International Journal of Mechanical Engineering, ISSN:2051-3232, Vol.41, Issue.

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The Application of Taguchi Method in Optimization of Tool Life in Turning Operation of High Carbon High Chromium Steel
Rahul Davis
Assistant Professor, Department of Mechanical Engineering, Shepherd School of Engineering & Technology, Sam Higginbottom Institute of Agriculture, Technology & Sciences-Deemed University Allahabad-211007, Uttar Pradesh, India E-mail: rahuldavis2012@gmail.com

Mohamed Alazhari
Assistant Professor Department of Mechanical Engineering, Hai Alandolas, Main Street, Triploi, Libya E-mail: tobzal@yahoo.com

Abdurahman HA Zubir
M.Tech Industrial Engineering & Management, Department of Mechanical Engineering, S.S.E.T., Sam Higginbottom Institute of Agriculture, Technology & Sciences-Deemed University Allahabad-211007, Uttar Pradesh, India E-mail: abdurahmanzubir@gmail.com
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ABSTRACT
The present work is focused with the optimization of tool life in turning of High Chromium High Carbon Steel. The paper presents the effect of cutting parameters like spindle speed, feed rate and depth of cut on the tool life of Carbide P-30 cutting tool during the wet turning of High Carbon High Chromium Steel. A plan of experiments based on Taguchis method was implemented to attain the data. An orthogonal array, the Signal-to-Noise (SN) ratio and the Analysis of Variance (ANOVA) were employed to investigate the cutting characteristics. In the end the confirmation tests were carried out to compare the predicted values with the experimental values confirm its effectiveness in the analysis of tool life.

Keywords-Tool Life, Taguchi Method, ANOVA, Signal

to Noise Ratio, Orthogonal Array, Turning Operation

1. INTRODUCTION
It has been observed that the industries of machine tools in India have made an excellent progress while the metal removing industries continue to suffer from a major shortcoming of not running the machine tools at the optimum working conditions. A Number of industrial practitioners and scientists have been dealing with the problem of optimization of the process parameters. Brewer and Rueda developed various nomograms to assist in the selection of optimum conditions [1]. Armarego and Brown implemented the principle of maxima /minima of

differential calculus for optimization of process parameters in turning operation [2]. Taguchi method consists of a plan of experiments with the objective of acquiring data in a controlled way, executing these experiments and analyzing data, in order to obtain information about the behavior of a given product or process. It uses orthogonal arrays to define the experimental plans and the treatment of the experimental results is based on the Analysis of Variance (ANOVA). High Carbon High Chromium Steel is a cold-work tool steel with substantial amounts of chromium and carbon. High-carbon high-chromium tool steels offer good dimensional accuracy, wear resistance, and machinability. The review of literatures indicates that most of the scientists have attempted to calculate the optimum cutting conditions in a turning operation There are three primary input control parameters in the basic turning operations i.e feed rate, spindle speed and depth of cut. Feed is the rate at which the tool advances along its cutting path. Speed always refers to spindle speed and the work piece. Depth of cut is the thickness of the material that is removed by one pass of the cutting tool over the workpiece [3].

2. METHODOLOGY
In the present research work the effect of three different factors (Spindle Speed, Depth of Cut & Feed Rate) on the Tool Life while turning the specimen material using L16 Taguchi orthogonal design was studied. Therefore a total number of 16 turning operations on the High Carbon High

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International Journal of Mechanical Engineering, ISSN:2051-3232, Vol.41, Issue.1

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Chromium steel specimens were carried out using Carbide P-30 Cutting tool in the Sparko Engineering Works, Allahabad (India) followed by measurement of tool life. The High Carbon High Chromium steel with the following chemical composition was selected as the specimen material: Table. No. 1 Chemical Composition of the Specimen Material Material High Carbon High Chromium Steel Carbon (%) 2.2 Chromium (%) 11.8 Molybdenum (%) 0.68

14 15 16

2100 2100 2100

1.0 1.0 1.0

1.81 3.62 1.81

1.97 1.01 1.22

5.8893 0.0864 1.7271

Table. No 4 ANOVA Table for Tool Life Parameter Depth of Cut Feed Rate Spindle Speed Error Total DF 1 1 1 12 15 SS 8.3088 2.9670 0.0770 6.0598 17.4126 MS 8.3088 2.9670 0.0770 0.5050 F 16.45 5.88 0.15 P 0.002 0.032 0.703

The values of the Control factors for the Turning Operations were as under: Table. no 2 Factors at their different Levels Factors Depth of cut (mm) Feed (mm/rev) Spindle Speed (rpm) Level 1 0.5 1.81 1400 Level 2 1.0 3.62 2100

Table. No 5 ANOVA Table for Signal-to-Noise (SN) Ratio Parameter Depth of Cut Feed Rate Spindle Speed Error Total DF 1 1 1 12 15 SS 123.481 46.259 1.387 78.896 250.023 MS 123.481 46.259 1.387 6.575 F 18.78 7.04 0.21 P 0.001 0.021 0.654

From the Table no. 3 it is clear that in the present experimental work was conducted according to the trial runs specified in L16 orthogonal array on the Lathe Machine and the assignment of factors was carried out using MINITAB-15 Software. Table. no 3 Results of Experimental Trials Trial No. Spindle Speed (rpm) 1400 1400 1400 1400 1400 1400 1400 1400 2100 2100 2100 2100 2100 Depth of Cut (mm) 0.5 1.0 0.5 0.5 1.0 1.0 1.0 1.0 0.5 0.5 0.5 0.5 1.0 Feed (mm/rev) Tool Life (Min.) 2.74 4.02 3.30 4.42 3.42 3.56 2.69 2.59 3.89 1.92 2.30 1.83 1.07 S/N Ratio

Table. No 6 Response Table of Signal-to-Noise (SN) Ratio Level 1 2 Spindle Speed (A) 822001 32584 Depth of Cut (B) .22.2 52658 Feed Rate (C) .26.0 .226.

1 2 3 4 5 6 7 8 9 10 11 12 13

3.62 1.81 3.62 1.81 3.62 1.81 3.62 1.81 3.62 1.81 3.62 1.81 3.62

8.7550 12.0840 10.3700 12.9080 10.6800 11.0290 8.5950 8.2660 11.7989 5.6660 7.2345 5.2490 0.5870

52.83 4234. 22623 Delta (max-min) 8 0 4 Rank In this experiment, the response is the tool life which should be maximised, so the desired SNR characteristic is in the category of larger the better. From Table no. 6, Optimal Parameters for Tool Life were A1, B1 and C1. Therefore the Predicted optimal value of S/N Ratio for Tool life p (Tool Life) = 7.3704+(10.228-7.3705)+(99.0907.3705)+(7.672-7.3705) = 12.249 Table no. 6 shows the SNR of the tool life for each level of the factors. The difference of SNR between level 1 and 2 indicates that Spindle Speed contributes the highest effect (max-min = 5.714) on the tool life followed by Depth of Cut (max-min = 3.439) and Feed Rate (max-min = 0.604).

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International Journal of Mechanical Engineering, ISSN:2051-3232, Vol.41, Issue.1

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Table. No 7 Response Table for Average Tool Life Level 1 2 Delta (max-min) Rank Spindle Speed (A)
42434 82.28 82338 8

Depth of Cut (B)

42250 028.8 22168 0

Feed Rate (C)

026.8 02550 2284. 4

Fig.2 shows the effect of the each level of the three factors on tool life for the mean values of obtained SN ratio at each level for all the 16 trial runs.

3.1. Confirmation Test

A Confirmation test was then performed with the repetitions of the same trial no. 4 of Table no. 3 to check and validate the results. Table. No 8 Results of Confirmation Tests
Trial No. 4 4 4 Spindle Speed (rpm) 1400 1400 1400 Depth of Cut (mm) 0.5 0.5 0.5 Feed (mm/rev) 1.81 1.81 1.81 Tool Life (Min.) 4.47 4.51 4.59

From Table 7 also, Optimal Parameters for Tool Life were A1, B1 and C1. The difference of SNR between level 1 and 2 also indicates that Spindle Speed contributes the highest effect (max-min = 1.441) on the surface roughness followed by Depth of Cut (max-min = 0.861) and Feed Rate (max-min = 0.139). p = 2.6215+(3.343-2.6215)+(3.052(tool life) 2.6215)+(2.691-2.6215) = 3.843 min. Thus the Predicted optimal value of tool life is p(tool life) = 3.843 min.

4. DISCUSSION
Comparing the predicted optimal value obtained of tool life p(tool life) = 3.843 min with the tool life value of 4th trials run of the Table no. 3 and the outcomes of Table no. 8 clearly depict that this combination of optimal parameter level will always give an improved outcome. From Table no. 6 and 7, optimal parameters for tool life are first level of Spindle Speed i.e 1400 rpm, first level of depth of cut i.e 0.5 mm and first level of feed i.e 1.81 mm/rev. So the combination of the factors found in 4 th trial in Table no. 3 gives the optimum result.

3. RESULTS
Comparing the F values of ANOVA Table no. 4 of Tool Life with the suitable F values of the Factors (F0.05;1;12 = 4.75) [4] shows that the Spindle speed (F=16.45) and Depth of Cut (F = 5.88) were the factors found to be significant, Change in Feed Rate has no significant effect on the tool life.

5. CONCLUSIONS
1) Optimization of the surface roughness was carried out using taguchi method and predictive equation was obtained. A confirmation test was also performed which indicated that the selected factors and predictive equation were accurate to within the limits of the measurement instrument. The important findings of the research can be acclaimed to get the maximum tool life for further similar type of research works. In this research work, the material used is High Carbon High Chromium Steel with carbon content 2.2%. The experimentation can also be done for other materials having greater hardness to see the effect of factors on tool life. Interactions of the different levels of the factors can also be included to extend the study.

2) Fig. 1 Main Effect Plot for Tool Life

Fig.1 shows the effect of the each level of the three factors on tool life for the mean values of measured tool life at each level for all the 16 trial runs.

3)

4)

ACKNOWLEDGEMENT
Firstly I would like to thank and glorify Lord Jesus Christ who is before everything. My special thanks to our Honourable Vice chancellor Prof. (Dr). R. B. Lal for providing me with an elite academic platform. I am deeply obliged to Er. James Peter (Associate Professor&

Fig. 1 Main Effect Plot for SN Ratio

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International Journal of Mechanical Engineering, ISSN:2051-3232, Vol.41, Issue.1

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Head, Dept. of Mechanical Engg.) for his timely sustenance favours and encouraging words for the research. I express my sincere gratitude to Er. Mohamed Alazhari and Er. Abdurahman HA Zubir for their valuable and constant work with me. I am deeply indebted to my father Mr. Peter Lal and mother Mrs. Shashi Lata Lal and my siblings for their constant Prayer support and inspirational encouragements.

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