regression
models. The predictive equations for the full quadratic regression 4.5. Optimum surface roughness and tool wear prediction
of surface roughness are given in Eq. (4) and tool wear given in
Eq. (5): In Figs. 9 and 10 and Table 7 show the surface roughness and
tool wear values of the S/N means response. The optimized values
Quadratic regression equation for surface roughness for the surface roughness and tool wear were calculated as
0:198452  0:0890224 r  0:00646256V  15:1912 f r1v1f2d1 and r2v2f3d2 respectively. Eq. (6) was used for calcula-
2
7:23537d 0:0000482308V2 102:775 f
2 Main Effects Plot for Means
 13:3059d  0:000558974 r V 0:0981571 r f Data Means
 1:08926 r d  0:0155000V f 0:00660000 V d 0.8
Nose Radius Cutting Speed

8:49359 f d: 4 0.7
0.6

Mean of Means
R-Sq 97:86% R-Sq adj 90:90% 0.5
0.4
1 2 1 2 3
Quadratic regression equations for Tool wear : Feed Rate Depth of Cut
0.8
0:201192 0:0536327 r  0:00107598V 0:409075 f 0.7
2
 0:470971 d 0:00000644872V2  2:52445 f 0.6

2 0.5
0:843816 d  0:0000878205r V  0:335391 r f 0.4
 0:0192526r d  0:0000265152V f  0:000343939V d 1 2 3 1 2 3

0:0384615 f d: 5 Fig. 9. The effect of cutting parameters on means response characteristics for
surface roughness.

Main Effects Plot for Means

1.1 Variable Data Means
Predicted Roughness
Nose Radius Cutting Speed
1.0 Actual Roughness 0.130
0.9 0.125
Roughness values

0.8 0.120
Mean of Means

0.115
0.7
0.110
0.6 1 2 1 2 3
0.5 Feed Rate Depth of Cut
0.130
0.4 0.125
0.3 0.120

0.2 0.115
2 4 6 8 10 12 14 16 18 0.110
Samples 1 2 3 1 2 3

Fig. 7. Comparison of the regression model and experimental results for surface Fig. 10. The effect of cutting parameters on means response characteristics for tool
roughness. wear.

0.14 Table 7
Variable
Predicted Tool Wear The effect of cutting parameters on means response table for surface roughness and
Actual Tool Wear tool wear.
0.13 Levels Control factors
Tool Wear

Nose radius Cutting speed Feed rate Depth of cut

0.12 Surface roughness

1 0.4694 0.4173 0.5333 0.5022
2 0.6323 0.4762 0.4395 0.6445
0.11 3 0.7592 0.6798 0.5060
Delta 0.1629 0.3418 0.2403 0.1423
Tool wear
0.10 1 0.1232 0.1233 0.1268 0.1252
2 4 6 8 10 12 14 16 18 2 0.1182 0.1100 0.1230 0.1160
Samples 3 0.1288 0.1123 0.1210
Delta 0.0050 0.0188 0.0145 0.0092
Fig. 8. Comparison of the regression model and experimental results for tool wear.
 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116 115

Table 8
Comparison of predicted and confirmation test result.

Test Taguchi prediction Quadratic regression prediction

Experimental Predicted Error (%) Experimental Predicted Error (%)
Surface roughness
r1v1f2d1 (optimum) 0.194 0.176 9.3 0.194 0.231 19.1
r2v1f2d1 (Random) 0.421 0.339 19.4 0.421 0.362 14.0
Tool wear
r2v2f3d2 (optimum) 0.095 0.094 1.1 0.095 0.096 1.1
r1v2f3d3 (Random) 0.104 0.108 4.3 0.104 0.102 1.3

tion of optimized surface roughness and Eq. (7) used for calculation ting parameters. Based on the ANOVA and S/N ratio analysis, the
of optimized tool wear. following conclusions can be made

Raopt r1  AvRa v1  AvRa f2  AvRa d1  AvRa AvRa

Vbopt r2  AvVb v2  AvVb f3  AvVb d2  AvVb AvVb
Raopt denotes the predicted mean of surface roughness and
Vbopt denotes the tool wear at optimum condition. The AvRa state
the average value of surface roughness and AvVb state the average
value of tool wear calculated from the experimental study (Table 5).
As per Eqs. (6) and (7), it was calculated that Raopt = 0.176 lm and
Vbopt = 0.094 mm. In Taguchi optimization technique, the opti-
mized conditions need to be evaluated. The confirmation experi-
ment was used to evaluate the optimized parameter.
The following Eqs. (8) and (9) were used to calculate confidence
interval [14]. The assumed condition for the reliability is 95%
CI F a; 1; f e V c f1=Neff 1=Rg
1=2
and
Neff fN=1 T dof g
 According to results of ANOVA analysis, the main contributing
6 factors affecting the surface roughness and tool wear were cut-
ting speed with a contribution of 49.1% and 50.2% respectively.
The significant contributions of the nose radius, feed rate and
7 depth of cut on the surface roughness were found to be 14.6%,
21.6% and 9.7% respectively and on tool wear found to be 5%,
30.2% and 11.3% respectively.
 Based on the S/N ratio using smaller is the better approach,
the optimum level of cutting parameters for surface roughness
r1v1f2d1 (i.e., Nose radius = 0.8 mm, cutting speed = 50 m/min,
Feed rate = 0.08 mm/rev, and depth of cut 0.2 mm) and tool
wear were r2v2f3d2 (i.e., Nose radius = 0.4 mm, cutting
speed = 100 m/min, Feed rate = 0.12 mm/rev, and depth of cut
0.3 mm). The good surface finish was achieved in 0.8 mm nose
radius and minimum tool wear achieved in 0.4 mm nose radius.
 Surface roughness and tool wear values predicted using quadra-
8 tic regression analysis was in close adhering to the experimen-
tal values with high correlation coefficients.
 The confirmation test result shows that the measured values
9 were 95% within the confidence level.

where the F-ratio required for 95 % CI, F (a, 1, fe), a is the significance
level = 0.05, fe is the error of degrees-of-freedom = 10, Vc is error
variance = 0.00405, R is the confirmation experiments number of
replications = 3, Neff is effective no. of replication, N is total number
of trails in the experiment = 18 and Tdof is total main degrees of
freedom = 7. F (0.05, 1, 10) = 4.9646 (from standard F table). Substi-
tuting the above values in Eqs. (8) and (9), we calculated that
Neff = 2.25 and CIRa = 0.0177 and CIVb = 0.0032. The predicted
optimal surface roughness is to be 0.176 0.125 lm and tool wear
is to be 0.094 0.0053 mm at 95% confidence level.
4.6. Confirmation test
Table 8 shows the comparison of confirmation test results and
predicted results calculated by Taguchi and full quadratic regres-
sion equations. The experimental values and predicted values are
adhering close to each other. The error value should be lower than
20% for reliable statistical analysis [24]. The maximum percentage
of error calculated for surface roughness and tool wear 19.4% and
4.326% respectively, there are within the acceptable range. The test
result obtained from confirmation test indicates the successful
optimization.
5. Conclusions
In this paper, Taguchi orthogonal array L18 was used. The opti-
mal cutting parameters were determined in the turning of austem-
pered ductile iron (grade 3) using CVD-coated carbide inserts
under dry turning conditions the Taguchi method was used. The
confirmation experiments were used to validate the optimum cut-
In this work, it was found that the Taguchi method was success-
fully used in the reduction of production cost and production time
in the turning of ADI. The results obtained in this work can be used
as standards both academic research and industrial applications. In
future, the other factors could be considered like different coating
materials, lubricants, and cutting tool geometry, all these factors
would affect on the surface roughness and tool wear.
Acknowledgement
The authors acknowledge with thanks to M/s Indoshell Cast
(Pvt) Limited, Coimbatore, India for providing castings, technical
ideas and help in this experimental work.
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