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Analysis and Optimization of turning operation : Taguchi and Principal Component

Analysis Approach 2013

Mechanical Engineering Department

Sikkim Manipal Institute of Technology Page 1

CHAPTER 1

INTRODUCTION

Metal cutting is one of the eminent and most commonly used manufacturing processes in any

metal processing or business industries. By machining processes or manufacturing operations,

attempts are made to make a particular product in several steps as of required dimensions and

shapes to assure the quality of machining products for the intended applications made for. The

step-by-step machining is done on the material to diminish the machining costs thereby

enhancing the machining effectiveness. Every manufacturing industry aims at producing a large

number of products within comparatively lesser time. It has long been determined that conditions

during cutting, such as feed rate, cutting speed and depth of cut, should be selected to optimize

the economics of machining operations, as assessed by productivity, total manufacturing cost per

component or some other convenient criterion. The optimization of cutting parameters during

machining is a toilsome task as it involves a number of aspects such as knowledge of machining,

empirical equations of tool life, cutting forces, power consumed, machining surface finish etc.

All these aspects should be studied during machining optimization to develop an effective

optimization criterion. Manufacturing industries have long relied on the skill and experience of

shop-floor machine-tool operators for optimal selection of cut-ting conditions and cutting tools.

1.1 LATHE

The lathe is basically a machine tool that removes unwanted material from a rotating

workpiece in the form of chips with the aid of a tool which is traversed across the work and can

be fed deep in work. The tool should be harder than the workpiece and must be held securely and

rigidly on the machine. Basically, the lathe is used to produce cylindrical surfaces and plain

surfaces at right angles to the axis of rotation. A lathe can also produce tapers. The workpiece is

either clamped in the chuck or between the centers.





1.2 SPECIFICATIONS OF LATHE

Generally, a lathe is designated by:

a. Height of centre measured above the lathe bed.

b. Maximum diameter or swing that can be rotated.

c. Shipping dimensions: LENGTH * BREADTH * HEIGHT * WIDTH * WEIGHT.

d. Maximum length of the job that can be held between the centers.

e. Spindle speed range.

f. Type of bed: It can be straight or gap bed.

g. Horse power of the driving motor.

1.3 CLASSIFICATION OF LATHES

The various types of lathes are as under:

a. Speed lathe: It is the simplest of all the lathes. Speed lathes can run at high speeds and is

generally used for turning woods, metals, spinning and polishing.

b. Engine lathe: This lathe derives its name from the early lathes that were driven by steam

engines and is the most important member of the lathe family. It’s also called centre

lathe and is the most widely used lathe across the globe.

c. Tool room lathe: The tool room lathe is basically similar in appearance to the centre

lathe but is built more precisely and accurately and has a wide range of speeds and is

equipped with many extra attachments and accessories and is used commonly for

precision works on tools, jigs, fixtures etc.





d. Bench lathe: Bench lathe is a small lathe mounted on a bench and performs all the

operations of an engine lathe. It’s basically used for small precision works and the only

difference is its size.

e. Capstan and Turret lathe: In this type of lathe, the tailstock is altered by a hexagonal

turret, on which multiple tools can be fitted and fed into the workpiece in proper

sequence. A number of identic jobs can be produced in minimum time, using this type of

lathe.

f. Special purpose lathe: These types of lathes are specifically designed to manufacture

unique parts. Some of the examples of these types of lathes are GAP LATHE, OIL

COUNTRY LATHEand WHEEL LATHE etc.

g. CNC lathe: Computer numerical controlled (CNC) lathes are rapidly replacing the older

production lathes (multispindle, etc.) due to their ease of setting, operation, repeatability

and accuracy. They are designed to use modern carbide tooling and fully use modern

processes. The part may be designed and the tool paths programmed by the CAD/CAM

process or manually by the programmer and the resulting file uploaded to the machine,

and once set and trialled the machine will continue to turn out parts under the occasional

supervision of an operator. The machine is controlled electronically via a computer menu

style interface; the program may be modified and displayed at the machine, along with a

simulated view of the process. The setter/operator needs a high level of skill to perform

the process, however the knowledge base is broader compared to the older production

machines where intimate knowledge of each machine was considered essential. These

machines are often set and operated by the same person, where the operator will

supervise a small number of machines (cell).





1.4 COMPONENTS OF LATHE

a. BED: The lathe bed constitutes the base of the machine. It must be tough enough to resist

deflection in any direction under load.It is made of cast iron or alloy steel.

It comprises flat or inverted V-shaped inner or outer guideways to guide the carriage

headstock and tailstock. The headstock and tailstock are situated at the either end of the

bed and the carriage lies over the lathe bed and slides over it.

b. HEAD STOCK: It is fixed at the left-hand –side of the lathe bed on the inner

guideways. It supports the spindle which is driven through the gear-box housed within

the headstock. Gear-box provides a wide range of speed of the spindle. The spindle is

hollow so that the long bars may be fed through it for continuous production. A live

centre, a face-plate, collector or a chuck can be fitted to a spindle nose to hold and drive

the work.

c. TAILSTOCK: It is located on the inner guideways at the right-hand-side of the lathe. It

basically has two main functions:

I. To support the free end of the workpiece when machined between the centers.

II. To hold tools for various operations such as drilling, tapping and reaming.

The body of the tailstock can be adjusted along the guideways by sliding it to the required

position and can be clamped by bolt and plate. It can be also offset for cutting a small

angle taper.

d. GUIDEWAYS: They may be V or flat shaped surface on which the carriage and

tailstock are moved left to right. Each has its separate pair of ways; often one flat surface

for stability and one V way for guidance in a perfectly straight line.

e. CARRIAGE: The carriage of the lathe has swivel parts that support, move and control

the cutting tool. It comprises the following parts:





I. Saddle: It is an H shaped casting that fits over the bed and slides along the

guideways. It carries the cross-slide and the tool post.

II. Cross-slide: The cross-slide carries the compound rest and tool post. It is used to give

depth of cut.

III. Compound rest: It is fitted on the top of a cross-slide and is used to support the

cutting tool. It can be moved in and out by its hand-wheel for facing or for setting the

depth of cut. It can also be rotated and fed by its hand-wheel at any angle.

IV. Tool post: It is mounted on the compound rest to hold the tool and enable it to be

adjusted to a convenient working position.

It can be of several types:

i. Single screw tool post

ii. Four way tool post

iii. Quick change tool post

V. Apron: The apron is fastened to the saddle and hangs over the front of the bed It

contains the gears, clutches for transmitting motion from feed rod to carriage and also

has split nut which engages with engages lead screw while thread cutting.

f. FEED ROD: It is a long shaft that has a key-way. The power is transmitted from the

lathe spindle to the apron gears through a feed rod via. a large number of gears. It is used

to move the carriage on cross-slide for turning, facing and all other operations except for

thread cutting.

g. LEAD SCREWS: It is powered by gears from the head stock and is used for providing

specifically accurate mechanized movements for cutting threads on the workpiece. In

some lathes, the lead screw performs the function of feed rod and there is no separate

feed rod.





1.5 LATHE ACCESSORIES

The devices used for holding and supporting the work and tool on the lathe are called lathe

accessories. Some of the lathe accessories are described as under:

a. CHUCKS: These are used for holding up the workpiece on lathe during the

machining operations. The workpiece of short length or large diameter or of irregular

shape, which cannot be held between the centers are held quickly and aptly in a

chuck. The chuck is attached to the lathe spindle by help of bolts with the back plate

screwed to the spindle nose. The different types of chucks are:

I. Three jaw universal chucks: It is also called self-centering chuck and all three

jaws move together in equal amounts to clamp the work. Therefore, the job is

automatically centered. The jaws have a series of teeth that mesh with the spiral

grooves on a circular plate with the chuck. This plate can be rotated by the

inserting a key in the square socket; resulting simultaneous radial motion of the

jaw.

II. Four jaw independent chucks: Each jaw is moved independently by rotating the

screw which meshes with the teeth cut on the underside of the jaw. They are used

for holding square, octagonal and large independent irregular components.

III. Combination chucks: They have the combination of both the above principles

and are provided with four jaws which can be operated either by scroll disc or

individually by separate screws.

IV. Magnetic chucks: These are used to hold the steel workpieces that are too thin to

be held in ordinary chucks. The faces of the chucks are magnetized with

permanent magnets contained within the chucks.

V. Collet chucks: They provide a quick means of holding the bar stock. Draw in

type collets are in common use. Their front portions are splitted which provide a

spring action and hence the grip.

VI. Hydraulic chucks: In these types of chucks, air or hydraulic pressure is used to

press the jaws against the job. The pressure is provided by a cylinder and piston





mechanism mounted on the back of the head stock and controlled by a valve by

the operator.

VII. Drill chucks: They are used for holding straight shank drills, taps and reamers for

drilling, tapping and reaming operations. They may be held either the head stock

or the tail stock. They have self centering jaw and are operated by keys.

b. FACE PLATES: They are large circular discs bored out and threaded to fit the nose

of the spindle. These have radial planes and T-slots for holding work by bolts and

clamps. They are used for holding the workpieces that cannot be held conveniently by

the chucks.

c. ANGLE PLATES: They are cast iron plates having two faces machined to make

them absolutely at right angles to each other. They are used for holding works in

conjunction with the face plates, when works cannot be directly mounted on the face

plates.

d. LATHE CENTRES: They are hardened steel devices used for holding and locating

the works to be machined. The centre fitted in head stock is live centre and in tail

stock is dead centre.

e. MANDRELS: They are used to hold and rotate hollow works between the centers.

They are made of high carbon steel and are slightly tapered. The mandrels are rotated

by lathe dogs and catch plates and the works are driven by friction.

f. STEADY RESTS: They comprise a cast iron frame made of two parts hinged

together on one side. The upper part can be swung back for inserting or removing the

jobs without disturbing the position of the steady rests. They can be clamped at any

position desired on the lathe bed guide ways. The main function of the steady rests is

to provide support to the long cylindrical works.





g. FOLLOWER RESTS: They consist of a C-shaped casting having two adjustable

jaws that support the work. They are attached to the saddle and move along the tool.

They prevent the job from springing away when cut is given.

1.5 LATHE ATTACHMENTS

a. GRINDING ATTACHMENT: It consists of a grinding wheel driven independently by

a small motor which is mounted on a cross slide. The job is held as usual in a chuck or

between centers and the rotating grinding wheel is fed against the job instead of the usual

cutting tool.

b. MILLING ATTACHMENT: It’s mounted on compound rest in the place of tool post. It

consists of a slide swivel vice. The base of swivel vice is graduated in degrees and can be

set at any required angle. This attachment is used for face milling, T-slot cutting, keyway

cutting etc.

c. STOPS: They are used on the carriage and cross slide to position them accurately. They

are used for repeated work. They save set up time and give more accurate results.

d. TAPER TURNING ATTACHMENTS: They are used for producing tapers on

cylinders. Similarly, various attachments like copying attachments, relieving

attachments etc. can be used on a lathe.

1.6 LATHE OPERATIONS

a. CENTERING: When the work is required to be turned between the centers or between

the chucks, a center, conical-shaped hole is to be provided at the end of the workpiece.

Centering is the operation of providing conical hole in the workpiece. The first step is to





locate the centre, after that a center punches and hammer is used to make deep

indentation. Center holes are produced by using a combined drill or a counter sink drill.

b. TURNING:It is the most commonly used operation on the lathe. In this method, excess

material is removed from the workpiece to produce conical or cylindrical surfaces. Fig

1:shows the basic turning mechanism.

Fig 1: Turning mechanism

The common methods of turning are:

I. PLAIN/STRAIGHT/SIMPLE TURNING: The workpiece is held in the spindle

and is rotated and the tool is fed in the direction parallel to the axis of rotation. The

surface generated is cylindrical.

II. TAPER TURNING:A conical surface by gradual reduction in the diameter of the

cylindrical job is produced by the operation. This can be obtained by the following

ways:

By Compound Feed: Longitudinal and cross feed is simultaneously engaged

which results in diagonal movement of the tool to produce a taper to the

workpiece. The direction of the resultant feed may be changed by varying the

rate of feeds by using the gears in the apron.





By Swivelling The Compound Rest: The work is held in the chuck or

between centers. The compound rest is swiveled to the desired angle (half of

taper angle) with respect to the work. The tool is fed manually by rotating the

hand-wheel of the compound rest.

Advantages:

Easy setting.

Steep tapers can be produced.

Both internal and external tapers can be made.

By Tailstock Setover Method: Principles of this method is to shift the axis of

rotation of the workpiece at an angle to the lathe axis and feeding the tool

parallel to the lathe axis. The angle at which the axis of rotation of the

workpiece is shifted is half the taper angle.

Advantages:

Good surface finish can be obtained.

Power feed can be obtained.

By Using Taper Turning Attachment: Taper turning attachment is provided

in few of the modern lathes. Its principle is to guide the tool in a straight path

set at an angle to the axis of rotation of the workpiece, while the work is being

held in the chuck.

Taper turning attachment is provided in the rear side of the lathe by means of

a bracket. It consists of swivel side which can be adjusted to the required





angle. A guide block sliding in this swivel slide is connected to the rear end of

the cross-slide. To turn the taper, swivel slide is set at half of the taper angle.

The cross-slide fixing screw is loosened. As the carriage travels in

longitudinal direction, the tool on cross-slide will follow straight angular path

set by the guide-block.

Advantages:

Good surface finish can be obtained.

The alignment of the lathe centers is not disturbed.

Lengthy tapers can be produced.

By Using A Form Tool: The broad hose tool having straight cutting edge is

set on tot the work at half taper angle and is fed straight into the work to

produce tapered surfaces.

c. FACING: It is an operation of generating flat surface at the ends of the workpiece. The

work is rotated and the tool is fed in a direction perpendicular to the axis of work. This is

used to cut the work of required length and to provide flat surface with axis of rotation of

the workpiece.

d. PARTING OFF:It is used for cutting away the required length from the bar stock, using

a flat nose tool, and feed is given in direction perpendicular to the axis of rotation.

e. GROOVING: It is the process of reducing the diameter of a workpiece over a narrow

surface. It is also known as recessing or necking operation. It is often at the end of a

thread or adjacent to a shoulder to ensure correct shape of mating.

f. KNURLING: It is the process of embossing diamond shaped pattern on the job. The

purpose of knurling is to provide:





Good grip; so that it doesn’t slip while operating.

Good appearance.

For raising the diameter to a small range for the assembly to get a press-fit.

g. CHAMFERING: It is the method of beveling the extreme ends of a workpiece. This is

done to remove the unwanted metal projection at the end and protect the end of the

workpiece from being damaged.

h. DRILLING: It is the process of making a hole in the workpiece. Before drilling, the

work should be faced and centered. The drill bit is held stationary in the tail-stock and the

drill is fed into the workpiece which is revolving in the chuck.

i. BORING: It is the operation of enlarging a drilled hole. The boring tool in held in the

tail-stock.

j. MILLING: It is the operation of removing metals by feeding the workpiece against the

rotary milling cutters. The milling cutters may be held by chuck or by attachment

mounted on the carriage.

k. GRINDING: Both internal and external surfaces may be ground by using grinding

attachment mounting on the cross-slide. Grinding should be done on a lathe only when no

other alternate machine is available, because for this lathe must be equipped with

reversing switches as the workpiece as the workpiece should rotate in opposite direction

to the grinding wheel.





l. THREAD CUTTING: It is one of the most important operations performed on the lathe.

The principle of thread cutting is to produce helical grooves on cylindrical or conical

surfaces by feeding the tool longitudinally when the job is revolved between the centers.

1.8 TOOL

A cutting tool is basically a metallic object which is used for removal of metal from a stock

part. In lathe, basically a single point cutting tool is employed for the removal of materials from

the workpiece in form of chips by feeding the tool to the job while the job is rotating.

1.9 TOOL NOMENCLETURE

a. FACE: Surface over which the chips flow.

b. FLANK: Surface below the cutting edge.

c. NOSE: The junction of side and end cutting angle.

d. SIDE CUTTING EDGE: It is formed by the intersection of flank and side flank. It does

the main cutting.

e. END CUTTING EDGE: It is the intersection of face and flank.

f. BACK RAKE ANGLE: It measures the downward slope of the top surface of the tool

from nose to the rear along the longitudinal axis.

i. It guides the direction of chip flow.

ii. It is called positive if it slopes downwards towards the shank. It is used to cut low

tensile strength ferrous materials.





iii. It is called negative if it slopes upwards towards the shank. It is used to cut high

tensile strength materials.

g. SIDE RAKE ANGLE: It measures the op surface of the tool to the side in the direction

perpendicular to the longitudinal axis.

h. SIDE RELIEF ANGLE: It is the angle made by the flank of the tool and a plane

perpendicular to base just under the side cutting edge. This allows the tool to be fed

sideways into the job; so that it can cut without rubbing.

i. END RELIEF ANGLE: It is a secondary relief angle between a plane perpendicular to

the base and end flank.

j. SIDE CUTTING EDGE ANGLE: It is the angle between the side cutting edge and the

longitudinal axis of the plane.

k. NOSE RADIUS: It is the curve formed by joining the side cutting and end cutting edges.

For heavier depths of cut and feeds and interrupted cuts, the nose is given a radius of

1.5mm for obtaining a higher tool life and better surface finish.

Note: Depth of cut should be more than nose radius.

Fig 2 gives a view of the basic tool nomenclature.





Fig 2: View of tool nomenclature

1.10 PROCEDURE FOR GRINDING HSS GENERAL PURPOSE LATHE TOOLS

First, begin by dressing the grinding wheel. Next, look up the optimum angles for the

workpiece material, then follow the steps described in the under given figure. Dip the tool in

coolant frequently to keep it away from annealing and over-heating, any discoloration on the bit

indicates it was drawn and was no longer hardened. Then, start over again from the beginning.

Tool bit angles are not critical and most tools will cut the material satisfactorily, but not

effectively.

Fig 3 describes the basic steps for sharpening of HSS tool bits.





Fig 3: Steps for sharpening of HSS tool bits

1.11 TOOL WEAR

During machining operation, the cutting edge of the tool gradually wears out and at

certain stage stops cutting.

The various types of tool wear are:

a. FLANK WEAR: Flat portion behind the cutting edge is worn out, which eliminates

some clearance and relief. It occurs while machining brittle materials like cast iron or

when feed is less than 0.15 mm/rev.

b. CRATER WEAR: It occurs on the rake face of the tool in the form of pit. It is formed at

some distance from the cutting edge. Crater wear is a temperature dependent

phenomenon.

c. SPALLING OR CRUMBLING: It takes place at the cutting edge while machining

extremely hard materials when cutting edges are not well supported.





d. LOSS OF HARDNESS: Under cutting conditions when the temperature and stresses are

high, plastic deformation may cause loss of hardness, and thus the cutting ability.

e. FRACTURE BY PROCESS OF MECHANICAL BREAKAGE: It takes place when

the cutting force is very large or by developing fatigue cracks under chatter conditions.

f. NOSE WEAR: This occurs after using the tool for a considerable amount of time. It

occurs only after crater wear occurs in unfavorable conditions like vibrations while

machining.

1.12SELECTION OF CUTTING SPEED AND FEED

a. WORKPIECE MATERIAL: Harder the material more is the force required and hence,

more is the wear of tools. Therefore, hard materials should be machined at decreased

cutting speed and smaller feed.

b. TOOL MATERIAL: An increase in cutting speed will result in more heat generation;

hence, more resistant tool should be used. They can also be used under heavier feeds.

c. TOOL GEOMETRY AND DIMENSION:A change in profile angles will

correspondingly change the force due to cutting action; as well as the condition for heat

transmission.

d. TYPE OF FINISH: Increased cutting speed and fine feed will give better surface finish.





e. SIZE OF CHIP CROSS-SECTION: It affects the forces due to cutting and

consequently amount of heat generated. Tool wear is more rapid. With increase in cutting

speed than with increase in the chip cross-section. The cross-section increase with the

increase in depth of cut.

f. RIGIDITY OF MACHINE: The operation performed should not produce vibration in

the machine.

g. TYPE OF COOLANT: Increased cutting speeds and increased feeds may be used with

the proper administration of coolants.





CHAPTER 2

LITERATUREREWIEW

Hasan et al. [1] in the year 2007 focused on the analysis of optimum cutting conditions to

get lowest surface roughness in turning SCM 440 alloy steel by Taguchi method. The challenge

of modern machining industries is mainly focused on the achievement of high quality, in terms

of workpiece dimensional accuracy, surface finish, high production rate, less wear on the cutting

tools, economy of machining in terms of cost saving and increase the performance of theproduct

with reduced environmental impact.

Krishankant et al. [2] in the year 2012 reports on an optimization of turning process by

the effects of machining parameters applying Taguchi methods to improve the quality of

manufactured goods, and engineering development of designs for studying variation. EN24 steel

is used as the work piece material for carrying out the experimentation to optimize the Material

Removal Rate.Taguchi orthogonal array is designed with three levels of turning parameters with

the help of software Minitab 15.Taguchi method stresses the importance of studying the response

variation using the signal–to–noise (S/N) ratio, resulting in minimization of quality characteristic

variation due to uncontrollable parameter.

Kivak et al.[3]in the year 2012 reports effect of deep cryogenic treatment and drilling

parameters on surface roughness and roundness error that were investigated in drilling of AISI

316 austenitic stainless steel with M35 HSS twist drills. In addition, optimal control factors for

the hole quality were determined by using Taguchi technique. Two cutting tools, cutting speeds

and feed rates were considered as control factors, and L8 orthogonal array was determined for

experimental trials. Multiple regression analysis was employed to derive the predictive equations

of the surface roughness and roundness error achieved via experimental design. Minimum

surface roughness and roundness error were obtained with treated drills at 14 m/min cutting

speed and 0.08 mm/rev feed rate. Confirmation experiments showed that Taguchi method

precisely optimized the drilling parameters in drilling of stainless steel.





Shivakoti et al. [4] in the year 2012 report the application of various optimization

techniques that are playing vital role which seeks identification of the best process parametric

condition for that particular manufacturing or metal removal process. In this research paper,

Genetic Algorithm (GA) has been applied for optimizing of machining parameters during turning

operation of mild steel using conventional lathe machines. The purpose of this paper is to find

the optimum parameters values for turning operations for maximizing the material removal rate.

The machining parameters that been consider in this paper are cutting speed, feed rate and

spindle speed. The Turbo C compiler is used to develop the GA simulation. GA can be used in

optimization problems such as scheduling, materials engineering, optimal control, and so forth.

Swamy[5]in the year 2012 obtained an optimal setting of turning parameters (Cutting

speed, Feed and Depthof Cut) which results in an optimal value of Surface Roughness while

machining Al 6351-T6 alloy with Uncoated Carbide Inserts. Several statistical modeling

techniques have been used to generate models including Genetic Algorithm, Response Surface

Methodology. In our study, an attempt has been made to generate a model to predict Surface

Roughness using Regression Technique. Also an attempt has been made to optimize the process

parameters using Taguchi Technique. S/N ratio and ANOVA analysis were also performed to

obtain significant factors influencing Surface Roughness.

Hasluck [6] in the year 1883 sharedpractical knowledge on the turning processes vividly.

The effects of spindle speed, cutting speed, rake angle, depth of cut, feed rate etc. on turning

processes is explained clearly and shown vividly by diagrams. Of all the mechanical arts, none

can claim a more important place than that of turning, and practice of this branch of mechanical

manipulation is capable of developing the highest skill and intelligence of the artificer.

Woolf [7] explained everything about the Taguchi method generously. The design of

experiments, the orthogonal arrays etc. are all being shown in a much easier and compatible way.

This book carries message that efficient experimental design helps to optimize the process and

determine factors that influence variability. It also teaches us that factorial designs are easy to

construct but can be impractically large and Taguchi and random designs often perform better

depending on size and assumptions.





Hagiwara [8] in the year 2005 studies that unlike straight turning, the effective cutting

conditions and tool geometry in contour turning operations are changing with changing work

piece profile. This causes a wide variation in machining performance such as chip flow and chip

breakability during the operation. This thesis presents a new methodology for optimizing the

machining performance, namely, chip breakability and surface roughness in contour finish

turning operations. In machining operations, chip control is one of the most important factors for

achieving good surface finish and part quality, operator safety, machine productivity, cost

efficiency, and tool sustainability.

Nalbant et al.[9]in the year 2006 studies that the Taguchi method is used to find the

optimal cutting parameters for surface roughness in turning. The orthogonal array, the signal-to-

noise ratio, and analysis of variance are employed to study the performance characteristics in

turning operations of AISI 1030 steel bars using TiN coated tools. Three cutting parameters

namely, insert radius, feed rate, and depth of cut, are optimized with considerations of surface

roughness. Experimental results are provided to illustrate the effectiveness of this approach.

Kshirsagar et al. [10] in the year 2012 studies that the Taguchi method is a statistical

approach to overcome the limitation of the factorial and fractional factorial experiments by

simplifying and standardizing the fractional factorial design. The objective of the current study is

to illustrate the procedures and strengths of the Taguchi method in Lathe facing operation. The

orthogonal array, the signal-to-noise ratio, and analysis of variance are employed to study the

performance characteristics in facing operation. Theoretical analysis has been performed to find

the critical parameters. Three cutting parameters namely, feed rate, depth of cut and spindle

speed, are the cutting parameters considered. An orthogonal array has been selected and

constructed according to the need of the experiment.

Experimental runs according to the orthogonal array will be conducted and surface roughness

will be measured. Accordingly, S/N ratio will be calculated to construct an ANOVA table. With

help of linear graphs, optimum parameter values will be obtained and confirmation experiments

have to be conducted.

Usman [11] in the year 2012 explains the effect of tool rake angles on tool life.The rake

angles of 00, 5

0, 10

0, 15

0, and 20

0 and a constant clearance (Relief angle) of 8

0 were used to turn





bright mild steel on the lathe machine, with a high speed steel of 18mm side as cutting tooland

soluble oil was used as coolant. This is all in order to explore the energy savings opportunities

during regrinding of tools, useful production time and energy is being wasted due to regrinding

or re-sharpening of tools when cutting tools got worn or blunt, selection of the best rake angle

which elongates tool life goes a long way in saving these time and energy. It was observed that,

the rake angle of 200 gave the longest tool life as well as the best surface finish and yielded

continuous chips formation.

Miroslav et al. [12]in the year 2012 proposed the optimization of cutting parameters

based on cutting force in tube turning of S235 G2T steel by coated carbide tool using Taguchi

method . Three cutting parameters, namely cutting speed, feed and depth of cut are optimized

with considerations of cutting force as performance characteristic. The effects of cutting

parameters on the cutting force components were experimentally investigated. As per Taguchi’s

orthogonal arrays, experimentation was conducted. Three cutting parameters with three levels

are arranged in L9 orthogonal array. The orthogonal array, measured values of cutting force

components, signal-to-noise ratios, and analysis of variance are employed in order to study the

cutting force. Based on this analysis the optimal cutting parameters settings were determined.

Chaudhari et al. [13]in the year 2009 studies that a single characteristic response

optimization model based on Taguchi Technique is developed to optimize process parameters,

such as speed, feed, depth of cut, and nose radius of single point cutting tool. Taguchi’s L9

orthogonal array is selected for experimental planning. The experimental result analysis showed

that the combination of higher levels of cutting speed, depth of cut and lower level of feed is

essential to achieve simultaneous maximization of material removal rate and minimization of

surface roughness. This paper also aims to determine parametric relationship and its effect on

surface finish.

Kirby.[14]in the year 2006 investigates the use of Taguchi Parameter Design for

optimizing surface roughness generated by a CNC turning Operation. This study utilizes a

standard orthogonal array for determining the optimum turning parameters, with an applied noise

factor. Controlled factors include spindle speed, feed rate, and depth of cut; and the noise factor

is slightly damaged jaws. The noise factor is included to increase the robustness and applicability





of this study. After experimentally turning sample workpieces using the selected orthogonal

array and parameters, this study produced a verified combination of controlled factors and a

predictive equation for determining surface roughness with a given set of parameters.

Gopalsamy et al.[15]in the year 2009 utilizes a standard orthogonal array for determining

the optimum turning parameters, with an applied noise factor. Controlled factors include spindle

speed, feed rate, and depth of cut; and the noise factor is slightly damaged jaws. The noise factor

is included to increase the robustness and applicability of this study. After experimentally turning

sample workpieces using the selected orthogonal array and parameters, this study produced a

verified combination of controlled factors and a predictive equation for determining surface

roughness with a given set of parameters.

Dubey et al. [16] in the year 2007 made a hybrid approach of Taguchi method (TM) and

principal component analysis (PCA) for multi-objective optimization (MOO) of pulsed Nd:YAG

laser beam cutting (LBC) of nickel-based superalloy (SUPERNI718) sheet to achieve better cut

qualities within existing resources. The three-quality characteristics kerf width, kerf deviation

(along the length of cut), and kerf taper have been considered for simultaneous optimization. The

input parameters considered are assist gas pressure, pulse width, pulse frequency, and cutting

speed. Initially, single-objective optimization has been performed using TM and then the signal-

to-noise (S/N) ratios obtained from TM have been further used in PCA for multi-objective

optimization. The results of MOO include the prediction of optimum input parameter level and

their relative significance on multiple quality characteristics (MQC). The responses at predicted

optimum parameter level are in good agreement with the results of confirmation experiments

conducted for verification tests.

So, after studying the above mentioned research papers, basically an attempt to design an

L9orthogonal array using TM and as per the design of the model, attempt has been taken to

perform nine experiments to find out the maximum MRR considering the process parameters viz.

Spindle Speed, Depth of Cut and Rake Angle.





CHAPTER 3

OBJECTIVE OF THE PROJECT

It can be very clearly seen from the review of past research that a lot of theoretical and

experimental works have been carried out for proper understanding of the basic process of

turning using a lathe and for identifying the actual process parameters setting to optimize turning

performance criteria.

Some researchers have applied the lathe for turning of difficult and intricate shapes. These

shapes can be easily and efficiently machined with CNC lathes. Due to recent advancement of

the computer numerical technology, various new types of X-Y-Z CNC controlled lathe machines

are available in the manufacturing industries. Some of the researchers have used the types of

lathes for their experiments. But these machines are very costly and their maintenance is much

complicated. So for the sake of low cost of production, an attempt has been made to optimize the

various cutting parameters viz. spindle speed, depth of cut and rake angle, using TM which is

one of the most commonly used optimization technique. Using the Taguchi optimization

technique, it was tried to seek out under which optimal conditions, the MRR will be maximum.

Later, the maximum value procured from the TM was compared with the value of optimum

MRR using PCA technique.

Therefore, the objectives can be defined as follows:

I. Experimental Design using Taguchi Method.

II. Calculation of various MRR’s and MT’s.

III. Analysis of Material Removal Rate.

IV. Development of regression equations of MRR and MT.

V. Comparison of experimental and regression predicted values for MRR.

VI. Single objective Optimization using Taguchi Method.

VII. Multi objective optimization using Principal Component Analysis.





CHAPTER4

EXPERIMENTAL PLANNING AND ANALYSIS OF

TURNINGOPERATION

4.1 EXPERIMENTAL PLANNING

In this work a mild steel bar of 25mm diameter was collected. The bar was then cut into nine

equal pieces. Turning operation was carried out on each of the workpieces using HSS tool as per

the orthogonal array design of the experiment using Taguchi method. The MRR and MT were

calculated for each of the experiment. Fig 1, 2, 3 respectively show the lathe, HSS tool and the

mils steel bar workpieces used for the experiment. Table 1 shows the levels of the various

process parameters and table 2 and 3 respectively show the chemical composition of mild steel.

Fig 4: The lathe used for the experiment





Fig 5: The HSS tool used for the experiment

Fig 6: The workpieces used for the experiment

Table1:Levels of the various process parameters

Machining parameters Level 1 Level 2 Level 3

Spindle speed 200 300 450

Depth of cut 0.5 1.0 1.5

Rake angle 5 10 15





Table 2: Chemical composition of mild steel:

Elements Carbon

(C)

Manganese

(Mn)

Silicon

(Si)

Others

Percentage 0.25 0.4-0.7 0.1-0.5 Balance

Table 3: Chemical composition of HSS

Elements

Carbon

(C)

Chromium

(Cr)

Molybdenum

(Mo)

Tungsten

(W)

Vanadium

(V)

Cobalt

(Co)

Percentage

0.94 4.1 5.0 6.0 2.0 5.0

Fig 7: Chemical Composition of HSS

Carbon

Chromium

Molybdenum

Tungsten

Vanadium

Cobalt





4.2 FORMULAE OF VARIOUS CUTTING PARAMETERS WITH EXPLANATION

For machining operations, it is necessary to have relative motion between the workpiece

and the tool, e.g. for drilling operation, we may rotate the drill bit or the workpiece and besides

this, we need to press the drill against the workpiece so that it penetrates the workpiece.

First motion (i.e. rotation of drill bit or workpiece) is called primary or cutting motion

and the second one is called feed motion.

I. SPINDLE SPEED: It is the speed at which the spindle attached to the chuck in the

head stock rotates.

It is expressed in RPM

Spindle speed is given by the relation

N=v × 1000/π d (1)

Where,

d = Diameter of the job in mm.

N= Spindle speed in RPM

v = Cutting speed in mm/min

II. FEED: It refers to the amount of tool advancement per revolution of the job parallel

to the surface of the job. It enables the cutting process to be extended to the entire

surface of the job.

It is expressed in mm.

III. DEPTH OF CUT: It refers to the advancement of the tool in the tool in a direction

perpendicular to the surface being machined.

Depth of cut= (d1-d2)/2 (2)

Where,

d1= Diameter of uncut surface.

d2=Diameter of machined surface.





IV. MACHINING TIME: Machining time of lathe depends upon the speed, feed and

length of the job.

It is given by the relation

T= l/fN (3)

Where,

l = length of the job.

f = feed.

N= Spindle speed

V. MATERIAL REMOVAL RATE: It is the volume of metal removed per unit time.

It is expressed in mm3/min.

It is given by the relation

MRR= π×d×D×f×N (4)

Where,

d= diameter of the uncut job.

D= depth of cut.

f= feed

N= Spindle speed

4.3 DESIGN OF EXPERIMENT BASED ON TAGUCHI

The basic orthogonal array design of L9 Taguchi method is shown in Table 4.

Table 4: Orthogonal array L9 of Taguchi

Sl no. Parameter 1 Parameter 2 Parameter 3

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

Table 5 shows the design of experiment on orthogonal array L9 of Taguchi method.

Table 5: Experimental Design based on Orthogonal array L9 of Taguchi

Sl no. Spindle Speed

(x1)(RPM)

Depth of Cut (x2)

(mm)

Rake Angle (x3)

(degrees)

1 200 0.5 5

2 200 1.0 10

3 200 1.5 15

4 300 0.5 10

5 300 1.0 15

6 300 1.5 5

7 450 0.5 15

8 450 1.0 5

9 450 1.5 10

4.4 EXPERIMENTAL RESULTS

After conducting the experiment on different test workpieces the under given results were

obtained as shown in Table 6.





Table 6: The different values achieved after performing the experiment

Sl no. Spindle Speed

(RPM)

x1

Depth of Cut

(mm)

x2

Rake Angle

(degrees)

x3

MRR

(mm3/min)

MT

(sec)

1 200 0.5 5 725.26 11.05

2 200 1.0 10 1806.18 6.46

3 200 1.5 15 2226.6 8.46

4 300 0.5 10 1142.75 5.48

5 300 1.0 15 1822.04 8.45

6 300 1.5 5 2261.95 8.35

7 450 0.5 15 1024.95 6.11

8 450 1.0 5 1555.09 8.02

9 450 1.5 10 2014.56 9.15





4.5 ANALYSIS OF MRR

Fig 8 shows the effect of machining parameters of MRR

Fig 8: Effect of machining parameters on MRR

I. Spindle speed: It is very clearly visible from the graph that MRR is maximum at 300

rpm. It is due to the fact that at 450 rpm the tool wears and machining is improper if

the supply of coolant is absent (as in this case).

II. Doc: From the graph is it noticeable that maximum MRR is achieved when the depth

of cut is the most (1.5mm as in this case).

III. Rake angle: From the graph it’s seen that maximum MRR is obtained when rake

angle is set to 15 .

4.6 REGRESSION ANALYSIS

The first necessary step for process parameter optimization in any metal cutting process

is to understand the principles governing the cutting processes by developing an explicit

mathematical model. Here, statistical regression technique has been used to model the equation

using Analysis of Variance (ANOVA). The objective consists of adjusting the parameters of a





model function to best fit a data set. A simple data set consists of n points (data pairs) (xi, yi) i =

1, ..., n, where xi is an independent variable and yi is a dependent variable whose value is found

by observation. The model function has the form f(x, β), where the m adjustable parameters are

held in the vector β. The goal is to find the parameter values for the model which "best" fits the

data. The least squares method finds its optimum when the sum, S, of squared residuals

S = ∑ i

2 (5)

is a minimum. A residual is defined as the difference between the actual value of the dependent

variable and the value predicted by the model.

ri = yi – f (xi , β) (6)

An example of a model is that of the straight line. Denoting the intercept as β0 and the slope as

β1, the model function is given by

f (x , β) = β0 + β1x (7)

A data point may consist of more than one independent variable. For an example, when fitting a

plane to a set of height measurements, the plane is a function of two independent variables, x and

z, say. In the most general case there may be one or more independent variables and one or more

dependent variables at each data point. The minimum of the sum of squares is found by setting

the gradient to zero. Since the model contains m parameters there are m gradient equations.

= 2∑ i

= 0, j = 1,…,m (8)

From equation (6) and (8), the gradient equation can be written as

-2∑

= 0, j = 1,…,m (9)

The gradient equations apply to all least squares problems. Each particular problem requires

particular expressions for the model and its partial derivatives. A regression model is a linear one

when the model comprises a linear combination of the parameters, i.e.

( ) ∑ (10)





Here the coefficients, , are functions of .

Letting

xij =

= (11)

In case the least square estimate (or estimator, in the context of a random sample),β is given by

= (XT

X)-1

XT

y (12)

The following regression equation has been developed based on the experimental results shown

in Table 6. This regression equation is achieved by feeding the experimental data to the statistical

Minitab software.

The regression equation is

MRR = - 1132 + 0.793 x1 + 1736 x2 + 273 x3 + 1.57 x1x2 - 125 x2x3 - 0.382 x1x3 (13)

R-Sq= 99.9%

MT = 18.8 - 0.0150 x1 - 4.27 x2 - 1.61 x3 - 0.0022 x1x2 + 0.772 x2x3+ 0.00224 x1x3 (14)

R-Sq = 74.9%

Here, x1, x2 and x3 correspond to the process parameters spindle speed, depth of cut and rake

angle in uncoded values.

Tables 7 and 8 respectively show model of various factors, interactions and outputs calculated

during the performance of experiment and Percentage error difference between the experimental

and regression predicted values of MRR.

Figures 9 and 10 respectively show plot of experimental and regression predicted values of

MRR against experiment number and plot of experimental and regression predicted values of

MRR against percentage error.





Table 7: Model of Various Factors, Interactions and Outputs Calculated During the

Performance of Experiment

Sl no. Spindle

Speed

(RPM)

x1

Depth

of Cut

(mm)

x2

Rake

Angle

(degrees)

x3

x1 x2 x2 x3 x1 x3 MRR

(mm3/min)

MT

(sec)

1 200 0.5 5 100 2.5 1000 725.26 11.05

2 200 1.0 10 200 10 2000 1806.18 6.46

3 200 1.5 15 300 22.5 3000 2226.6 8.46

4 300 0.5 10 150 5 3000 1142.75 5.48

5 300 1.0 15 300 15 4500 1822.04 8.45

6 300 1.5 5 450 7.5 1500 2261.95 8.35

7 450 0.5 15 225 7.5 6750 1024.95 6.11

8 450 1.0 5 450 5 2250 1555.09 8.02

9 450 1.5 10 675 15 4500 2014.56 9.15





Table 8: Percentage Error Difference Between the Experimental and Regression Predicted

Values of MRR

Average predicted error is 0.64 %

Sl. no Experimental Regression predicted %error

1 725.26 722.1 0.435

2 1806.18 1792.6 0.752

3 2226.6 2238.1 0.516

4 1142.75 1168.4 2.24

5 1822.04 1813.9 0.447

6 2261.95 2270.9 0.396

7 1024.95 1025.1 0.014

8 1555.09 1547.85 0.465

9 2014.56 2024.6 0.498





Fig 9: Plot of experimental and regression predicted values of MRR against experiment

number





Fig 10: Plot of experimental and regression predicted values of MRR against percentage

error

4.7ANALYSIS OF VARIANCE (ANOVA)

To test whether the data predicted by regression model is well fitted or not, analysis of

variance (ANOVA) has been carried out. The ANOVA results for MRR model have been shown

in table given under. From the table, it is clear that the calculated F-values for the MRR against

Spindle Speed, Depth of Cut and Rake Angle are 0.09, 38.50 and 0.07 respectively which are in

the acceptable ranges. Also, p-values of the source of regression model are 0.913, 0.000 and

0.936 respectively. Table 9 and figure 11 shows the percentage contribution of various process

parameters.





Table 9: Percentage contribution chart

Source Degree of

Freedom

Sum of

Squares

Mean Sum

of Squares

F-value P-value %

Contribution

Spindle

Speed

2 71777 35889 0.09 0.913 3.06

Error 6 2326072 387679

Total 8 2397849

Depth of

Cut

2 2224529 1112264 38.50 0.000 94.71

Error 6 173320 28887

Total 8 2397849

Rake

Angle

2 52421 26211 0.07 0.936

2.24

Error 6 2345428 390905

Total 8 2397849





3.8 COMPARISON BETWEEN LOWEST AND HIGHEST MRR

Here, we see that the highest MRR has been achieved in the 6thrun of the experiment, i.e.

when the spindle speed is R M, depth of cut is 1. mm and the rake angle is which is

2261.95 mm3/min.

This has been compared with the 1strun of the experiment, i.e. when the spindle speed is

R M, depth of cut is . mm and the rake angle is which is . mm3/min.

The percentage improvement of MRR is thus 67.93 %.

Fig: 11 Percentage contribution of various process parameters

Spindle Speed

Depth of cut

Rake angle





CHAPTER 5

OPTIMIZATION OF TURNING PROCESS

5.1 PRINCIPAL COMPONENT ANALYSIS

The PCA is a multivariate statistical method that selects a small number of components to

account for the variance of original multi-response. In PCA, the original dataset are converted

into PC which is a linear combination of multi-responses obtained in a trial run. The procedure

of PCA can be described as follows:

1. The S/N ratios of each quality characteristics obtained from TM are normalized as

xi*(j) = ( xi(j) - xi(j)

- ) / ( xi(j)

+- xi(j)

- ) (15)

where xi*(j) is the normalized S/N ratio for jth quality characteristic in ith experimental run, xi(j) is

the S/N ratio for jth quality characteristic in ith experimental run, x(j)-is the minimum and x(j)

+ is

the maximum of S/N ratios for jth quality characteristic in all experimental runs.

2. The normalized multi-response array for m quality characteristics and n experimental

runs can be represented by matrix X* as

X*= [

] (16)

3. The correlation coefficient array (Rjl) of matrix X* is evaluated as follows:

Rjl =

, j = 1, , …, m; l = 1, , …, m (17)





Where

is the covariance of sequences and

and is the

standard deviation of

4. The Eigen values and Eigen vectors of matrix Rjl are calculated.

5. The PC are computed as follows:

∑

(18)

Where pi (k) is the kth PC corresponding to ith experimental run, is jth element of kth Eigen

vector.

6. The total principal component index (TPCI) corresponding to ith experimental run (pi) is

computed as follows:

∑ (19)

∑

(20)

Where is the kth Eigen value.

7. The TPCI for each experimental run is used to find out the average factor effect at each

level. The optimum parameter level that corresponds to the maximum TPCI is also

predicted.

The values of S/N ratio obtained using Minitab software is provided as under:





Table 10: Values of S/N ratio of MRR and MT

Sl no. MRR MT

1 57.2099 -20.0433

2 65.1352 -16.2047

3 66.9528 -18.5474

4 61.1590 -14.7756

5 65.2112 -18.5371

6 67.0897 -18.4337

7 60.2141 -15.7208

8 63.8351 -18.0835

9 66.0836 -19.2284

Next, the Normalized values for MRR and MT obtained and the Eigen analysis of the correlation

matrix are shown in tables 11 and 12

Table 11: Normalized S/N Ratio Values of MRR and MT

Sl no. MRR MT

1 0 0

2 0.8022 0.7287

3 0.9861 0.2839

4 0.3997 1

5 0.8099 0.2859

6 1 0.3056

7 0.3040 0.8206

8 0.6706 0.3720

9 0.8981 0.1547





Table 12: Eigen Analysis of the Correlation Matrix

Eigen Value 1.1504 0.8496

Proportion 0.5750 0.4250

Cumulative 0.5750 1.0000

Variable PC1 PC2

n1 0.7070 0.7070

n2 -0.7070 0.7070

The C’s are analyzed as shown in table 13 and the TPCI values obtained are shown in table 14.

Table 13: PC values for MRR and MT

Sl no. MRR MT

1 0 0

2 0.0520 1.0823

3 0.4965 0.8979

4 -0.4244 0.9896

5 0.3705 0.7747

6 0.4909 0.9231

7 -0.3562 0.7951

8 0.2111 0.7371

9 0.5256 0.7443





Table 14: The TPCI values

Sl no. TPCI

1 0

2 0.4896

3 0.6670

4 0.1763

5 0.5422

6 0.6745

7 0.1277

8 0.4345

9 0.6185

The response values for TPCI is depicted in table 15 and figure 12 shows effects of factor levels

on TPCI.

Table 15: Response table for TPCI

Parameters Level 1 Level 2 Level 3 Maximum -

Minimum

Rank

Spindle Speed 0.3855 *0.4643 0.3936 0.0788 2

Depth of

Cut

0.1013 0.4888 *0.6533 0.5520 1

Rake

Angle

0.3707 0.4281 *0.4456 0.0749 3





Fig 12: Effects of factor levels on TPCI

5.2 RESULTS OF CONFIRMATION OF EXPERIMENT

Seeing from the above table, we can conclude that the values of x2, x3 and x3 respectively of the

process parameters viz. spindle speed, depth of cut and rake angle when put in the regression

equation, will produce the maximum MRR. Table 16 shows the results of confirmation

experiment for multi objective optimization. Table 16 shows the confirmation results.





Table 16: Results of confirmation experiment for multi objective optimization

Levels Initial Values Optimal Values

Spindle Speed 200 300

Depth of Cut 0.5 1.5

Rake Angle 5 15

MRR 725.177 1979.9

MT 11.05 10.20

5.3 ANALYSIS OF VARIAANCE (ANOVA)

To test whether the data predicted by regression model is well fitted or not, analysis of

variance (ANOVA) has been carried out. The ANOVA results for MRR model have been shown

in table given under. From the table, it is clear that the calculated F-values for the MRR against

Spindle Speed, Depth of Cut and Rake Angle are 0.07, 59.66 and 0.06 respectively which are in

the acceptable ranges. Also, p-values of the source of regression model are 0.935, 0.000 and

0.945 respectively both the responses hence the developed regression model for both the

responses are significant and adequate.

Table 17 shows the results of ANOVA for TPCI and figure 13 shows the percentage

contribution of various process parameters.





Table 17: Results of ANOVA for TPCI

Source Degree of

Freedom

Sum of

Squares

Mean Sum

of Squares

F-value P-value %

Contribution

Spindle

Speed

2 0.0113 0.0056 0.07 0.935 2.83

Error 6 0.4948 0.0825

Total 8 0.5061

Depth of

Cut

2 0.48149 0.24095 59.66 0.000 95.33

Error 6 0.02423 0.00404

Total 8 0.50612

Rake Angle 2 0.0095 0.0047 0.06 0.945

1.78

Error 6 0.4966 0.0828

Total 8 0.5061





5.4COMPARISON BETWEEN INITIAL AND OPTIMAL MRR AND MT

Here, we see that the optimal MRR has been achieved when the spindle speed is

R M, depth of cut is 1. mm and the rake angle is 1 which is 1 . mm3/min.

This has been compared with the initial run of the experiment, i.e. when the spindle speed

is R M, depth of cut is . mm and the rake angle is which is 725.144 mm3/min.

The percentage improvement of MRR is thus 63.37 %.

imilarly, for optimal MT has been achieved when spindle speed is R M, depth of

cut is 1. mm and the rake angle is 1 which is 1 . sec.

This has been compared with the initial run of the experiment, i.e. when the spindle speed

is R M, depth of cut is . mm and the rake angle is which is 11. sec.

The percentage improvement of MT is thus 8.33 %.

Fig 13: Percentage contribution of various process parameters

Soindle speed

Depth of cut

Rake angle





CHAPTER 6

CONCLUSION

The concluding remarks on the paper can be summarized as below:

a. In single objective optimization method using TM, the highest MRR was found in the 6th

experiment as 2261.95 mm3/min.

b. It was comprehended that this MRR could be achieved when Spindle Speed was 300

RPM, Depth of Cut was 1.5 mm and Rake Angle was 1 .

c. The percentage improvement of MRR from its lowest value to its highest value was

calculated to be 67.93 % and the various percentage contribution factors of Spindle

Speed, Depth of Cut and Rake Angle was respectively calculated as 3.06 %, 94.71 % and

2.24 %.

d. In multi objective optimization method using PCA technique, the optimal MRR and MT

was found to be 1979.9 mm3/min and 10.20 sec respectively.

e. The percentage improvement of MMR was calculated as 63.37 % and that of MT was

calculated as 8.33 %.

f. Later, the percentage contribution of Spindle Speed, Depth of Cut and Rake Angle was

respectively calculated as 2.83 %, 95.33 % and 1.78 % for TPCI.

This experiment was conducted to find out the highest achievable MRR by optimizing the

process parameters namely Spindle Speed, Depth of Cut and Rake Angle. The results

obtained in this paper can be effectively utilized for machining, particularly turning operation

of mild steel material in shop floor manufacturing.





CHAPTER 7

REFERENCE

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c. Turgay Kivak, Adem Cicek, Gurcan Samtas(2012) Application of Taguchi Method for

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