ACKNOWLEDGEMENT

I express my deep sense of gratitude and indebtedness to my thesis supervisors DR. R S U M

RAJU, Associate Professor, Department of Mechanical Engineering MVGR College of
Engineering (A) and Dr Subrata Kumar Mandal, Principal Scientist of DMSE, CMERI,
Durgapur and Mr. Ashok Kr. Prasad, Senior Scientist of DMSE, CMERI, Durgapur for
providing precious guidance, inspiring discussions and constant supervision throughout the
course of this work. Their timely help, constructively criticism, and conscientious efforts
made it possible to present the work contained in this thesis.
I express my sincere thanks to Mr. Arup Majumder, Technical Officer in Advanced
Manufacturing Lab. I am also thankful to Mr R.K Padhi, Mr. Abhijit Das, Mr. Nitish Kumar,
Mr. Tapan Ray, Mr. Biplob Roy, Mr. Shankar Chel, Technical Officers of DMSE, CMERI and
all the staff members of DMSE, CMERI, Durgapur for providing me the necessary facilities
in the department.
I am also thankful to Dr Atanu Maity, Senior Principal Scientist and head of the department
of DMSE and all the staff members of the department of Mechanical Engineering and to all
my well-wishers for their inspiration and help.
I would also like to thank my parents for their moral support, without them I would not be
where I am right now.
Finally, the author is thankful to all those whosoever contributed in this work directly and
indirectly.

MANDA SUNDEEP KUMAR

ROLL NO 17331D3407
 ABSTRACT

In today’s manufacturing market, quality and productivity play very significant role. Every
manufacturing industry concerns about the quality and productivity that directly involved in
the profit for the industry. For survival in manufacturing market, there is a requirement of
certain techniques for the improving the quality and productivity of the product/process.
Turning is mostly widely employed machining process for producing rotating parts. Material
removal rate, surface finish, cutting forces, tool life and power consumptions have been
recognised as quality characteristics of the machining operations.

This thesis refers to the optimization of the turning process parameters applying Taguchi
Methods. The literature survey reveals that a limited work undertaken on EN24 alloy steel.
Taguchi technique is used to investigate the effect of turning process parameters i.e. material
removal rate and surface roughness. The aim of the study is to evaluate an optimum result
obtained from ANOVA and find the improvement in S/N and the dominant factors which
mostly affect the responses of turning process parameters. The experiments were conducted
as per Taguchi’s L9 Orthogonal Array. Turning experiments were carried out on EN24 of alloy
steel bars and each experiment uses a new insert to ensure accurate reading of response. The
Signal to Noise (S/N ratio) and Analysis of Variance (ANOVA) are applied to investigate the
effect of cutting speed, feed rate and depth of cut on material removal rate and surface
roughness. ANOVA analysis revealed that maximum percentage contribution in affecting
material removal is depth of cut (99.79%) followed by feed rate (0.1383%); and in case of
surface roughness, depth of cut is dominant parameter with percentage contribution
(55.9803%). The optimal results were confirmed through confirmation experiment.

Keywords: quality, productivity, turning process, material removal rate, surface finish,
cutting
forces, tool life, Taguchi method, orthogonal array, speed, feed, depth of cut, signal to noise
ratio, ANOVA
 CONTENTS

TOPIC PAGE NO
List of Figures
List of Tables
Nomenclature
CHAPTER 1: INTRODUCTION
1.1 Machining
1.2 Turning Operation
1.3 Principle of Metal Cutting
1.4 Controllable Cutting parameters in Turning
1.5 Material Removal Rate
1.6 Surface Finish in Machining
1.7 Objective of Work
CHAPTER 2: LITERATURE SURVEY
2.1 Background
2.2 Literature Survey
2.3 Gaps Identified in Literature Survey
CHAPTER 3: TAGUCHI METHOD
3.1 Introduction
3.2 Quality Definition by Taguchi
3.3 Taguchi Philosophy
3.4 Signal to Noise ratio
3.5 Taguchi method for design of experiments
3.6 Procedure for experimental design and analysis
CHAPTER 4: EXPERIMENTATION
4.1 Process parameters and their levels
4.2 Selection of Orthogonal Array
4.3 CNC Machine
4.4 Experiment Set up of CNC Lathe
4.5 Machine specification of CNC Lathe
 4.6 Workpiece Used
4.7 Analysis of Variance
4.8 Material Removal Rate Measurement
4.9 Experimentation
CHAPTER 5: ANALYSIS OF DATA, RESULT AND DISSUSSIONS
5.1 Calculation of Material Removal Rate
5.2 Mean S/N ratio of Material Removal rate
5.3 Main effects plot for S/N ratio
5.4 ANOVA Calculations
5.5 Percentage contribution of process parameters
5.6 ANOVA Table
5.7 Confirmation of experiment for MRR
5.8 Calculation for Surface Roughness
5.9 Mean S/N ratio for Surface Roughness
5.10 Main effects plot for S/N ratio
5.11 ANOVA Calculation
5.12 Percentage Contribution for process parameters
5.13 ANOVA Table
5.14 Confirmation Experiments for Surface Roughness
CHAPTER 6: CONCLUSION AND SUGGESTION FOR FUTURE WORK
6.1 Conclusion
6.2 Suggestion for the future work
REFERENCE
 LIST OF FIGURES

FIGURE NO: TITLE PAGE NO

1.2 Geometry of Turning process
1.3 Turning operation with adjustable parameters
1.4.3 Cutting Parameters in Turning
1.5 Material being removed in the form of chip
1.6 Idealised Model for Surface Roughness
1.6.1 Surface Roughness measured technique by stylus equipment
3.1 Taguchi Quality Loss Function
3.6 Steps Involved in Taguchi Experiment
4.1 Ishikawa cause effect diagram
4.3 Block diagram of CNC Machine
4.4 Experimental Set up of CNC Lathe
4.5 CNC Lathe machine specification
5.6 Main Effect Plot for S/N ratio for MRR
5.7 Main Effect Plot for S/N ratio for Surface Roughness
 LIST OF TABLES

TABLE NO: TITLE PAGE NO

4.1 Process parameters and their levels
4.2 Taguchi L9 runs of experimental design
4.5 Machine specifications of CNC Lathe
4.6 Chemical Composition of EN24 Alloy Steel
4.7 Mechanical Properties of EN24 Alloy Steel
4.9 Control log for experimentation
4.10 Response Variable
5.1 Calculation for S/N ratio for each level for MRR
5.2 Response Table for S/N ratio for MRR
5.6 Percentage contribution of Process Parameters MRR
5.7 Confirmation for MRR
5.8 Calculation for S/N ratio for each level of Surface Roughness
5.9 Response Table for S/N for Surface Roughness
5.13 Percentage contribution of process parameters for
surface roughness
5.14 Confirmation for Surface Roughness

NOMENCLATURE
s Cutting Speed
f Feed rate
d Depth of cut
MRR Material removal rate
S/N Signal to Noise Ratio
ANOVA Analysis of Variance
DOF Degrees of freedom
OA Orthogonal Array
SS Sum of Squares
MS Mean Square
F ratio Variance Ratio
SR Surface Roughness
GTSS Grand Total Sum of Squares

LB Signal to Noise ratio in “larger the better”

SB Signal to Noise ratio in “smaller the better”

NB Signal to Noise ratio in “nominal the best”

MSD Mean Square Deviation

μRA Predicted Mean of Surface Roughness
 CHAPTER 1: INTRODUCTION

1.1 MACHINING
Machining is essentially the process of removing unwanted material from wrought (rolled)
stock, forgings, or castings to produce a desired shape, surface finish, and dimension. It is one
of the four major types of manufacturing processes used to create product components.
Machining is done by shaving away the material in small pieces, called chips, using very hard
cutting tools and powerful, rigid machine tools. The cutting tool may be held stationary and
moved across a rotating workpiece as on a lathe, or a rigidly held workpiece may move into a
rotating cutting tool as on a milling machine. Machining processes remove material in the
form of chips that are disposed or recycled. Machining is costlier than casting, moulding, and
forming processes, which are generally quicker and waste less material, but machining is
often justified when precision is needed. The performance of the cutting tool used to remove
workpiece material determines the efficiency and cost of a machining operation. The
geometry of the cutting edge controls the shearing action as a chip is torn away from the part.
The cutting tool material determines how fast the operation may progress, and since time is
money in manufacturing activities this is an important factor in the cost of the operation.

Machining is any process in which a cutting tool is used to remove small chips of material
from the workpiece (the workpiece is often called the "work"). To perform the operation,
relative motion is required between the tool and the work. This relative motion is achieved in
most machining operation by means of a primary motion, called "cutting speed" and a
secondary motion called "feed". The shape of the tool and its penetration into the work
surface, combined with these motions, produce the desired shape of the resulting work
surface (Kalpakjian and Schmid, 2008).

Machining operations require two basic simultaneous motions; one motion creates cutting
speed, and the other is the feed motion. Cutting speed is the rate at which the workpiece
moves past the tool or the rate at which the rotating surface of the cutting edge of the tool
moves past the workpiece. Regardless of whether the tool rotates or the workpiece rotates, the
relative motion between the two creates the cutting speed. Higher cutting speed shortens the
time required to complete the machining cut but can greatly shorten the useful life of the
cutting tool. Cutting speeds that are too low tend to tear instead of cut, produce rough
finishes, and distort the grain structure at the surface of the workpiece, all of which can cause
early failure of a machined part. Speeds should be as high as can be maintained without
causing the tool to wear out too quickly. Recommended cutting speeds for machining
operations can be found in commonly available tables. These suggested speeds vary based on
the workpiece material, cutting tool material, and type of machining operation.

1.2 TURNING OPERATION

The turning operation is a basic metal machining operation that is used widely in industries
dealing with metal cutting (Kumar, 2013). In a turning operation, a high-precision single
point cutting tool is rigidly held in a tool post and is fed past a rotating work piece in a
direction parallel to the axis of rotation of the work piece, at a constant rate, and unwanted
material is removed in the form of chips giving rise to a cylindrical or more complex profile
(Trent and Wright, Dash 2012). This operation is carried out in a Lathe Machine either
manually under an operator’s supervision, or by a controlling computer program. There are
two types of motion in a turning operation. One is the cutting motion which is the circular
motion of the work and the other is the feed motion which is the linear motion given to the
tool. The basic turning operation with its nomenclature and the motions involved are shown
in Fig. 1., Fig 1.2, and Fig. 1.3.

Fig. 1.1: Basic turning operation in Lathe (Halim, 2008)

 Fig 1.2: Motions in turning operation (Halim, 2008)

Fig. 1.3: Single point cutting tool using in turning and its nomenclature (Khandey, 2009)

Among various cutting processes, turning process is one of the most fundamental and most
applied metal removal operations in a real manufacturing environment. The surface
roughness of the machined parts is one of the most significant product quality characteristics
which refers to the deviation from the nominal surface. Surface roughness plays a vital role in
many applications such as precision fits, fastener holes, aesthetic requirements and parts
subject to fatigue loads. Surface roughness imposes one of the most significant constraints for
the selection of cutting parameters and machine tools in development of a process (Abhang
and Hameedullah, 2010). Turning is the primary process in most of the production activities
in the industry and surface finish of turned components has greater influence on the quality of
the product. Surface finish in turning has been found to be influenced in varying amounts by
a number of factors such as feed rate, work material characteristics, work hardness, unstable
built-up edge, cutting speed, depth of cut, cutting time, tool nose radius and tool cutting edge
angles, stability of machine tool and work piece setup, chatter, and use of cutting fluids
(Palanikumar et al., 2006). The need for selecting and implementing optimal machining
conditions and the most suitable cutting tool has been felt. Fig. 1.4 shows the schematic
diagram with geometry of turning process. The performance of turning is measured in terms
of surface finish, cutting forces, power consumed and tool wear. Surface finish influences
functional properties of machined components. Surface finish, in hard turning, has been
found to be influenced by a number of factors such as feed rate, cutting speed, work material
characteristics, work hardness, cutting time, tool nose radius and tool geometry, stability of
the machine tool and the work piece set-up, the use of cutting fluids, etc.

Fig. 1.4: Schematic showing geometry of turning process

Turning is a material removal process, a subtractive form of machining which is used to

create parts of circular or rotational form of desired geometry/shape by removing unwanted
material. The essential elements of the turning process are machine or lathe, workpiece
material which is a piece of a pre-shaped part, the fixture to which the material is attached.
The fixture is secured to the turning machine and is then allowed to rotate for a wide range of
speeds. The other end of the workpiece is hooked up with the tail stock to allow perfect
rotation and avoid eccentric rotations. The conceptual representation of a turning machine is
depicted in Fig. 1.5.
 Fig. 1.5: Representation of a lathe machine
The cutter in the turning operation is usually a single-point cutting tool, except for a few
exceptions where multi-point tools are used. The tool is secured to the tool post which is then
attached to the machine. During the operation, the cutting tool is fed into the rotating work
piece with lateral motion along with the axis of rotation. The unwanted material is removed
in the form of chips until the desired shape is attained. Fig. 1.6 shows the cutting process in
the turning operation.

Fig. 1.6: Cutting process in turning operation.

Turning is usually opted as a secondary process; it is chosen in order to improve and refine
the characteristics and features on parts made by using other processes. Turning is used to
produce rotational, typically axi-symmetric, parts that have many features, such as holes,
grooves, threads, tapers, various diameter steps, and even contoured surfaces. Parts
completely made only on a turning machine are used as prototypes or parts with limited
quantity, e.g. designed shafts and fasteners. The turning process offers very high tolerance
and good surface roughness; hence, using it for improvements in the already existing part is
recommended. The accuracy of any process depends on involvement of operational variables.
The operating parameters that contribute to the turning process are cutting feed (linear
distance covered by the tool during one revolution of the workpiece), cutting speed (Speed of
the workpiece surface relative to the edge of the cutting tool during a cut), spindle speed (the
work piece’s revolution speed per minute), feed rate (linear velocity of the cutting tool with
respect to the workpiece), depth of cut (depth of the tool tip with respect to the surface of the
workpiece). Vibrations, tool wear, tool life, surface finish, and cutting forces, etc. are also in
direct relation with values selected for process parameters. Hence, to improve the efficiency
of the process and the quality of the product, it is necessary to control the process parameters.

1.3 PRINCIPLE OF METAL CUTTING

Metal cutting is one of the important methods of removing unwanted material from the
performed blank in the form of chips from mechanical components. It is a process of
producing a job which involve removal of material from the workpiece. Fig. 1.7 shows the
schematic diagram of a metal cutting principle during which a wedged formed tool is about to
define depth of cut and moves relative to the workpiece that is clamped on the spindle. The
metal undergoes shear sort deformation and a layer of metal gets removed within the variety
of chip.

Fig. 1.7: schematic showing turning operation with adjustable parameters

All machining process involves formation of chips. This happens by deforming the work
material on the surface of the piece of work with the assistance of cutting tool. Relying upon
the tool geometry, cutting conditions and work piece material chips are produced in several
shapes and sizes. The various types of chips made in turning operation reveal the knowledge
about deformation suffered by the work material and therefore the surface quality made
throughout cutting operation.

1.4 CONTROLLABLE CUTTING PARAMETERS IN TURNING

The turning operation is governed by geometry factors and machining factors. Among them
the three primary adjustable machining parameters in a basic turning operation are speed,
feed and depth of cut. Fig. 1.8 shows these three parameters. Material removal is obtained by
the combination of these three parameters (Halim, 2008). Other input factors influencing the
output parameters such as surface roughness and tool wear also exist, but the latter are the
ones that can be easily modified by the operator during the course of the operation (Khandey,
2009).
1.4.1 Cutting Speed
Cutting speed may be defined as the rate at which the uncut surface of the work piece passes the
cutting tool (Kumar, 2013). It is often referred to as surface speed and is ordinarily expressed in
m/min, though ft./min is also used as an acceptable unit (Kumar, 2013; Choudhury et al., ).
Cutting speed can be obtained from the spindle speed. The spindle speed is the speed at which the
spindle, and hence, the work piece, rotates. It is given in terms of number of revolutions of the
work piece per minute i.e. rpm. Cutting speed is expressed in metre per min (m/min). Cutting
speed is usually between 3 and 200 m/min. The rotational speed (RPM) of the spindle is
usually constant during a single operation, so that when cutting a complex from the cutting
speed varies with the diameter being cut at any instant. At the nose of the tool the speed is
always lower than at the outer surface. The best possible cutting speed for a given job
depends on the hardness of the material being machined, the material of the tool bit and how
much feed and depth of cut is required.
If the spindle speed is N rpm, the cutting speed Vc in (m/min) is given as

Where is the cutting speed in turning, D is the initial diameter of the workpiece in mm, and N is
the spindle speed in RPM.

1.4.2 FEED RATE (f):

Feed is that term applied to the distance moved by the tool tip along its path of travel for
every revolution of the work. Feed rate during turning is also called un-deformed chip
thickness. On most power-fed lathes, the feed is directly associated with the spindle speed in
mm of (tool advance) per revolution of the spindle mm/rev. Sometimes it is also expressed in
mm/min. Feed is dependent on the kind of tool, surface finish desired, power obtained at the
spindle, characteristics of the machine being cut, tooling set up, strength of the workpiece and
rigidity of the workpiece.
= f. N

Here is the feed in mm per minute, f is the feed in mm/rev and N is the spindle speed in
RPM.
1.4.3 DEPTH OF CUT (d):
Depth of cut is the thickness of the material being removed from the workpiece in a single
pass. Also, it is the distance from the newly machined surface to the uncut surface. It is also
referred to as chip width thickness in turning. It is important to note the diameter after
machining is reduced by twice the depth of cut as this thickness is removed from both sides
due to the rotation of the work. Fig.8 shows the cutting parameters in turning.

where, d1 represents the initial diameter of the job and d2 represents the final diameter of the
job in mm.

Fig. 1.8: Cutting parameters in turning

1.5: MATERIAL REMOVE RATE (MRR)

The concept of metal removal rate is very important in metal cutting in cutting tool selection
and in the designing process to ensure proper quality of the product. The material removal
rate is defined as volume of the material removed divided by the machine time. A ring shaped
of the material is being removed for each revolution of the workpiece. Fig. 1.9 shows the
material removal in the form of a chip.

Fig. 1.9: schematic showing material being removed in the form of chip

Formula used for finding out material removal rate:

MRR = (π × × d × f × N) /min

where, = average diameter of the workpiece in mm (Di + Df/2)

Do is the initial diameter of workpiece before turning in mm and Df is the final diameter of
workpiece after turning in mm

where, d is the depth of cut in mm and f represents feed in mm/rev and N is the rotational
speed of the workpiece in rpm.
1.6: SURFACE FINISH IN MACHINING
The resultant roughness produced by machining process can be thought of as the combination
of two independent quantities:
a) Ideal Roughness
b) Natural Roughness
a) Ideal Roughness
Ideal surface roughness is a function of feed and geometry of the tool. It represents the best
possible finish which can be obtained for a given tool and shape. It can only be achieved if
the built-up edge, chatter, inaccuracies in the machine tool movements are eliminated
completely. Fig.1.10 shows the idealised model for surface roughness.

Fig. 1.10: schematic showing idealised model for surface roughness

For a sharp tool without nose radius, the maximum height of unevenness is given by:

Where f is feed rate, φ is major cutting-edge angle and β is the minor cutting-edge angle.

The surface roughness value is given by, = /4

Practical cutting tools are provided with a round corner. It can be shown that the roughness
value is closely related to the feed and corner radius (turning cutting tools are usually
provided with rounded corner) by the following expression:

Where is the average height of the profile, f is feed and r is radius of rounded corner of
cutting tool.
b) Natural Roughness
In practical, it is not usually possible to achieve conditions such as those described above,
and normally the natural surface roughness forms a large portion of the actual roughness. One
of the main factors contributing to natural roughness is the occurrence of a built-up edge and
vibration of the machine tool. Thus, larger the built-up edge, the rougher would be the surface
produced, and factors tending to reduce chip-tool friction and to eliminate or reduce the built-
up edge would give Improved surface finish.
1.6.1 Surface roughness measurement
Direct method assess surface finish by means that of a stylus type device. Measurements are
obtained employing a stylus drawn on the surface to be measured as shown in Fig. 1.11. The
stylus motion perpendicular to the surface is registered. The registered profile is then used to
calculate the surface parameters. This method needs interruption of the machining process,
and the sharp diamond stylus will build micro-scratches on the surface. Basically, this method
uses a stylus that tracks tiny changes in surface height, and a skid that follows massive
changes in surface height. The use of the two together reduces the consequences of non-flat
surface on the surface roughness measurement.

Fig. 1.11: schematic showing of surface roughness measurement technique by stylus

equipment

1.7. OBJECTIVE OF WORK

Optimum machining parameters are of great concern in manufacturing environments, where
economy of machining operation plays a key role in competitiveness in the market. Due to
high capital and machining costs of Numerical Control (NC) machines, there is an economic
need to operate NC machines as efficiently as possible in order to obtain the required pay
back. Since the cost of machining on NC machines is sensitive to the machining parameters,
optimal values have to be determined before a part is put into production. A number of
researchers have dealt with the optimization of machining parameters, considering only
turning operations and graphical methods to determine the optimum speed and feed (Brewer
and Reuda, 1963; Colding, 1969; Ermer, 1972;
Lwata, 1972; Gopalakrishnan and Faiz, 1991). Few researchers concentrated on multi-tool
machining operations and solved by a constrained mathematical programming methods (Rao
and Hati, 1978). Recently different methods have been reported in the literature to optimize
machining parameters of face milling operations. These methods include Genetic Algorithm
(GA) (Shanmugham et al., 2000) using real number coding, and Genetic Algorithm (GA)
using binary coding, Simulated Annealing (SA) algorithm and hybrid algorithm (Baskar et
al., 2002). Many researchers optimized machining parameters based on multi-pass milling
operation via geometric programming and dynamic programming (Ihsan Sonmez A et al.
(1999). A multi-tool machining analysis was carried out by some researchers (Zompi et al.,
1979; Ravignani et al., 1979). However, it is obvious that the real optimum values of
machining parameters cannot be achieved without considering the objective function and
constraint equations. Wang and Armarego (1995) studied a method to optimize the machining
parameter for cutting operation. However, this work was restricted only to the face milling
operation. Some researchers considered power as the only constraint and ignored, other
constraints, e.g., cutting force, tool life and surface finish. Significant work has been made on
the optimization of milling operations for multi-tool application (Tolouei-Rad M et.al., 1997)
and CAD-CAM integration for milling operations has been developed using optimum
machining conditions.
In the present work, a work piece was machined by CNC machining centre, is evaluated
according to the rules of the optimization problem. Three objective functions (minimum
production cost, minimum production time and maximum profit rate) have been considered
during the operations. Optimum machining parameters resulting from this work are intended
for use by NC machines in order to improve machining efficiencies. The depth of cut is taken
as the maximum permissible depth for given work piece – cutting tool combination.

The objective of work is to observe the cutting parameters in turning and to calculate the
optimum value of the parameters in order to optimize the surface roughness and material
removal rate using Taguchi Method. The statistical analysis was performed for better
machining operation which can be used for quality control of machining parts. This will help
to facilitate research and development researchers and industrial experts.
 CHAPTER-2: LITERATURE SURVEY

2.1 BACKGROUND
The art of metal cutting was spearheaded at the turn of 19th century by F.W. Taylor. He
performed over 30,000 rigorously recorded analyses producing around 400 tons of chips.
Taylor's objective was to make a straightforward answer for the complex issue of setting
protected and effective cutting conditions which could "be illuminated in under a large
portion of a moment by any great workman". It is still not easy to decide the ideal spindle
speeds and feed rates for metal removal process and surface finish of work piece. The shop
floor practice still depends on the "aligned vehicle" of the talented machinist alongside with
lookup tables. For mould and die machining the geometry of metal removal process is
constantly changing and setting of optimum cutting parameter has likely for great economic
advantage and at the same time it is also very challenging. Most machining shops utilize the
conventional technique of steady feed rate cutting for designed surface parts. This can result
in noteworthy tolerance deviation. A common turning activity produces parts which have
basic highlights requiring a predefined surface roughness. The applications include direction
and races, bearing surfaces on axle, ultra-clean surfaces in contaminant-delicate segments and
fixing surfaces on bores and cylinders.

2.2 LITERATURE SURVEY

An investigation was carried out to investigate the affecting parameters while machining
materials are surface roughness and MRR on CNC Turning operation process parameters are
feed rate, depth of cut and rotational speed, lubricant, have been analysed on MRR and
Surface roughness by using EN19 stainless steel material. Taguchi’s L18 mixed type
orthogonal array experimental design has been selected for investigation. (Kiran Kumar et al.,
2017)
An investigation was carried out optimum machining conditions by LM6 aluminium alloy.
tools used in parameter design are Taguchi orthogonal arrays and signal to noise ratio (S/N)
and the process parameters are taken speed, feed, depth of cut and coolant. The experiment
is carried out by Taguchi and the statistical analysis results in optimum parameter. The result
obtained through Taguchi is confirmed. (Baskar et al., 2017)
An investigation was carried out optimization by turning process using TAGUCHI METHOD
AND ANOVA ANALYSIS to find impacts of process parameters. An orthogonal array of size L9
has been constructed to find out the optimal levels and further signal-to-noise (S/N) ratio
has been computed to construct ANOVA table. From the ANOVA analysis it has been found
that the depth of cut plays most significant factor and feed is least significant factor. The
confirmation experiments have conducted to validate the optimal cutting parameters and
improvement of MRR. (Jha, 2016)
An investigation was carried out to analyse the significance of turning parameters on surface
roughness while machining of aluminium alloy material in CNC. Experimental runs, Factor
effects and Mathematical modelling have been conducted studied and done by Box-Behnken
method, ANOVA and surface methodology. Predicted turning condition has been validated
through confirmatory experiment. (Sahoo et al., 2016)
An investigation was carried optimization to identify optimal combination of turning
parameters by using Taguchi L9 orthogonal array and the parameters which include cutting
speed, feed rate, depth of cut and nose radius to measure the surface roughness (Ra). To
confirm the effectiveness of the Taguchi optimization, confirmation test and regression
model are used. (Samya et al., 2016)
Have studied a single optimization method for lower surface roughness and maximum metal
removal rate in terms of process parameters while carrying out CNC turning and the
parameters which include are spindle speed, feed rate and depth of cut and developed a
relationship between them to get minimum surface finish and maximum MRR. Taguchi L9,
S/N ratio and ANOVA were employed to study the performance characteristics of EN 351
alloy steel. The MINITAB–17 software was used to analysis the responses. Results indicate
that the cutting speed has the most significant factor followed by feed rate on both responses.
(Sanjay Kajal et al., 2015)
Have carried out optimization of cutting parameters for surface roughness & material removal rate in
the turning process to obtain the optimal setting. L9 array is used and S/N ratio has been calculated.
The number of experiments is to be obtained using full factorial design for optimal result. (Kumar et
al., 2017)
Have carried out optimization of cutting parameters on surface finish and MRR of EN24
employing Taguchi techniques and L9, S/N ratio and ANOVA were employed to study the
performance characteristics and the parameters taken are Speed, Feed, Depth of cut, Nose
radius, cutting environment (wet and dry). Minitab 16 statistical software is used. (Agarwal
et al., 2012)
Aim of this experiment is reduction in the surface roughness as well as tolerance. In this
experiment optimization of input parameter has been done for improvement of quality. Feed
Rate, Spindle speed & Depth of cut are taken as the input variables and the dimensional
tolerances and the surface roughness are taken as quality output. In the present work L9 Array
has been used in design of experiment for optimization of input parameters. This project
attempts to introduce and verifies experimentally as to how Taguchi parameter design could
be used in identifying the significant processing parameters and optimizing the surface
roughness of the turning. (Prabhat et al., 2013)
Have carried out optimization of surface roughness of step turning. The parameters such as
velocity of cutting, force of cutting, feed rate, depth of cutting on the roughness of surface in
a turning operation are investigated by using the Taguchi optimization method. The step turn
model is created in Pro-Engineer software and turning operations are performed using
SPINNER15 CLASSIK CNC Lathe machine. Taguchi Orthogonal Array is selected in Minitab18
software to evaluate S/N ratio and Mean. The good surface smoothness is obtained. (Dev
Singh et al., 2018)
Have carried out machining of EN36B steel to find optimal parameters. The Taguchi’s L9
Orthogonal array is used and to analysis the effect of each parameter on the machining.
Parameters such as Speed, Feed and Depth of cut. It is found that these parameters have a
significant influence on machining characteristics such as MRR and Surface roughness SR.
The ANOVA and S/N ratio are used to study the performance characteristics in turning
operation. (Yojith et al., 2016)
Have investigated the optimization of turning operation based on Taguchi method and the
material used is AISI 1040. Parameters used are cutting speed, feed, depth of cut, nose radius
and cutting fluid concentration are optimized for power consumption. L27 Orthogonal Array
was used and analysis of variance (ANOVA) is also applied to identify most significant
factor. It has been observed that cutting speed has most significant factor followed by depth
of cut and cutting fluid concentration on power consumption. (Aditya Kulkarni et al., 2014)
Have carried out optimization of surface roughness in turning operation. Parameters such as
cutting speed, depth of cut and feed are employed to a achieve minimum tool wear. Taguchi
L9 orthogonal array technique was performed to identify the effect of cutting parameters.
The results characterize the main factors effecting surface roughness and lower speed, feed
rate was found to be most significant parameters to influence surface roughness in turning.
(Srinivas et al., 2018)
Have carried out optimization turning process using Taguchi method. The material used is
AISI 1045 steel with coated cemented carbide tool under dry cutting condition. L9 array, S/N
ratio and ANOVA were employed to find the MRR and minimum surface roughness.
Optimum results are finally verified with the help of confirmation experiments. (Narendra
Kumar et al., 2015)
Have investigate optimization on turning process by various parameters such as speed, feed,
depth of cut. Extended Taguchi L9 method is performed to identify the effect on parameters.
(Mathew et al., 2014)
Have discussed parameter optimization for surface roughness using Taguchi L9 orthogonal
method where three parameters cutting speed, feed rate and depth of cut with its combination
surface roughness is measured and analysed and recorded by signal to noise ratio. (Suraj et
al., 2017)

2.3 GAPS IDENTIFIED IN THE LITERATURE SURVEY

From the above literature review, it has been revealed that a lot of work has been done in the
area of turning process for optimization of process parameters, but there is limited research
work reported in machining of material like EN24. EN24/817M40 alloy steel is mainly used
in power transmission gears and shafts, aircraft landing gear, punches and dies, drills and
bushings and other structural parts. Hence the present work has been attempted for
optimization of the performance characteristics i.e. material removal rate (MRR) and surface
roughness by achieving optimal setting of input parameters cutting speed, speed and depth of
cut in turning of EN24 steel.

CHAPTER-3: TAGUCHI METHOD

3.1 INTRODUCTION
Taguchi’s optimization technique is one of the best accomplished of 20th century. Taguchi
Method is evolved via Dr. Genichi Taguchi, a Japanese first-class management
representative. The method explores the idea of quadratic exceptional loss function and uses a
statistical degree of overall performance referred to as Signal to Noise (S/N) ratio. The S/N
ratio takes both the imply and the variability into account. The S/N ratio is the ratio of the
imply (Signal) to the usual deviation (Noise). The ratio depends at the high-quality
characteristics of the product/technique to be optimized. The general S/N ratios normally
used are as follows: - Nominal is Best (NB), Lower the Better (LB) and Higher the Better
(HB). Customarily, one factor at any given time approach was used in which only one factor
at a time was varied keeping other variable steady throughout the experimentation. This kind
of experimentation reveals the impact of the chosen variables underneath bound set of
condition. The most important disadvantage of this approach is that it does not show what
would happen if the other variables are changing simultaneously. This method does not
permit finding out the impact of interaction between the variables and the response
characteristics. The interaction is that the failure of one factor to response at different levels
of another variable. On the other hand, full factorial design needs experimental information
for all the attainable combinations of the factors concerned within the study. Consequently, a
very large number of trails have to be compelled to perform. Therefore, within the case of
experiments involving a greater number of factors, only small fraction of the combination of
factors are selected that produces most of the information to reduce the experimental efforts.
This approach is named as “fractional factorial” design of experiment. The analysis of end in
this approach is complicated because of non-availability of usually accepted guidelines. The
Taguchi method provides an answer to the current variety of optimization issues. Taguchi
strategies focus on the effective application of engineering method instead of advanced
statistical technique. Taguchi developed an off-line strategy for quality improvement as an
alternative to an endeavour to examine quality into a product on the production line. He finds
that poor quality cannot be improved by the process of inspection screening. No amount of
inspection can put quality back into the product. In the present work Taguchi’s parametric
design approach is used to employed to review the effect of process parameter of various of
turning of EN24. Quality improvement program are a part of strategic planning process of
successful companies. The strategic planning issues are the importance of design and the
ideas of designing quality into products and processes. The Taguchi philosophy and its
associated experimental design has been extensively employed manufacturing environment to
improve production process. The success and failure of Taguchi approach to parametric
design have been widely mentioned. Taguchi main success has been to emphasise the
importance of quality in design and to analyse the use of experimental design as a general-
purpose tool for quality engineers. This method explores the idea of quadratic quality loss
function and uses a statistical measure of performance known as Signal-to-Noise (S/N) ratio.
S/N ratio measures the purposeful strength of product and process. The ratio depends on the
standard characteristics of the product/process to be optimized. This methodology is based on
Orthogonal Array (OA) experiments, offers abundant reduced variance for the experiment
with optimal setting of control parameters.

3.2 QUALITY DEFINATION BY TAGUCHI

Taguchi defines the ‘Quality’ as deviation from on-target performance. According to him,
quality of a manufactured product is the total loss generated by that product to the society
from the time it is shipped. Taguchi loss function is always a way to show how each non-
perfect part produced, results in loss for the company. This method explores the concept of
quadratic quality loss function (Figure 3.1) uses a statistical measure of performance called
Signal-to-Noise (S/N) ratio. The S/N ratio takes both mean and variability into account. The
S/N is the ratio of the mean (Signal) to the standard deviation (Nose).

Fig. 3.1: Schematic showing Taguchi’s quality loss function

FORMULA USED: L(y) = k

y objective characteristic

m target value

k constant

k Cost of defective product/ (tolerance)2

3.3 TAGUCHI’S PHILOSOPHY
Genichi Taguchi ‘s quality engineering system has been used with successfully by several
companies in Japan and all over the world. He stresses the importance of coming up with
quality into product/process, instead of reckoning on a lot of traditional tools of on-line
quality control. Taguchi’s approach differs from that alternative leading quality gurus therein
he focuses a lot of on engineering aspects of quality instead of on management philosophy of
statistics. Dr Taguchi uses experimental design primarily as a tool to form products more
robust rendering less sensitive to noise factor. That is, he viewed experimental design as a
tool for reducing the effects of variation on products and quality characteristics process.
Earlier applications of experimental design targeted more on optimizing average performance
characteristics while not considering effects on variations. Taguchi’s quality philosophy has
seven basic elements:
i. An important dimension of the quality of a manufactured product is the total loss
generated by that product to society.
ii. In a competitive economy, continuous quality improvement and cost reduction is
necessary for staying in business.
iii. A continuous quality improvement program includes incessant reduction in variation
of product performance characteristics about their targeted values.
iv. The customer’s loss due to a product’s performance variation is often approximately
proportional to the square of the deviation of the performance characteristic from the
targeted value.
v. The final quality and cost of a manufactured product are determined to a large extent
by the engineering designs of the product and its manufacturing process.
vi. A product’s (or process) performance variation can be reduced by exploiting the
nonlinear effects of the product (or process) parameters on the performance
characteristics.
vii. Statistically planned experiments can be used to identify the setting of product (and
process) parameters that reduce performance variation.

3.4 SIGNAL TO NOISE (S/N) RATIO

In Taguchi design, a measure of robustness used to control factors that reduces variability in a
product or process by minimizing the effects of process parameters that can be controlled.
Control factors are those designs and process parameters that can be controlled. Noise factors
cannot be controlled during production or product use however, it can be controlled during
experimentation. In an exceedingly Taguchi design experiment, you manipulate noise factor
to force variability to occur and from the results, determine optical control factor setting that
build the method or product strong, or resistant to variation from the noise factors. Higher
values of signal-to-noise (S/N) ratio determine control factor setting that minimize the results
of noise factors.
Taguchi experiments usually uses two step optimization process. In step one, use the signal to
noise ratio to identify those control factors that reduces variability. In step two, identify the
control factor that move mean to target and have a small or no effect on the signal to noise
ratio. The signal to noise ratio measures how the response varies relative to the nominal or
target value under different conditions. Usually there are three categories of performance
characteristic in the analysis of S/N ratio.
● Taguchi’s S/N ratio for Smaller-the-better
n = -10 [ mean of sum of squares of measured data]

This is usually the chosen S/N ratio for all undesirable characteristics for which the ideal
value is zero. But when the ideal value is zero, then the difference between measured data
and the ideal value is expected to be small as possible. The generic form of S/N ratio
becomes:
n = -10 [ mean of sum of squares of {measured – ideal}]

● Taguchi’s S/N ratio for Larger-the-better

n = -10 [mean of sum of reciprocal of measured data]

Taking the reciprocals of measured data and taking the value of S/N ratio as in the smaller-the
better case, we convert it into smaller-the-better case.
● Taguchi’s S/N ratio for Nominal-the-best
n = -10 [square of mean / variance]

This case arises when a specified value is most desired, meaning that neither a smaller nor a
larger value is desirable.
In difference, the S/N ratio is a predictor of quality loss that isolates the sensitivity of the
products function to noise factors. In robust design one minimizes the sensitivity of noise by
seeking combinations of the design parameters setting that maximize the S/N ratio.

3.5 TAGUCHI METHOD FOR DESIGN OF EXPERIMENTS:

The general steps involved in the Taguchi Method are as follows:
1. Define the process objective, or more specifically, a target value for a performance
measure of the process. This may be a flow rate, temperature, etc. The target of a process may
be also minimum or maximum; for example, the goal may be to maximize the output flow
rate. The deviation in the performance characteristic from the target value is used to define
the loss function for the process parameters.
2. Determine the design parameter affecting the process. Parameters are variables within the
process that affect the performance measure such as temperature, pressure etc. that can be
easily controlled. The number of levels that the parameters should be varied at must be

specified. For e.g. a temperature might be varied to a low and high value of 40 and 80 .
Increasing the number of levels to vary a parameter at increasing the number of experiments
to be conducted.
3. Create orthogonal array for the parameter design indicating the number of and conditions
for each experiment. The selection of orthogonal arrays is based on the number of parameters
and the levels of variation for each parameter, and will be expounded below.
4. Conduct the experiments indicating in the complete array to collect data on the effect on
the performance measure.

3.6 PROCEDURE FOR EXPERIMENTAL DESIGN AND ANALYSIS

The procedure for experimental design and analysis has been shown in Fig. 3.2.

Fig 3.6: Steps Involved in Taguchi’s Experiment

 CHAPTER-4: EXPERIMENTATION
The present study has been done through the subsequent set up of experiment:
1. Checking and making ready the CNC Lathe for performing the machining operations.
2. Performing initial turning operation on CNC Lathe to get desired dimensions of the
workpiece.
3. Calculating the dimension of every specimen.
4. Perform straight turning operation on workpiece in dry cutting conditions which
involves various set of process control parameters like spindle speed, feed and depth
of cut.
5. Calculate machine time for each experiment and then measure the dimension of
finished diameter after turning.
6. Measuring surface roughness value in with the help of portable stylus-type
profilometer.
4.1 PROCESS PARAMETERS AND THEIR LEVELS
For identification of process parameters that have an effect on the chosen machining quality
characteristics of turned parts, an Ishikawa cause-effect diagram was constructed. The
Ishikawa cause-effect diagram has been shown in Fig. 4.1.

Fig. 4.1: Ishikawa Cause-Effect Diagram

The following input parameters were selected for the experimentation:

1. Cutting Speed
2. Feed
3. Depth of Cut
The working range of the parameters for resulting design of the experiment is based on
Taguchi’s L9 Orthogonal Array (OA) design has been selected. In the present experimental
study cutting speed, feed and depth of cut has been considered as process variables. The
process variables with their notations and units are listed in the Table 4.1.
Table 4.1: Process Parameters and their levels
Process Parameters
Values in
coded form Cutting Speed (m/min) Feed (mm/rev) Depth of Cut (mm)
[A] [B] [C]
1 130 0.05 0.3
2 150 0.1 0.5
3 170 0.15 0.7

4.2 SELECTION OF ORTHOGONAL ARRAY

All the experiments have been carried out using Taguchi’s L9 Orthogonal Array (OA)
experimental design as given in Table 4.2.
Table 4.2: Taguchi L9 Runs of Experimental Design
Run Order Cutting Speed Feed (mm/rev) Depth of cut (mm)
(m/min)
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

4.3 CNC MACHINE

Nowadays, a lot of Computer Numerical Controlled are being employed in all types of
manufacturing process. In a CNC machine functions like program storage, tool offset and
tool compensation, varied degree of computation, program-editing capability and also ability
to send and receive information from a range of sources as well as remote locations can be
easily released through on-board computer. The computer can store multi-part programs
recalling them for various components. CNC machine radically changes the manufacturing
industry to produce complex curved profile as easy to cut as straight lines and also easy to
produce complex 3-D structures with the improved technology like automation of
manufacturing processes with CNC machining improved in consistency as well as the quality
of product. In CNC turning surface finish and material removal rate are the two most factors
which greatly influencing on the machining performances. CNC machines are considered
most suitable in flexible manufacturing system due to its flexibility and versatility as well as
capability of achieving reasonable accuracy, surface finish and very low processing time as
compared to the conventional machine. Fig. 4.3 shows the block diagram of the working
principle of CNC machine.

Fig: 4.3 Block diagram of CNC machine

4.4 EXPERIMENT SET UP OF CNC LATHE

All the experiments are conducted on ACE LT-20 CNC Lathe machine of 30KVA with
maximum power and maximum spindle speed 50-4000 rpm as shown in the Fig. 4.4 installed
at CSIR-Central Mechanical Engineering Research Institute, Durgapur.

Fig.: 4.4 CNC lathe used during the experiment

4.5 SPECIFICATIONS OF CNC LATHE
Table 4.3 CNC LATHE MACHINE SPECIFICATIONS
MODEL UNITS ACE LT-20
CAPACITY
SWING OVER BED mm 470
SWING OVER CARRIAGE mm 300
MAXIMUM TURNING mm 236
DIAMETER
MAXIMUM TURNING mm 485
LENGHT
DISTANCE BETWEEN mm 550
CENTRES
SPINDLE
SPINDLE SPEED RPM 50-4000
SPINDLE NOSE A2-6
BORE THROUGH SPINDLE MM 56
FEED RATE mm/min 0-5000
CHUCK SIZE mm 200
FRONT BEARING BORE mm 90
SPINDLE MOTOR (A.C kW 0-5000
MOTOR)-FANUC12I
AXES
X-AXES mm 130
Z-AXES mm 486
MAXIMUM TRANSVERSE IN mm/min 10
BOTH AXES
TAILSTOCK
TAILSTOCK QUIL STROKE mm 120
TAILSTOCK ROTARY MT-2
CENTRE TAPER

CONTROL SYSTEM FANUC OTC

CHUCK SIZE mm 200
LUBRICATION OIL
CROSS SLIDE INCLINATION degree 30
MAXIMUM POWER KVA 30
REQUIREMENT
4.6 WORKPIECE USED
The workpiece material selected for the study was EN24 steel. It is very high strength alloy
engineering steel. This alloy offers a good combination of strength, ductility and wear
resistance. The grade is nickel chromium molybdenum combination which offers high tensile
steel strength with good ductility, wear resistance and with relatively good impact properties
with at low temperatures. It is used in the manufacturing of high strength shafts, punches and
dies gears, retaining rings, drill bushings. EN24 is also suitable for a variety of elevated
temperature conditions. Chemical PROPERTIES and Mechanical Properties of EN24 are
shown in the Table 4.6 and Table 4.7 respectively.

Table 4.6: Chemical Composition of En24 Alloy Steel

Elements Values % Elements Values %
Carbon 0.36-0.44 Phosphorus 0.035
Silicon 0.10-0.35 Chromium 1.00-1.40
Manganese 0.45-0.70 Molybdenum 0.20-0.35

Table 4.7: Mechanical Properties of En24 Alloy Steel

Tensile Stress 850-1000 N/
Yield Stress 680 N/
Yield Stress 650 N/
0.2% Proof Stress 665 N/
0.2% Proof Stress 635 N/
Elongation 13%
Impact Strength 54 J
Thermal Conductivity 41.9 w/m-
Hardness 248-302 Brinell
Density 7840 kg/
Elastic Modulus 207×
Melting Point 1500

4.7 ANALYSIS OF VARIANCE (ANOVA)

Analysis of variance is a general method for studying sampled data relationship. The method
enables the difference between two or more sample means to be analysed, achieved by
subdividing the total sum of squares. One-way ANOVA is the simplest case the purpose is to
test for significant differences between class means, and this is done by analysing the
variances. ANOVA is similar to regression in that it is used to investigate and model the
relationship between a response variable and one or more independent variables. In effect,
analysis of variance extends the two-sample t-test for testing the equality of two population
means to be more general null hypothesis of comparing the equality of more than two means,
versus those that are not equal. ANOVA table used for analysis of the models developed in
this work. Sum of squares and means sum of square errors are calculated. ANOVA is a
statistical method for determining the existence of differences among several population
means. ANOVA is particularly effective tool for analysing highly structured experimental
data. Different factors affect the surface defect formation to a different degree. The relative
effect of the different factors can be obtained by the decomposition of variance, which is
commonly called ANOVA, ANOVA is also needed for estimating the error variance for the
factor effects and variance of the prediction effect. The purpose of ANOVA is to investigate
which design parameters significantly affect the quality characteristic. This is to accomplish
by separating the total variability of S/N ratio, which measured by the sum of the squared
deviation from the total mean S/N ratio, into the contribution by each of the design
parameters and the error. The total sum of spared deviations is decomposed into two sources:
the sum of squared deviations SSd due each parameter and the sum of squared error SSe. The
percentage contribution by each of the design parameter in the total sum of squared
deviations SST is a ratio of the sum of squared deviation SS d due to each design parameter to
the sum of squared deviation SST.

4.8 MATERIAL REMOVAL RATE MEASUREMENT

Material Removal Rate (MRR) has been calculated from formula:

MRR =

Where, Di = initial diameter before turning

Df = final diameter after turning
T = machine time taken during turning operation
L = length of turned workpiece in each experiment run.
4.9 EXPERIMENTATION
The experiments were conducted as per the design following the Taguchi Design of
Experiments. In the experiments, the measurable parameters were surface roughness and
material removal rate. The results were shown in Table 4.9.
Table 4.9: Experimental results
Experiment Cutting Feed Depth of Cut Surface Material
Run Order Speed (mm/rev) (mm) Roughness Removal
(m/min) (μm) Rate
(mm3/min)
1 130 0.05 0.3 1.45 15.78
2 130 0.1 0.5 0.92 26.30
3 130 0.15 0.7 0.90 47.34
4 150 0.05 0.5 0.95 27.81
5 150 0.1 0.7 0.65 47.13
6 150 0.15 0.3 1.10 15.95
7 170 0.05 0.7 0.71 47.51
8 170 0.1 0.3 0.77 14.98
9 170 0.15 0.5 0.83 27.09
 CHAPTER-5: ANALYSIS OF DATA, RESULTS AND DISCUSSIONS
5.1 CALCULATION OF MATERIAL REMOVAL RATE (MRR)
Material Removal Rate is considered under higher the better signal to noise ratio (S/N), this
can be calculated by using the equation. The tabulated values are shown in Table 5.1.
The S/N ratio “ɳ” is calculated as:

ɳ = -10 log10[MSD], where MSD

For experiment number 1:
ɳ1 = -10 log10[MSD], here MSD1 = [1/15.782] = 249.0084 so n1 = -10 log10[249.0084] =
23.9621
Similarly, the S/N ratio for each experiment will be calculated and the result will be
calculated and the results are shown.
For experiment number 2, MSD2 = [1/26.302] = 691.169, ɳ2 = -10 log10[691.169] = 28.3991
For experiment number 3, MSD3 = [1/47.342] = 2241.075, ɳ3 = -10 log10[2241.075] =
33.5045
For experiment number 4, MSD4 = [1/27.812] = 773.396, ɳ4 = -10 log10[773.396] = 28.8840
For experiment number 5, MSD5 = [1/47.132] = 2221.236, ɳ5 = -10 log10[2221.236] =
33.4659
For experiment number 6, MSD6 = [1/15.952] = 254.402, ɳ6 = -10 log10[254.402] = 24.0552
For experiment number 7, MSD7 = [1/47.512] = 2257.200, ɳ7 = -10 log10[2257.200] =
33.5357
For experiment number 8, MSD8 = [1/14.982] = 224.400, ɳ8 = -10 log10[224.400] = 23.5102
For experiment number 9, MSD9 = [1/27.092] =733.868, ɳ9 = -10 log10[733.868] = 28.6561
Table 5.1 Calculation for S/N ratio for each factor level for material removal rate
Experiment Cutting Feed Depth of Cut Material S/N Ratio
Number Speed (mm/rev) (mm) Removal
(m/min) Rate
(mm3/min)
1 130 0.05 0.3 15.78 23.9621 (ɳ1)
2 130 0.1 0.5 26.30 28.3991 (ɳ2)
3 130 0.15 0.7 47.34 33.5045 (ɳ3)
4 150 0.05 0.5 27.81 28.8840 (ɳ4)
5 150 0.1 0.7 47.13 33.4659 (ɳ5)
 6 150 0.15 0.3 15.95 24.0552 (ɳ6)
7 170 0.05 0.7 47.51 33.5357 (ɳ7)
8 170 0.1 0.3 14.98 23.5102 (ɳ8)
9 170 0.15 0.5 27.09 28.6561 (ɳ9)

5.2 MEAN S/N RATIO FOR MATERIAL REMOVAL RATE (MRR)

After calculating S/N ratio for each experiment, the average S/N value is calculated for each
factor and level. The average S/N value for each parameter in the array in the table is
calculated as:
1. For Cutting Speed (CS) factor varies from 130 to 170:

(mCS)130 = 1 + ɳ2 + ɳ3) = 28.6219

(mCS)150 = (ɳ4 + ɳ5 + ɳ6) = 28.8017

(mCS)170 = (ɳ7 + ɳ8 + ɳ9) = 28.5673

2. For Feed (F) factor varies from 0.05 to 0.15

(mF)0.05 = (ɳ1 + ɳ4 + ɳ7) = 28.7939

(mF)0.01 = (ɳ2 + ɳ5 + ɳ8) = 28.4584

(mF)0.15 = (ɳ3 + ɳ6 + ɳ9) = 28.7386

3. For Depth of Cut (DC) factor varies from 0.3 to 0.7

(mDC)0.3 = (ɳ1 + ɳ6 + ɳ8) = 23.8425

(mDC)0.5 = (ɳ2 + ɳ4 + ɳ9) = 28.6330

(mDC)0.7 = (ɳ3 + ɳ5 + ɳ7) = 33.5020

Table 5.2 shows the Response Signal to Noise Ratio for Material Removal Rate.

Table 5.2 Response Table for Signal to Noise Ratio for Material Removal Rate
LEVEL Cutting Speed FEED (mm/rev) Depth of Cut (mm)
(m/min) (A) (B) (C)
 1 28.6219 28.7939 23.8425
2 28.8017 28.4584 28.6330
3 28.5673 28.7386 33.5020
Delta 0.2344 0.3355 9.6595
Rank 3 2 1

Fig. 5.1 Average S/N ratio for cutting speed in case of MRR

Fig. 5.2 Average S/N ratio for feed in case of MRR

 Fig. 5.3 Average S/N ratio for depth of cut in case of MRR

The S/N ratio values are calculated for each factor and level they are tabulated as shown in
the table and graph, and the range here from high S/N ratio to low S/N ratio for each
parameter is calculated and entered into the table.

5.3 ANALYSIS OF VARIANCE (CALCULATION):

Analysis of variance (ANOVA) was utilized to determine the statistically significant factors
influencing the material removal rate and to determine the percentage contribution of each
control factor on response.
In ANOVA if any process parameter has a p value lower than 0.05 then it is determined that
those parameters had statistical and physical significance on the response whose value is
much lower, its impact value will be more.
With a percentage contribution calculation whose value of percentage is more than other
process parameter the it is decided that parameter plays a significant role.
In order to determine that a test is significant we need to have some test statistic.

Find average S/N ratio (ɳm) = )

)
 = 28.6636

Grand Total Sum of Squares (GTSS) of = , where = Individual S/N Ratio from
1-9 experiments.
Sum of Squares due to mean = Number of experiments × (Overall Mean)2
= 9 × (28.6636)2
= 7394.4176
1. Sum of Square due to factor Cutting Speed, CS:
3[(mCS)130 – Overall Mean Ratio]2 + 3[(mCS)150 – Overall Mean Ratio]2 + 3[(mCS)170 – Overall
Mean Ratio]2
= 0.0902
2. Sum of Square due to factor Feed, F:
3[(mF)0.05 – Overall Mean Ratio]2 + 3[(mF)0.1 – Overall Mean Ratio] 2 + 3[(mF)0.15 – Overall
Mean Ratio]2
= 0.1940
3. Sum of Square due to factor Depth of Cut, DC:
3[(mDC)0.3 – Overall Mean Ratio] 2 + 3[(mDC) – Overall Mean Ratio]2 + 3[(mDC) – Overall
Mean Ratio]2
= 139.9621
Total Sum of Square = GTSS – Sum of Square due to Mean

GTSS =

GTSS = (ɳ1)2 + (ɳ2)2 + (ɳ3)2 + (ɳ4)2 + (ɳ5)2 + (ɳ6)2 + (ɳ7)2 + (ɳ8)2 + (ɳ9)2
GTSS = 7534.6919
Total Sum of Square = GTSS – Sum of Square due to Mean
= 7534.6919 – 7394.4176
Pooled Error = Minimum Value of Sum of Square + Next Higher Value of Sum of Square
= 0.0902 + 0.1940
Pooled Error = 0.2842
Degree of Freedom (D0F) = Level -1, 3-1 =2
Total Degree of Freedom = Total Number of Experiments – 1, 9-1 = 8
Error = Total DOF – Level of each parameters = 8 -3 = 5
Total Sum of Square = Sum of Square due to Cutting Speed + Sum of Square due to Feed +
Sum of Square due to Depth of Cut)
= 0.0902 + 0.1949 + 139.9621
Total Sum of Square = 140.2463

Mean Square =

Mean Square for Cutting Speed =

= 0.0451

Mean Square for Feed =

= 0.097

Mean Square for Depth of Cut =

= 69.98105

Mean Square of Pooled Error =

= 0.071

Variance Ratio (F Ratio) =

F Ratio for Cutting Speed =

= 0.635 1

F Ratio for Feed =

= 1.366 2

F Ratio for Depth of Cut =

= 985.63 1000

5.4 PERCENTAGE CONTRIBUTION OF PROCESS PARAMETERS:

For determining the percentage contribution, we know the formula
 =

1. Percentage Contribution for Cutting Speed =

= 0.0643

2. Percentage Contribution for Feed =

= 0.1383

3. Percentage Contribution for Depth of Cut =

= 99.79

5.5 ANOVA TABLE

From the above data means process parameters, degree of freedom, sum of squares, mean
square, variance ratio, percentage contribution and rank are shown in the below table 5.6.
Table 5.6 ANOVA Table for MRR
Factors Degree of Sum of Mean F- Ratio Rank
Freedom Squares Square
Contribution
Cutting 2 0.0902 0.0451 0.635 1 0.0643 3
Speed
Feed 2 0.1940 0.097 1.366 2 0.1383 2
Depth of 2 139.9261 69.98 985.6 1000 99.79 1
Cut
Error 5
Pooled 4 0.2842 0.071
Error
Total 8 100

5.6 THE CONFIRMATION EXPERIMENTS FOR MATERIAL REMOVAL RATE

The initial readings of factors obtained from S/N Ratio, the optimum results obtained from
ANOVA and improvements in the results of Material Removal Rate are shown in the table
5.7.
 Table 5.7 Confirmation results for Material Removal Rate
Factors Initial Readings of Optimum Result Improvement In S/N
Factors Obtained from Ratio
ANOVA
Level A3B1C3 A3B2C1
MRR 47.51 50.74 34.107 – 33.5357 =
S/N Ratio 33.5357 34.107 0.571

So, the best combination for highest MRR are:

A3 i.e. Cutting Speed =170
B2 i.e. Feed = 0.1
C1 i.e. Depth of Cut = 0.3

5.7 CALCULATION FOR SURFACE ROUGHNESS (Ra)

Surface Roughness is considered under lower the best signal to noise ratio (S/N), this can be
calculated by using the equation.
The S/N ratio “ɳ” is calculated as:

ɳ = -10 log10[MSD], where MSD

ɳ1 = -10 log10[MSD], here MSD1 = [1.452] = 2.1025 so n1 = -10 log10[2.1025] = 3.2273

Similarly, the S/N ratio for each experiment will be calculated and the result will be
calculated and the results are shown.
For experiment number 2, MSD2 = [0.922] = 0.8464, ɳ2 = -10 log10[0.8464] = 0.7242
For experiment number 3, MSD3 = [0.92] = 0.81, ɳ3 = -10 log10[0.81] = 0.9151
For experiment number 4, MSD4 = [0.952] = 0.9025, ɳ4 = -10 log10[0.9025] = 0.4455
For experiment number 5, MSD5 = [0.652] = 0.4225, ɳ5 = -10 log10[0.4225] = 3.741
For experiment number 6, MSD6 = [1.102] = 1.21, ɳ6 = -10 log10[1.21] = 0.8278
For experiment number 7, MSD7 = [0.712] = 0.5041, ɳ7 = -10 log10[0.5041] = 2.9748
For experiment number 8, MSD8 = [0.772] = 0.5927, ɳ8 = -10 log10[0.5927] = 2.2701
For experiment number 9, MSD9 = [0.832] = 0.6889, ɳ9 = -10 log10[0.6889] = 1.6184
 Table 5.8 Calculation for S/N ratio for each factor level for Surface Roughness
Experiment Cutting FEED Depth of Cut Surface S/N Ratio
Number Speed (mm/rev) (mm) Roughness
(m/min) (Ra)
1 130 0.05 0.3 1.45 3.2273 (ɳ1)
2 130 0.1 0.5 0.92 0.7242 (ɳ2)
3 130 0.15 0.7 0.90 0.9151 (ɳ3)
4 150 0.05 0.5 0.95 0.4455 (ɳ4)
5 150 0.1 0.7 0.65 3.741 (ɳ5)
6 150 0.15 0.3 1.10 0.8278 (ɳ6)
7 170 0.05 0.7 0.71 2.9748 (ɳ7)
8 170 0.1 0.3 0.77 2.2701 (ɳ8)
9 170 0.15 0.5 0.83 1.6184 (ɳ9)

5.8 MEAN S/N RATIO FOR SURFACE ROUGHNESS(Ra)

After calculating S/N ratio for each experiment, the average S/N value is calculated for each
factor and level. The average S/N value for each parameter in the array in the table is
calculated as:

1. For Cutting Speed (CS) factor varies from 130 to 170:

(mCS)130 = 1 + ɳ2 + ɳ3) = 1.622

(mCS)150 = (ɳ4 + ɳ5 + ɳ6) = 1.6714

(mCS)170 = (ɳ7 + ɳ8 + ɳ9) = 2.2877

2. For Feed (F) factor varies from 0.05 to 0.15

(mF)0.05 = (ɳ1 + ɳ4 + ɳ7) = 2.2158

(mF)0.01 = (ɳ2 + ɳ5 + ɳ8) = 2.2451

(mF)0.15 = (ɳ3 + ɳ6 + ɳ9) = 1.1204

3. For Depth of Cut (DC) factor varies from 0.3 to 0.7

(mDC)0.3 = (ɳ1 + ɳ6 + ɳ8) = 2.1084

(mDC)0.5 = (ɳ2 + ɳ4 + ɳ9) = 0.9293

(mDC)0.7 = (ɳ3 + ɳ5 + ɳ7) = 2.5436

Table 5.9 Response Table for Signal to Noise Ratio for Surface Roughness
LEVEL Cutting Speed (m/min) Feed (mm/rev) Depth of Cut (mm)
1 1.6222 2.2158 2.1084
2 1.6714 2.2451 0.9293
3 2.2877 1.1204 2.5436
Delta 0.6655 1.1247 1.6143
Rank 3 2 1
Fig. 5.4 Average S/N ratio for cutting speed in case of surface roughness

Fig. 5.5 Average S/N ratio for feed in case of surface roughness
3. For DEPTH OF CUT S/N Ratio

Fig. 5.6 Average S/N ratio for depth of cut in case of surface roughness

The S/N ratio values are calculated for each factor and level they are tabulated as shown in
the table and graph, and the range here from high S/N ratio to low S/N ratio for each
parameter is calculated and entered into the table.
The optimum level of different control factors for surface roughness is indicated below.

5.9 ANALYSIS OF VARIANCE (ANOVA)

Analysis of variance (ANOVA) was utilized to determine the statistically significant factors
influencing the material removal rate and to determine the percentage contribution of each
control factor on response.
In ANOVA if any process parameter has a p value lower than 0.05 then it is determined that
those parameters had statistical and physical significance on the response whose value is
much lower, its impact value will be more.
With a percentage contribution calculation whose value of percentage is more than other
process parameter the it is decided that parameter plays a significant role.
In order to determine that a test is significant we need to have some test statistic.
Find average S/N ratio (ɳm) = )

= )

= 1.8604

Grand Total Sum of Squares (GTSS) of = , where = Individual S/N Ratio from
1-9 experiments.
Sum of Squares due to mean = Number of experiments × (Overall Mean)2
= 9 × (1.8604)2
= 31.1497
1. Sum of Square due to factor Cutting Speed, CS:
3[(mCS)130 – Overall Mean Ratio]2 + 3[(mCS)150 – Overall Mean Ratio]2 + 3[(mCS)170 – Overall
Mean Ratio]2
= 0.8250
2. Sum of Square due to factor Feed, F:
3[(mF)0.05 – Overall Mean Ratio]2 + 3[(mF)0.1 – Overall Mean Ratio] 2 + 3[(mF)0.15 – Overall
Mean Ratio]2
= 2.4656
3. Sum of Square due to factor Depth of Cut, DC:
3[(mDC)0.3 – Overall Mean Ratio] 2 + 3[(mDC) – Overall Mean Ratio]2 + 3[(mDC) – Overall
Mean Ratio]2
= 4.1847
Total Sum of Square = GTSS – Sum of Square due to Mean

GTSS =

GTSS = (ɳ1)2 + (ɳ2)2 + (ɳ3)2 + (ɳ4)2 + (ɳ5)2 + (ɳ6)2 + (ɳ7)2 + (ɳ8)2 + (ɳ9)2
GTSS = 43.2781
Total Sum of Square = GTSS – Sum of Square due to Mean
= 43.2781 – 31.1497
= 12.1284
Pooled Error = Minimum Value of Sum of Square + Next Higher Value of Sum of Square
= 0.8250 + 2.4656
Pooled Error = 3.2906
Degree of Freedom (DOF) = Level -1, 3-1 =2
Total Degree of Freedom = Total Number of Experiments – 1, 9-1 = 8
Error = Total DOF – Level of each parameters
= 8 -3, 5
Total Sum of Square = Sum of Square due to Cutting Speed + Sum of Square due to Feed +
Sum of Square due to Depth of Cut)
= 0.8250 + 2.4656 + 4.1847
Total Sum of Square = 7.4753

Mean Square =

Mean Square for Cutting Speed =

= 0.4125

Mean Square for Feed =

= 1.2328

Mean Square for Depth of Cut =

= 2.09235

Mean Square of Pooled Error =

= 0.82265

Variance Ratio (F Ratio) =

F Ratio for Cutting Speed =

= 0.5014 1

F Ratio for Feed =

= 1.4985 2
F Ratio for Depth of Cut =

= 2.5434 3

5.10 PERCENTAGE CONTRIBUTION OF PROCESS PARAMETERS

For determining the percentage contribution, we know the formula

1. Percentage Contribution for Cutting Speed =

= 11.0363

2. Percentage Contribution for Feed =

= 32.9832

3. Percentage Contribution for Depth of Cut =

= 55.9803

5.11 ANOVA TABLE

From the above data means process parameters, degree of freedom, sum of squares, mean
square, variance ratio, percentage contribution and rank are shown in the below table 5.13.
Table 5.13 ANOVA for Surface Roughness
Factors Degree of Sum of Mean F- Ratio Ratio Rank
Freedom Squares Square
Cutting 2 0.8250 0.4125 0.5014 1 3
Speed
Feed 2 2.4656 1.2328 1.4985 2 2
Depth of 2 4.1847 2.0923 2.5434 3 1
Cut
Error 5
Pooled 4 3.2906 0.8226
Error
Total 8 100

5.12 THE CONFIRMATION EXPERIMENTS FOR SURFACE ROUGHNESS(R a)

The initial readings of factors obtained from S/N Ratio, the optimum results obtained from
ANOVA and improvements in the results of Surface Roughness are shown in the table 5.14
 5.14 Table Confirmation for Surface Roughness

Factors Initial Reading of Optimum Result Improvement In S/N Ratio

Factors Obtained From
ANOVA
Level A2B2C3 A3B2C1
Surface Roughness 0.65 0.59 4.5829 – 3.7410 = 0.8419
S/N Ratio 3.741 4.5829

So, the best combination for minimum surface roughness are:

A3 i.e. Cutting Speed 170
B2 i.e. Feed 0.1
C1 i.e. Depth of Cut 0.3

Chapter-6: CONCLUSION AND SUGGESTION FOR FUTURE WORK

6.1 CONCLUSIONS:
Based on the experiment performed in the present investigation, the following conclusions
have been drawn:
 Cutting speed affects material removal rate dominantly followed by feed rate and
depth of cut in turning of EN24 alloy steel.
 It is concluded from the results that by setting input parameters i.e. cutting speed at
170 rpm, feed rate 0.1 mm/rev and depth of cut 0.8 mm gives the optimum results for
MRR.

 The percentage contribution of cutting speed (0.0643 ), is followed by feed rate

(0.1383 ) and depth of cut (99.79 ) in affecting the material removal rate.

 From the results it is found that cutting speed is most influencing parameter in
affecting the surface roughness.
 Results revealed that minimum surface roughness is achieved through the optimal
setting of the cutting parameter i.e. cutting speed 170 rpm, feed rate 0.1 mm/rev, and
depth of cut 0.3 mm.

 The percentage contribution of cutting speed (11.0363 ), is followed by feed rate

(32.9832 and depth of cut (55.9803 ) in affecting surface roughness.
  It is found from the present experiment that there is an improvement in the S/N ratio
in both the response variables that is Material Removal Rate (MRR) and Surface
Roughness (Ra).

6.2 SUGGESTIONS FOR THE FUTURE WORK:

The following suggestions may be useful for the future work:
1. Three parameters that is cutting speed, feed rate and depth of cut have taken for the present
study as input controllable factors. Other parameters like work material (hot worked, cold
worked), environmental condition (dry, wet), tool nose radius, cutting tool material can be
taken as input variables for investigation.
2. The investigation can be extended to other work material grade steel viz. EN35 steel, EN
42 steel, EN45 steel.
3. The other performance characteristics can be taken like tool life, dimensional accuracy,
power consumptions and forces exerted on the tool for the investigation.

Shanmugham, M.S., Bhaskara, Reddy S.V., Narendran, T.T., 2000. Selection of

Optimal Conditions in Multi-Pass Face Milling using a genetic algorithm.
International Journal of Machine Tool Manufacturing, 40:401–414.

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Conditions in Multi-Pass Face Milling using a genetic algorithm. Int J Mach Tool Manuf
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using Non Conventional Methods. Proceedings of the 20 th All India Manufacturing Technology,
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ware for multiple constraint face milling operations. 6
th
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on Manufacturing Engineering (ICME
’95), 29 Nov–1 Dec; Melbourne,
Australia, pp 535–540
14. Tolouei-Rad M et.al (1997) On the optimization of machining parame-
ters for milling operations. Int J Mach Tool Manuf 37(1):1–16

2. Brewer RC, Reuda RAA (1963) A simp

lified approach to the optimum
selection of machining parameters. Eng Dig 24(9):131–151
2. Colding BN (1969) Machining economics and industrial data manuals.
Ann CIRP 17:279–288
3. Ermer DS (1971) Optimization of the Constrained machining eco-
nomics problem by geometric programming. Trans ASME J Eng Ind
93:1067–1072
4. Lwata K, Murotsa Y, Jwotsubo T, Fuji S (1972) A probabilistic ap-
proach to the determination of the optimum cutting conditions. Trans
ASME J Eng Ind 94:1099–1107
5. Gopalakrishnan B, Faiz AK (1991) M
achining parameter selection for
turning with constraints: an analytical approach based on geometric
programming. Int J Prod Res 29:1897–1908
6. Rao SS, Hati SK (1978) Computerized Selection of Optimum Machin-
ing Conditions for a job Requiring multiple operations. Trans ASME J
Eng Ind 100:356–362
7. Shanmugham MS, Bhaskara Reddy SV, Narendran TT (2000) Selec-
tion of Optimal Conditions in Multi-Pass Face Milling using a genetic
algorithm. Int J Mach Tool Manuf 40:401–414
8. Baskar N, Asokan P, Saravanan R, Prabaharan G (2002) Selection of
Optimal conditions in Multi-Pass Face Milling using Non Conventional
Methods. Proceedings of the 20
th
All India Manufacturing Technology,
Design and Research Conference
9. Ihsan Sonmez A et al. (1999) Dynamic optimization of multipass
milling operations via genetic programming. Int J Mach Tool Manuf
39:297–320
10. Zompi A, Levi R, Ravig Nani GL (1979) Multi-Tool Machining Analy-
sis, Part I. Tool Feature Patterns Implications 101:230–236
11. Ravignani GL, Zompi A, Levi R (1979) Multi-Tool Machining An-
alysis, Part 2. Economic Evaluation in view of Tool life Scatter 101:
237–240
12. Cakir MC, Gurarda A (2000) Optimization of machining conditions for
multi-tool milling operations. Int J Prod Res 38:3537–3552
13. Wang J, Armarego EJA (1995) Optimization Strategies and CAM soft-
ware for multiple constraint face milling operations. 6
th
Int. Conference
on Manufacturing Engineering (ICME
’95), 29 Nov–1 Dec; Melbourne,
Australia, pp 535–540
14. Tolouei-Rad M et.al (1997) On the optimization of machining parame-
ters for milling operations. Int J Mach Tool Manuf 37(1):1–16

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