2014 INTERNATIONAL SCIENTIFIC CONFERENCE

21 22 November 2014, GABROVO

APPLICATION OF TAGUCHI METHOD FOR DETERMINING OPTIMUM

SURFACE ROUGHNESS IN TURNING OF MEDICAL STAINESS STEEL
Miroslav Radovanovi, Duan Petkovi, Predrag Jankovi, Milo Madi
University of Ni, Faculty of Mechanical Engineering, Serbia

Abstract
Application of Taguchi method for determining optimum surface roughness in turning of 316LVM stainless steel by
coated carbide tool is proposed in this paper. Four control factors namely, insert radius, depth of cut, feed and cutting
speed are optimized with considerations of surface roughness as response factor. The effects of control factors on the
surface roughness were experimentally investigated. Experimentation was conducted as per Taguchi's orthogonal
array. Four control factors with four levels are arranged in L16 orthogonal array. The orthogonal array, measured
values of surface roughness, signal-to-noise ratios and analysis of variance are employed to study the surface
roughness. Based on the analysis, the optimal control factor settings were determined. Through the confirmation test
with optimal control factor settings the effectiveness of the optimization approach are validated.

Keywords: turning, medical stainless steel, surface roughness, Taguchi method.

INTRODUCTION were presented an experimental investigation

Turning is a widely used machining
process in which a single-point cutting tool
removes material from the surface of a rotating
cylindrical workpiece. Researchers have
focused on improving the performances of
turning operation with the aim of minimizing
time and costs or maximize quality. A
common method of evaluating machining
performance in a finish turning operation is
based on the surface roughness. Turning is a
complicated process, where the surface
roughness depends upon a number of cutting
conditions. Finding process factors that
optimize surface roughness is an important
task towards enhancing efficiency of
machining process. Four control factors, i.e.
insert radius, depth of cut, feed and cutting
speed must be determined in a turning
operation. Proper selection of the cutting
factors can obtain better surface roughness.
Numerous authors have published studies
aimed at evaluating the effects of the control
factors variations on surface finish. In modern
planning of experiment it is effective to use
Taguchi method.
There are some studies regarding
optimization of control factors based on
performance related to surface roughness
using Taguchi method. Youssef Y. et al. in 1
of the effects of six factors (cutting speed,
feed, depth of cut, tool nose radius, workpiece
length and tool length), each at two levels,
together with their two-level interaction effects
on cut surface roughness in lathe cutting
operation for plain carbon steel AISI 1018
using L16 Taguchi design. Yang W. and Tarng
Y. in 2 were presented a study on turning of
S45C steel using tungsten carbide cutting tool.
An attempt has been made to study the effects
of process factors on machinability aspects
using Taguchi method. L9 orthogonal array is
employed to investigate the effects of three
factors (cutting speed, feed, and depth of cut),
each at three levels, on surface roughness.
Kopac J., Sokovic M., and Bahor M. in 3
were presented a study on CNC turning of cold
formed carbon steel C15E4 using cutting tool
with a cermet insert. They used Taguchi
method with L16 orthogonal array to
investigate the effects of five factors
(workpiece material, tool material, cutting
speed, depth of cut and consecutive cut), each
at two levels, on surface roughness. Nalbant
M., Gokkaya H. and Sur G. in 4 were
presented a study on turning of AISI 1030
steel using TiN coated tool. They used
Taguchi method with L9 orthogonal array to
investigate the effects of three factors (insert

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radius, feed and depth of cut), each at three
levels, on surface roughness. Thamizhmanii
S., Saparudin S. and Hasan S. in 5 were
presented a study on turning of SCM 440 alloy
steel using cutting tool insert coated with
Al2O3-TiC. They used Taguchi method with
L18 orthogonal array to investigate the effects
of three factors (cutting speed, feed and depth
of cut), each at three levels, on surface
roughness. Aslan E., Camuscu N. and
Birgoren B. in 6 were presented a study on
turning of hardened AISI 4140 steel (63 HRC)
using Al2O3+TiCN mixed ceramic tool. They
used Taguchi method with L27 orthogonal
array to investigate the effects of three factors
(cutting speed, feed and depth of cut), each at
three levels, on surface roughness. Gusri A. et
al. in 7 were presented a study on turning of
titanium alloy using cutting tool with tree type
of insert materials (uncoated carbide WC-Co,
coated carbide TiN-Al2O3-TiCN-TiN and
coated carbide TiAlN). They used Taguchi
method with L27 orthogonal array to
investigate the effects of four factors (cutting
speed, feed, depth of cut and tool type), each at
three levels, on surface roughness. Kirby D. in
8 was presented a study on turning using
cutting tool with two type of insert materials.
Taguchi method with L8 orthogonal array used
to investigate the effects of three control
factors (spindle speed, feed and depth of cut)
and two noise factors (type of tool insert and
tool manufacturer) on surface roughness.
In this paper was presented a study on
turning of medical 316LVM stainless steel
using coated tool. Taguchi method with L9
orthogonal array was used to investigate the
effects of four factors (insert radius, depth of
cut, feed and cutting speed), each at four
levels, on surface roughness. Optimization of
the cutting factors based on Taguchi method is
adopted to improve surface roughness in a
turning operation.
SURFACE ROUGHNESS
The surface parameter used to evaluate
surface roughness in this study is the
roughness average (Ra). This parameter is also
known as the arithmetic mean roughness
value, arithmetic average (AA), or centerline
average (CLA). Ra is recognized universally
as the commonest international parameter of
International Scientific Conference UNITECH 2014 Gabrovo
roughness. The average roughness is the area
between the roughness profile and its center
line, or the integral of the absolute value of the
roughness profile height over the evaluation
length. Therefore, Ra is specified by the
following equation:
1
L
Ra Y( x ) dx (1)
L0
where Ra is the arithmetic average deviation
from the mean line, L is the sampling length,
and Y is the ordinate of the profile curve.
Graphically, the average roughness is the
area shown in Fig. 1 between the roughness
profile and its center line divided by the
evaluation length (normally five sample
lengths with each sample length equal to one
cutoff).
Fig. 1. Surface roughness profile
TAGUCHI METHOD
Taguchi method of design of experiment
[9.10] is a relatively simple and powerful tool
for systematic modeling, analysis and
optimization of the machining process.
Taguchi method includes selection of
parameters, experimental design, conducting
an experiment, data analysis, determining the
optimal combination, and verification. Taguchi
method uses a special design of orthogonal
arrays where the experimental results are
transformed into signal-to-noise (S/N) ratio as
the measure of the quality characteristic.
Orthogonal array (OA) and signal to noise
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(S/N) ratio are two major tools used in tensile Rm of 860 MPa, and elongation of
Taguchi method. An OA is a small fraction of 12%.
full factorial design and assures a balanced Turning experiment was carried out in 12
comparison of levels of any factor or mm workpiece diameter on the universal lathe
interaction of factors. The columns of an OA Potisje PA-C30 (power of 11kW, spindle
represent the experimental factors to be speed range of n=202000 rpm, and feed
optimized and the rows represent the range of f=0.049.16 mm/rev) under dry
individual trials (combinations of levels). conditions. Cutting tool was tool holder
Traditionally, data from experiments is used to PCLNR 3225P12 with inserts CNMG
analyze the mean response (experimental 120404/08/12/16-MM 2015 for medical steel
result). In Taguchi method the mean and the (SANDVIK Coromant). The tool geometry
variance of the response at each factor setting was: cutting edge angle =90, rake angle =-
in OA are combined into a single performance 6. The cutting insert type, geometry, carbide
measure known as the signal-to-noise (S/N) grade and cutting conditions are corresponded
ratio. The S/N ratio is a quality indicator by with the workpiece material and hardness.
which the experimenters can evaluate the Surface roughness (Ra) was experimentally
effect of changing a particular experimental measured using measuring tool SurfTest SJ-
factor on the response (performance of the 301 (Mitutoyo), Fig.2. Evaluation length was
process). Depending on the criterion for the 2.5 mm, and cutoff was 0.8 mm.
quality characteristic to be optimized, the S/N
ratio characteristics can be divided into three
stages: smaller-the-better, larger-the-better,
and nominal-the-better, when the quality
characteristics are continuous for engineering
analysis. Regardless of the category of the
performance characteristic, the larger S/N ratio
corresponds to the better performance
characteristic. Therefore, the optimal level of
the parameter is the level with the highest S/N
ratio. The optimal factor levels are determined
using the analysis of means (ANOM) and
analysis of variance (ANOVA). A
confirmation experiment is the final step in
Taguchi method and is used to verify the
optimal combination of the factor settings.

DESIGN OF EXPERIMENT
The cutting experiment was planned and
conducted according to the Taguchis
experimental design using the L16 orthogonal
array. Taguchi method was applied for design
of experiment and to analyze the effect of
control factors, i.e., insert radius, depth of cut,
feed and cutting speed on the surface Fig. 2. Experimental results of surface roughness
roughness. Workpiece material used for
investigation is AISI 316LVM stainless steel The experiments were carried out according
(DIN X2CrNiMo 18 15 3). The chemical to Taguchi's design of experiments method.
properties of 316LVM stainless steel are: C Taguchi method involves selection of control
0.03%, Cr 17-19%, Ni 13-15%, Mo 2-3%, Mn factors, response factor and an orthogonal
2%, Cu 0.1%, Si 1%, P 0.025%, S 0.01%, N array. Four control factors selected for the
0.1%. The mechanical properties of 316LVM present investigation are: insert radius (r),
stainless steel are: yield Rp0.2 of 690 MPa, depth of cut (ap), feed (f) and cutting speed

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(vc). Since the considered factors are multi-
level factors, it has been decided to use four
level tests for each factor. The control factors
ranges were selected based on machining
guidelines provided by manufacturer of cutting
tools SANDVIK Coromant. The control
factors were set as: four levels of the insert
radius r=0.4, 0.8, 1.2, 1,6 mm, four levels of
the depth of cut ap=0.4, 0.5, 0.6, 0.7 mm, four
levels of the feed f=0.098, 0.107, 0.124, 0.142
mm/rev, and four levels of the spindle speed
n=600, 740, 910, 1100 rpm (cutting speed
vc=22.608, 27.883, 34.289, 41.448 m/min),
levels is presented in Fig. 3. S/N ratio
increases (i.e. the surface roughness decreases)
as the insert radius increases. S/N ratio
decreases (i.e. the surface roughness increases)
as the feed increases. Verticality of the line
indicates that the insert radius and feed are is
significant factors which have more influence
on the surface roughness. Depth of cut and
cutting speed are of little significance because
the verticality of line is small.
Main Effects Plot for SN ratios
Data Means
r a

Table 1. 5

Mean of SN ratios
Table 1. Control factors and levels
-5
Levels 0,4 0,8 1,2 1,6 0,4 0,5 0,6 0,7
Control factors f v
1 2 3 4
5

A
Insert radius, 0.4 0.8 1.2 1.6 0
r (mm)
Depth of cut, -5

B 0.4 0.5 0.6 0.7 0,098 0,107 0,124 0,142 22,608 27,883 34,289 41,448

ap (mm) Signal-to-noise: Smaller is better

Feed, Fig. 3. Main effects plot for S/N ratios

C 0.098 0.107 0.124 0.142
f (mm/rev)
Cutting speed, Analysis of means (ANOM) is a statistical
D 22.608 27.883 34.289 41.448
vc (m/min) approach of estimating the mean S/N ratios for
each factor and each of its levels. Response
The response factor selected for the table for S/N ratios, smaller is better is shown
experimentation is surface roughness (Ra). As in Table 2.
there are four factors and four levels for each
factor, 16 experiments were performed accor- Table 2. Response table for S/N ratios, smaller is better
ding to the standard L16 Taguchi orthogonal N Factors
Level average Max-
R
array. 1 2 3 4 Min
Insert
1 radius, r A -4.4433 2.0061 5.8133 7.9292* 12,37 1
ANALYSIS OF RESULTS AND
(mm)
CONFIRMATION TEST Depth of
The aim of the experiment is to optimize 2 cut, ap B 3.2982* 2.2779 2.6712 3.0581 1,02 3
the cutting conditions for turning 316LVM (mm)
stainless steel with regard to the minimum Feed, f
3 C 5.4975* 4.2772 2.2497 -0.7191 6,21 2
(mm/rev)
surface roughness. Used smaller-the-better Cutting
characteristic is defined as: 4 speed, vc D 3.1425* 3.0909 2.2310 2.8409 0,91 4
(m/min)
1 n * Optimum level
S / N 10 log10 y i2 (2)
n i 1 Table 2 shows the rank of factors. In the
first place is the insert radius, in the second
where is S/N - signal-to-noise ratio, n - place is feed, in the third place is depth of cut,
number of repetitions of the experiment, yi - and in fourth place is cutting speed. The
measured values of quality characteristic. results suggest that the optimum values of
To analyze the effect of control factors on control factors are given by A4B1C1D1, i.e. the
surface roughness a main effect plots were optimal control factors are: the insert radius of
generated. Main effects plot for S/N ratios of 1.6 mm, the depth of cut of 0.4 mm, the feed
surface roughness with respect to the factor of 0.098 mm/rev, and the cutting speed of

International Scientific Conference UNITECH 2014 Gabrovo III-319

22.608 m/min,. This combination gives the
lower surface roughness within the range of
experiments.
Analysis of variance (ANOVA) is a
statistical technique, which is used to estimate
the relative significance of each process factor.
It is also required for estimating the variance
of error. In ANOVA, the ratio between the
variance of the factor and the variance of error
is called Fishers ratio (F). It is used to
determine whether the factor has a significant
effect on the quality characteristic by
comparing the F test value of the factor with
the standard F table value (F) at the %
significance level. Greater the F-ratio more
significant is the control factor. ANOVA was
carried out to find the relative effect of control
factors on the surface roughness. Table 3
shows analysis of variance for surface
roughness (Ra).
Table 3. Analysis of variance for surface roughness
N Factors DF SS MS F p %
Insert
1 radius, r A 3 4,20849 1,40283 112,12 0,001 77.12
(mm)
Depth of
2 cut, ap B 3 0,16143 0,05381 4,30 0,131 2.96
(mm)
Feed, f
3 C 3 0,93947 0,31316 25,03 0,013 17.21
(mm/rev)
Cutting
4 speed, vc D 3 0,11018 0,03673 2,94 0,200 2.02
(m/min)
Residual
3 0,03754 0,01251 - - 0.69
error
Total 15 5,45711 - - - 100
DF - degree of freedom, SS - sum of square, MS - mean
square, F - variance ratio, p - probability value and % -
percent contribution
From the ANOVA, it can be seen that
control factors, insert radius and feed have a
strong (clearly statistically significant) effect
on the surface roughness. Depth of cut and
cutting speed have only a moderate effect.
Percent contribution of source to the total
variation defines factor sensitivity. Insert
radius, depth of cut, feed and cutting speed
affect the surface roughness with contribution
of 99.31%. Insert radius is the most significant
factor affecting the surface roughness with
contribution of 77.12%, followed by the feed
with contribution of 17.21%, depth of cut with
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contribution of 2.96% and cutting speed with
contribution of 2.02%.
The predicted S/N ratio using the optimal
levels of the control factors ( opt ) can be
calculated as:
p 1 nt
opt (i,opt ) , i (3)
i 1 n t i 1
opt 2.83 (7.9292 2.83) (3.2982 2.83)
(5.4975 2.83) (3.1425 2.83) 11.38dB
1
(4.4433 2.0061 5.8133 7.9292 3.2982
16
2.2779 2.6712 3.0581 5.4975 4.2772 2.2497
0.7191 3.1425 3.0909 2.2310 2.8409) 2.83dB
where is i ,opt - mean S/N ratio for i-th factor at
the optimal level, - total mean S/N ratio, p -
number of factors that significantly affect the
quality characteristic, nt - total number of
trials, and i - S/N ratio in i-th trial in the OA.
The predicted optimal value of surface
roughness (Ra), according equation (2), is:
11.38
Ra 10 20
10 20
3.71m
In order to statistically judge the closeness
of predicted to observed data, the confidence
interval was determined. Confidence interval
(C.I.) for the predicted mean value of the
response can be calculated as [5]:
1 1
CI F (1,f e ) Ve (4)
n n ver
1 1
CI 10.1 0.03754 0.48
3.69 3
where F(1;fe) is the F value from the F-table at
a required confidence level of 1- = 0.95 at
DF=1, and DF of error fe=3, F0.05(1;3)=10.1,
Ve=0.03754 is the error variance, nver=3 is the
validation test trial number, and n N 3.69
1
is the effective number of replications where
N=163=48 is the total number of experiments
and =43=12 is the total DF of all
parameters.
 The 95% confidence interval of the
predicted value of surface roughness (Ra) is:
Ra C.I. Ra Ra C.I. (5)
3.23 Ra (m) 4.19
Confirmation experiment is the final step in
Taguchi method and is used to verify the
optimal combination of the factor settings. For
that purpose, a confirmation experiment was
performed using optimal condition
(A4B1C1D1) for surface roughness. Predicted
and experimentally observed values of surface
roughness at the optimum levels of the control
factors are shown in Table 4.
Table 4. Predicted values and experimental results
Taguchi optimal factor settings
Prediction Experiment
Factor levels A4B1C1D1 A4B1C1D1
Surface roughness Ra1 Ra2
3.71
Ra (m) 3.80 4.00
S/N ratio (dB) 11.38 11.59 12.04
Since the prediction errors are within C.I.
values, the combination of control factor levels
can be validated.
CONCLUSION
Surface roughness is an important
performance for many turned parts. Taguchi
method is now widely used to efficiently
optimize the machining process. Orthogonal
array, measured values of surface roughness,
S/N ratios and ANOVA are applied to study
surface roughness and to optimize the control
factors. Significant control factors were
identified and the optimal combination of the
control factor levels was determined. Optimal
control factor levels: insert radius of 1.6 mm,
depth of cut of 0.4 mm, feed of 0.098 mm/rev
and cutting speed of 22.608 m/min give the
lower value of surface roughness within the
range of experiment based on smaller-the-
better characteristic. ANOVA analysis showed
that insert radius is the most significant
parameter affecting the surface roughness with
contribution of 77.12%, followed by the feed
with contribution of 17.21%. Little effect has
depth of cut with contribution of 2.96% and
cutting speed with contribution of 2.02%.
International Scientific Conference UNITECH 2014 Gabrovo
ACKNOWLEDGEMENT
The paper is part of the project III41017 -
Virtual Human Osteoarticular System and its
Application in Preclinical and Clinical
Practice, sponsored by Ministry of Education,
Science and Technological Development of
the Republic of Serbia for period 2011-2014.
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