INTERNATIONAL JOURNAL OF ADVANCED RESEARCH IN ENGINEERING International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976

6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME AND TECHNOLOGY (IJARET)
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OPTIMIZATION OF END MILLING PARAMETERS OF AISI 1055 BY TAGUCHI METHOD

Kareem Idan Fadheel Ministry of Higher Education & Scientific Research, Foundation of Technical Education, KUT Technical Institutes, Republic of Iraq Dr. Mohammad Tariq Department of Mechanical Engineering, Shepherd School of Engineering and Technology, SHIATS-DU, Naini, Allahabad-211007

ABSTRACT CNC End milling is a unique adaption of the conventional milling process which uses an end mill tool for the machining process. During the End milling process, the material is removed by the end mill cutter. Surface finish is an important indicator of the milling operation in manufacturing process. This paper, aims to optimize milling parameters depend on the Taguchi method for minimizing surface roughness (Ra). The experiments were conducted using the L18 orthogonal array in a CNC milling machine with respect to three different cutting parameters. These parameters were cutting depth, cutting speed and feed rate. Dry milling tests were performed on hardened AISI 1055 (48HRC) with APTK 1705 LT 30 carbide inserts as a cutting condition in order to reduce optimization parameters such as the coolant. Each experiment was repeated five times and a new insert was used for each test to ensure accurate readings of surface roughness. In addition, the statistical methods of signal to noise ratio (S/N) and analysis of variance (ANOVA) were carried out to investigate the effects of cutting parameters on surface roughness. As a result of the experiment, the feed rate has the most dominant effect on average surface roughness. The effects of interactions of factors appear to be important, especially cutting speed-feed rate pair. These statistical methods can be very useful in manufacturing units to optimize the manufacturing processes. Keywords: Taguchi Method, End Milling, S/N Ratio, Surface Roughness, ANOVA.

International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME

1. INTRODUCTION Milling operates on the principle of rotary motion. A milling cutter is spun about an axis while a workpiece is advanced through it in such a way that the blades of the cutter are able to shave chips of material with each pass. Milling processes are designed such that the cutter makes many individual cuts on the material in a single run; this may be accomplished by using a cutter with many teeth, spinning the cutter at high speed, or advancing the material through the cutter slowly. Most often it is some combination of the three [2]. The speed at which the piece advances through the cutter is called feed rate, or just feed; it is most often measured in length of material per full revolution of the cutter. As material passes through the cutting area of a milling machine, the blades of the cutter take swarfs of material at regular intervals. This non-continuous cutting operation means that no surface cut by a milling machine will ever be completely smooth; at a very close level (microscopic for very fine feed rates), it will always contain regular ridges. These ridges are known as revolution marks, because rather than being caused by the individual teeth of the cutter, they are caused by irregularities present in the cutter and milling machine; these irregularities amount to the cutter being at effectively different heights above the workpiece at each point in its rotation. The height and occurrence of these ridges can be calculated from the diameter of the cutter and the feed [4]. These revolution ridges create the roughness associated with surface finish. Robust design is an engineering methodology for obtaining product and process conditions, which are minimally sensitive to the various causes of variation to produce high-quality products with low development and manufacturing costs [12]. Taguchis parameter design is an important tool for robust design. It offers a simple and systematic approach to optimize design for performance, quality and cost. Two major tools used in robust design are [1214]: signal to noise ratio, which measures quality with emphasis on variation Orthogonal arrays, which accommodate many design factors simultaneously. The successful applications of Taguchi methods by both engineers and statisticians within British industry have lead to the formation of UK Taguchi Club [15]. Taguchis approach is totally based on statistical design of experiments [12], and this can economically satisfy the needs of problem solving and product/process design optimization [16]. By applying this technique one can significantly reduce the time required for experimental investigation, as it is effective in investigating the effects of multiple factors on performance as well as to study the influence of individual factors to determine which factor has more influence, which less [12,16]. Some of the previous works that used the Taguchi method as tool for design of experiment in various areas including metal cutting are listed in [1723] references. 1.1 Taguchi methods Taguchi methods are statistical methods developed by Genichi Taguchi to improve the quality of manufactured goods, and more recently also applied to engineering [1], biotechnology [2, 3], marketing and advertising [4]. Professional statisticians have welcomed the goals and improvements brought about by Taguchi methods, particularly by Taguchi's development of designs for studying variation, but have criticized the inefficiency of some of Taguchi's proposals [5]. Taguchis work includes three principal contributions to statistics: A specific loss function The philosophy of off-line quality control Innovations in the design of experiments
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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, , IAEME

1.2 Design of Experiments Taguchi developed his experimental theories independently. Taguchi read works following R. A. Fisher only in 1954. Taguchi's framework for design of experiments is idiosyncrat idiosyncratic and often flawed, but contains much that is of enormous value. He made a number of innovations. The sequential designs of response surface methodology require far fewer experimental runs than would a sequence of Taguchi's designs [8]. 2. METHODOLOGY The design of parameters in the Taguchi method aims to determine the parameters generating the best levels of optimum cutting conditions. To find the optimum cutting conditions, the Taguchi method uses the signal to noise ratio (S/N) via an orthogonal arra array. y. S/N ratio is used as a measurable value. The signal to noise ratio characteristics can be calculated in three different ways; Smaller the better The larger the better The nominal-the best The equations of the three levels are given by eq. (1-3). Smaller the better (1)

Larger-the the better

(2)

Nominal the best

(3)

where n is repeat number of experiment and is measured variable value in in equ equation is the average of observed data, the variance of y, n the number of observations, and y the observed data. For each type of the characteristics, with the above S/N ratio transformation, the higher the S/N ratio the better is the result. The optimum cutting parameters required for the best surface roughness were obtained by using eq.1 the smaller the better. By using the smaller-the smaller the better (eq.1), S/N ratios of parameters and levels were estimated. S/N ratios according to the mentioned e equations quations are given in following paragraphs.

Fig 1: Shear length and shear angle in chip formation process

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, , IAEME

The chip formation process is influenced by the shear length (ls) in the shear zone. The shear length (ls) is given as: (4)

where t is undeformed chip thickness and is the shear angle [25]. Philip [ [24] found the shear angle is large at high cutting speeds, therefore the shear length (ls) is small, as shown in figure 1. End milling is aim to removing material by two continuous motions. Those are the tool and work pieces. Basically the tool has rotating motion (spindle speed) and the work pieces is linear ones (feed rate) as shown in fig. 2.

Fig. 2: End milling operation

2.1 Experimental design Response surface rface methodology (RSM) is a procedure which is able to determine a relationship between independent input process parameters (e.g. cutting parameters) and output data (process response, e.g. Ra). ). In the current study, the relationship between the input pa parameters, as the cutting conditions (cutting speed (vc, m/min), feed rate (f, mm), depth of cut (t, , mm), and the output parameters, defined as the machinability aspect (Ra) ( which is given as: Ra= (vc, f, t) where is the response function. The approximation of Ra is proposed by using the following equation which consists of linear and quadratic effects of the input parameters and their interactions as well: (5)

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME
R b b v b f b t b v b f b t b v f b v t b ft

(6)

where bis are the calculated coefficients, vc, f and t are input parameters, and is the experimental error. Chemical composition of AISI 1055 Table 1: Chemical Composition of the Alloy Steel AISI 1055 S. No. Constituents Chemical Composition Limits, (%) 1 C 0.5 0.6 2 Mn 0.6 0.9 3 P 0.04 (Max.) 4 S 0.05 (Max.) Table 2: Estimated Physical Properties of Hot Rolled Carbon Steel Bars S. No. Properties Estimated Minimum Values 1 Tensile Strength (psi) 94,000 2 Yield Strength (psi) 51,500 3 Elongation In 2in., (%) 12 4 Reduction in Area, (%) 30 5 Brinell Hardness 192

2.2 Experimental Procedure In order to achieve the correlation between cutting parameters and surface roughness, different parameters were used in the experiments. As work material, hardened AISI 1055 (200x50x50 mm) steel was used. The hardness of AISI 1055 steel was increased by applying heat treatment and measured hardness of AISI 1055 steel was 48 HRC. Hardened AISI 1055 steel parts were machined with KAFU CNC milling machine. The samples were prepared by cutting all surfaces at 2 mm depth of cut with the milling process to obtain clear surface for measurement and their sizes were fixed to 50x50x40 mm dimension because of the dimensional differences of work part size at the end of heat treatment. The experiment was performed under dry conditions. The tool holder and insert were used as 5 slots RILT730-M-W-D2500/5 and APTK 1705 LT30 respectively. The measurement of the average surface roughness (Ra) on surface of hardened AISI 1055 was taken by Mitutoyo SJ 301P portable device within the sampling length of 250 mm and the measurements. The levels of cutting parameters; depth of cut (a), feed rate (f) and cutting speed (v) were chosen from the insert manufacturers catalogue in accordance with recommended test values. The cutting parameters were given in Table 3. The Taguchi and variance of analysis were carried out to reduce the number of the experiments and optimize cutting parameters. 3. RESULTS AND DISCUSSION The experiment has done to optimize the milling parameters to get better (i.e. low value) surface roughness; the smaller the better characteristics are used. Table 4 shows the actual data for surface roughness and corresponding computed S/N ratio for these parameters. Whereas table 5, 6, 7 and 8 show the mean S/N ratio for each levels of surface roughness for various parameters (A, B and C) and their one interaction namely BXC. Fig 3 shows the mean S/N ratio for various parameters of surface roughness.
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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME

Table 3: Input parameters taken for calculations Factor Level 0 1 A- Cutting Speed (vc, m/min) 250 300 B - Feed (f, mm/tooth) 0.10 0.20 C - Radial Depth of Cut (t, mm) 0.25 0.50

2 350 0.30 0.75

Table 4: Experimental results for Surface roughness and their S/N ratio Factor S/N Ratio Measured Parameters Exp. Run Designation A B C Surface roughness Ra (m) 14.609 1 0 0 0 0.186 A B C 15.139 0.175 2 0 1 1 A B C 7.290 0.432 3 0 2 2 A B C 10.574 4 1 0 0 0.296 A B C 10.420 0.301 5 1 1 1 A B C 9.972 0.317 6 1 2 2 A B C 4.861 7 2 0 0 0.571 A B C 4.642 8 2 1 1 0.586 A B C 4.350 0.606 9 2 2 2 A B C 10.995 10 0 0 1 0.282 A B C 5.916 11 0 1 2 0.506 A B C 6.669 12 0 2 0 0.464 A B C 12.280 13 1 0 1 0.243 A B C 2.786 14 1 1 2 0.726 A B C 11.025 15 1 2 0 0.281 A B C 10.144 0.311 16 2 0 1 A B C 3.715 17 2 1 2 0.652 A B C 3.185 18 2 2 0 0.693 A B C -0.992 19 0 0 2 1.121 A B C 1.808 20 0 1 0 0.812 A B C 0.695 21 0 2 1 0.923 A B C -3.817 22 1 0 2 1.552 A B C 0.800 23 1 1 0 0.912 A B C 0.724 24 1 2 1 0.920 A B C -3.290 25 2 0 2 1.461 A B C -1.705 26 2 1 0 1.217 A B C -2.529 27 2 2 1 1.338 A B C It is clearly indicated from the table 4.2 that the S/N ratio has very limited variation irrespective to the actual values of surface roughness.

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME

Table 5: Experimental results for Mean S/N ratio for cutting speed at different levels for Surface roughness S. No. Calculated S/N Ratio Calculated S/N Ratio Calculated S/N Ratio Cutting Speed (A) Cutting Speed (A) Cutting Speed (A) Level 0 Level 1 Level 2 1 14.609 10.574 4.861 2 15.139 10.420 4.642 3 7.290 9.972 4.350 4 10.574 12.280 10.144 5 5.916 2.786 3.715 6 6.669 11.025 3.185 7 -0.992 -3.817 -3.290 8 1.808 0.800 -1.705 9 0.695 0.724 -2.529 Mean S/N Ratio 6.856 6.76 2.59 Table 6: Experimental results for Mean S/N ratio for feed rate at different levels for Surface Roughness S. No. Calculated S/N Ratio Calculated S/N Ratio Calculated S/N Ratio Feed Rate (B) Level 0 Feed Rate (B) Level 1 Feed Rate (B) Level 2 1 14.609 15.139 7.290 2 10.574 10.420 9.972 3 4.861 4.642 4.350 4 10.995 5.916 6.669 5 12.280 2.786 11.025 6 10.144 3.715 3.185 7 -0.992 1.808 0.695 8 -3.817 0.800 0.724 9 -3.290 -1.705 -2.529 Mean S/N Ratio 6.151 4.835 4.597 Table 7: Experimental results for Mean S/N ratio for Depth of Cut at different levels for Surface Roughness S. No. Calculated S/N Ratio Calculated S/N Ratio Calculated S/N Ratio Depth of Cut (C) Depth of Cut (C) Depth of Cut (C) Level 0 Level 1 Level 2 1 14.609 15.139 7.290 2 10.574 10.420 9.972 3 4.861 4.642 4.350 4 6.669 10.995 5.916 5 11.025 12.280 2.786 6 3.185 10.144 3.715 7 1.808 0.695 -0.992 8 0.800 0.724 -3.817 9 -1.705 -2.529 -3.290 Mean S/N Ratio 5.758 6.945 2.881

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME

Table 8: Experimental results for Mean S/N ratio for interaction (BXC) at different levels for Surface Roughness S. No. Calculated S/N Ratio Calculated S/N Ratio Calculated S/N Ratio Interaction (BC) Interaction (BC) Interaction (BC) Level 0 Level 1 Level 2 1 14.609 10.995 -0.992 2 15.139 5.916 1.808 3 7.290 6.669 0.695 4 10.574 12.280 -3.817 5 10.420 2.786 0.800 6 9.972 11.025 0.724 7 4.861 10.144 -3.290 8 4.642 3.715 -1.705 9 4.350 3.185 -2.529 Mean S/N Ratio 9.095 7.412 -0.922

Fig 3: Mean S/N ratio for various parameters of Surface roughness

Table 9: Response table for average S/N ratio for surface roughness factors and significant interaction for Surface Roughness Cutting Parameters Max-Min Net Value Cutting Speed (A) 6.856-2.59 4.266 Feed Rate (B) 6.151-4.597 1.554 Depth of Cut (C) 6.945-2.881 4.064 9.095 (-0.922) 10.017 Interaction (BC)

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME

4. DESIGN OF EXPERIMENT In this experiment with three factors at three levels each, the fractional factorial design used is a standard L27 (313) orthogonal array [12]. This orthogonal array is chosen due to its capability to check the interactions among factors. Each row of the matrix represents one trial. However, the sequence in which these trials are carried out is randomized. The three levels of each factor are represented by a 0 or a 1 or a 2 in the matrix. Factors A, B, and C are arranged in columns 2, 5 and 6, respectively, in the standard L27 (313) orthogonal array as shown in Appendix A. 4.1 Pareto ANOVA Analyses One of the methods to analyze data for process optimization is the use of Pareto ANOVA. Pareto ANOVA is a simplified ANOVA method which uses Pareto principles. It is a quick and easy method to analyze results of parameter design. It does not require an ANOVA table and therefore does not use F-tests. Following are the Pareto ANOVA table for surface roughness analysis. The Pareto ANOVA technique of analysis has been performed, which requires least knowledge about ANOVA method and suitable for engineers and industrial practitioners. The use of S/N ratio for selecting the best levels combination for surface roughness suggests that cutting speed (factor A) and interaction BC have strong effect on the surface roughness. From the result obtained, the best combination to get low value of surface roughness is at level 2 of cutting speed, level 0 of feed rate, and level 1 of depth of cut. Since the role of depth of cut is least in obtaining good surface finish, it is indicated that in order to achieve good surface finish, always use high cutting speed and low feed rate. By increasing the cutting speed, surface roughness values are kept at minimum. Table 10: Pareto ANOVA analysis for surface roughness
Sum of Factor Level 0 1 2 Sum of Squares of differences (S) Contribution ratio (%) BXC 81.857 66.715 -8.306 13986.796 69.818 A 61.434 54.764 25.902 2140.027 10.682 B 55.364 43.521 41.381 340.36 1.698 Factor and interaction C BXC AXB 51.826 41.351 52.985 62.51 42.981 46.906 25.93 55.934 40.375 2122.846 383.1 238.62 10.596 1.912 1.191 AXC 44.284 54.003 41.979 244.348 1.219 AXB 43.624 56.299 40.343 450.567 2.249 AXC 51.285 42.111 46.87 126.302 0.630

75 70 65 60 55
Contribution ratio (%)

BXC

Values in (%)

50 45 40 35 30 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9
Factors and Interactions

C
AXB BXC

AXC

AXB

AXC

Fig 4: Pareto diagram for surface roughness From the table 10, the optimum combination of significant factor level is A0B0C1 (maximum) for surface roughness. Figure 4 shows the maximum value to (BXC) for surface roughness.
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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME

Table 11: Calculated BXC two way tables for surface roughness Factor level B0 B1 B2 C0 30.044 0.903 20.879 C1 33.419 30.201 -1.11 C2 -8.099 12.417 21.612 TOTAL 55.364 43.521 41.381

TOTAL 51.826 62.51 25.93 140.266

From the BC two way table 11, B0C1 (max) is found to be an optimal condition for surface roughness. 4.2 Discussion In the above experimental results, two techniques of data analysis have been used. Both techniques draw similar conclusions. The cutting speed has found to be the most significant effect to produce low value of average surface roughness (Ra). The explanation for the influence of cutting speed on surface finish is still not available. This could be explained in terms of the velocity of chips that is faster at high cutting speed than at low cutting speed. This leads to a shorter time for the chips to be in contact with the newly formed surface of workpiece and the tendency for the chips to wrap back to the new face form is little as compared to low speed. The condition of seizure and sub layer plastic flow occurred at high speed and the term flow-zone is used to describe secondary deformation in this range [27]. The time taken for the chips at this flow-zone for high speed cutting is short as compared to lower speed, as the velocity of chip is faster. The use of S/N ratio for selecting the best levels of combination for surface roughness (Ra) value suggests the use of low value of feed rate in order to obtain good finish. Smaller angle of tool angular position is obtained at lower depth of cut [28]. Therefore, it is preferable to set the depth of cut to a low value. Therefore, one can say that the set values for level 0 and 1 are both suitable to obtain good quality of surface finish. From the result, the interaction of factor B and factor C is more important than the effect of the individual factors. In other words, in order to get the best result it requires experience to combine these two factors to achieve a suitable combination of feed rate and depth of cut. 4.3 Conclusion This paper illustrates the application of the parameter design (Taguchi method) in the optimization of end milling operation. The following conclusions can be drawn based on the above experimental results of this study: Taguchis Method of parameter design can be performed with lesser number of experimentations as compared to that of full factorial analysis and yields similar results. Taguchis method can be applied for analyzing any other kind of problems as described in this paper. It is found that the parameter design of the Taguchi method provides a simple, systematic, and efficient methodology for optimizing the process parameters REFERENCE 1. Rosa, Jorge Luiz ; ROBIN, Alain ; SILVA, M. B. ; BALDAN, Carlos Alberto ; PERES, Mauro Pedro. Electro deposition of copper on titanium wires: Taguchi experimental design approach. Journal of Materials Processing Technology, Vol. 209, p. 1181-1188, 2009. Rao, Ravella Sreenivas; C. Ganesh Kumar, R. Shetty Prakasham, Phil J. Hobbs (2008). The Taguchi methodology as a statistical tool for biotechnological applications: A critical appraisal, Biotechnology Journal 3 (4): 510523.
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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 5, Issue 3, March (2014), pp. 09-20, IAEME

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25. H.Z. Li, X.P. Li, Milling force prediction using a dynamic shear length model, Int. J. Mach. Tools Manuf. 42 (2002) 277286. 26. M. E. Martellotti, An analysis of the milling process, Trans. ASME (1941) 677695. 27. E. M. Trent, Metal Cutting, 3rd ed., Butterworths, Heinemann, 1991. 28. C. H. Borneman, Chip thickness in milling, Am. Mach. Ref. Book Sheet 82 (1938) 189190. 29. S. Madhava Reddy, Optimization of Surface Roughness in High-Speed End Milling Operation using Taguchis Method, International Journal of Mechanical Engineering & Technology (IJMET), Volume 4, Issue 4, 2013, pp. 249 - 258, ISSN Print: 0976 6340, ISSN Online: 0976 6359. 30. Prabhat Kumar Sinha, Manas Tiwari, Piyush Pandey and Vijay Kumar, Optimization of Input Parameters of CNC Turning Operation for the Given Component using Taguchi Approach, International Journal of Mechanical Engineering & Technology (IJMET), Volume 4, Issue 4, 2013, pp. 188 - 196, ISSN Print: 0976 6340, ISSN Online: 0976 6359.

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