Journal of Cleaner Production 39 (2013) 242e254

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Journal of Cleaner Production

journal homepage: www.elsevier.com/locate/jclepro

Optimization of cutting parameters for minimizing power consumption and

maximizing tool life during machining of Al alloy SiC particle composites
Rajesh Kumar Bhushan*
Shri Mata Vaishno Devi University, Katra, Jammu, J&K, India

a r t i c l e i n f o a b s t r a c t

Article history: Reducing the energy consumption during machining of metal matrix composites (MMC) can significantly
Received 23 January 2012 improve the environmental performance of manufacturing systems. To achieve this, calculation of energy
Received in revised form consumption in the computerized numerical controlled (CNC) turning machine is required. It is
6 August 2012
important to minimize the power consumption and maximize tool life during machining operations,
Accepted 9 August 2012
being performed on the CNC turning machine. However, this is challenging due to complexity of
Available online 23 August 2012
manufacturing systems and the nature of material being machined. This paper presents the findings of
experimental investigations into the effects of cutting speed, feed rate, depth of cut and nose radius in
Keywords:
Metal matrix composite
CNC turning of 7075 Al alloy 15 wt% SiC (particle size 20e40 mm) composite. Design of experiment
7075 Al alloy techniques, i.e. response surface methodology (RSM) has been used to accomplish the objective of the
SiC experimental study. The machining parameters such as cutting speed, feed rate, depth of cut and nose
Machinability radius are optimized by multi-response considerations namely power consumption and tool life. A
Tool life power consumption composite desirability value is obtained for the multi-responses using individual desirability values from
the desirability function analysis. Based on composite desirability value, the optimum levels of param-
eters have been identified, and significant contribution of parameters is determined by analysis of
variance. Confirmation test is also conducted to validate the test result. It is clearly shown that the multi-
responses in the machining process are improved through this approach. Thus, the application of
desirability function analysis in response surface methodology proves to be an effective tool for opti-
mizing the machining parameters of 7075 Al alloy 15 wt% SiC (20e40 mm) composite. Result of this
research work show that when turning is be carried out at values of machining parameters obtained by
multi response optimization through desirability analysis route this will reduce power consumption
by13.55% and increase tool life by 22.12%.
Ó 2012 Elsevier Ltd. All rights reserved.

1.. Introduction
The manufacturing sector is a key industry that relies on the use
of energy in driving value during manufacturing processes.
Mechanical machining is widely used in most manufacturing
industries hence represents a major demand for energy. Despite
decades of optimizing of machining operations based on cost and
productivity, optimizing energy use had not received significant
attention. There is an abundant amount of research work done on
the machining process but environmental issues of machining
processes have rarely been given much attention. The energy
required for the machining process is drawn from the electrical
grid. The energy (electricity) is generated from different power
sources like thermal, nuclear and hydraulic. Saving in electrical
* Tel.: þ91 (0) 9419163504; fax: þ91 (0) 1991 285694.
E-mail address: rkbsmvdu@gmail.com.
energy will result less emission of harmful gases, if a thermal or
nuclear source has been used for generation of electricity and
saving of precious water resources, if hydraulic route has been used
for generation of electricity.
The first step toward reducing power consumption and maxi-
mize the life of tools in machining is to analyze the impact of
machining parameters on power consumption and tool life.
Reducing the energy consumption of machine tools can signifi-
cantly improve the environmental performance of manufacturing
processes and systems. Furthermore, given that machining
processes are used in manufacturing many consumer products,
improving the energy efficiency of machining-based
manufacturing systems could yield significant reduction in the
environmental impact of consumer products.
This research work presents a new and novel model and
methodology for selecting optimum cutting conditions for
machining, based on minimum energy requirements. The
energy savings associated with using such methodologies are

0959-6526/$ e see front matter Ó 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.jclepro.2012.08.008
 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254
quantified and found to be very significant. This work makes
a distinct and important contribution to the machining science
for reducing the energy there by resulting in minimizing
harmful emissions.
2. Literature review
Hauschild et al. (2005) report suggests that the deficiency in the
evaluation of the life cycle and the process involved in product’s
manufacturing to provide substantial consumption amounts of
energy and other resources and, as a result, have a measurable
impact on the environment.
The work of Kara and Li (2011) presents an empirical approach
to develop unit process energy consumption models for material
removal processes. For the selected machine tools, the derived
models provide a reliable prediction of energy consumption for
removing material at certain material removal rate. Within this
information, the energy requirement of machining a product with
turning or milling processes can be easily calculated. Thus, a more
accurate assessment of environmental impact of manufacturing
processes can be achieved. Meanwhile, reduction of energy
consumption and improvement of environmental performances
can be acted proactively during product design and process plan-
ning stage.
Hu et al. (2012) proposed a new on-line approach without using
any torque sensor or dynamometer which leads to a decreased
implementation cost. The energy efficiency monitoring model of
this approach is constructed based on an energy consumption
model of machine tool. Then the entire machine-tool energy
consumption can be divided into two parts, i.e. constant energy
consumption and variable energy consumption (Kalpakjian and
Schmid, 2006). The former is measured in advance and stored in
database, and the latter is derived from cutting power that can be
estimated on-line according to power balance equation and addi-
tional load loss function. The additional load loss function can be
identified off-line through input power and cutting power of the
machine-tool spindle. Several experiments were performed on
a CNC machine tool CJK6136 and the results showed the effec-
tiveness of the proposed method.
He et al. (2012) proposed a modeling method of task-oriented
energy consumption for machining manufacturing system. The
energy consumption characteristics driven by task flow in
machining manufacturing system are analyzed, which describes
that energy consumption dynamically depends on the flexibility
and variability of task flow in production processes. Based on the
task-oriented energy consumption characteristics, an event graph
methodology has been exploited to model the energy consumption
driven by tasks in production processes of machining
manufacturing system. The proposed modeling method is solved in
programming Simulink simulation environment (part of Mathlab
mathematical package), and applied to select the flexible processes
of tasks for optimizing energy consumption. The results show
a valuable insight of energy consumption in machining
manufacturing system so as to make robust decisions on the
potential for improving energy efficiency.
Reducing the energy consumption of machine tools can signif-
icantly improve the environmental performance of manufacturing
systems. To achieve this, monitoring of energy consumption
patterns in the systems is required. It is vital in these studies to
correlate energy usage with the operations being performed in the
manufacturing system. However, this can be challenging due to
complexity of manufacturing systems and the vast number of data
sources. Event stream processing techniques are applied to auto-
mate the monitoring and analysis of energy consumption in
manufacturing systems (Vijayaraghavan and Dornfeld, 2010).
243
The aim of the work reported in Rajemi et al. (2010) was to
develop a new model and methodology for optimizing the energy
footprint for a machined product. The total energy of machining
a component by the turning process was modeled and optimized to
derive an economic tool-life that satisfies the minimum energy
footprint requirement. The work clearly identifies critical parame-
ters in minimizing energy use and hence reducing the energy cost
and environmental footprint. Additionally, the paper explores and
discusses the conflict and synergy between economical and envi-
ronmental considerations as well as the effect of system boundaries
in determining optimum machining conditions.
In the work developed by Avram and Xirouchakis (2011), there
is an energy consumption reduction perspective by considering
alternative machining strategies and system components inter-
actions translated into variable and constant power flows with
respect to various use phase regimes of a machine tool system.
The methodology is able to estimate the mechanical energy
requirements of the spindle and feed axes with respect to 2.5D
machining strategies by taking into account steady-state and
transient regimes. In addition, the specific amount of fixed energy
drawn by a machine was determined based on a careful moni-
toring of the energy share amongst the auxiliary equipment that
supports the accomplishment of the machining tasks. The
numerical results were experimentally validated and the good
agreement between them led to the conclusion that the proposed
methodology can be used effectively for the calculation of the
total energy required by a machine tool system for the milling of
a part. This enables a straightforward comparison of different
milling part programs with respect to their energy consumption
levels.
Machining tasks are performed on machine tools with enor-
mous amount of energy consumption in manufacturing system.
The energy consumption characteristics driven by task flow in
machining manufacturing system are analyzed, which describes
that energy consumption dynamically depends on the flexibility
and variability of task flow in production processes. Based on
the task-oriented energy consumption characteristics, an event
graph methodology has been exploited to model the energy
consumption driven by tasks in production processes of
machining manufacturing system. The proposed modeling
method is solved in Simulink simulation environment, and
applied to select the flexible processes of tasks for optimizing
energy consumption. The results show a valuable insight of
energy consumption in machining manufacturing system so as to
make robust decisions on the potential for improving energy
efficiency (He et al., 2012).
The aim of the work reported by Hanafi and Khamlichi (2012), is
to outlines the application of gray relational theory and Taguchi
optimization methodology in order to optimize the cutting
parameters for PolyEther Ether Keytone reinforced with 30% of
carbon fibers. The material is turned by using TiN coated tools
under dry conditions. The objective of optimization is to achieve
simultaneously the minimum power consumption and the best
surface quality. This involves in practice reducing the environ-
mental footprint related to such manufacturing process while
providing enhanced functional performance in terms of surface
integrity of machined parts. The obtained results have indicated
that cutting speed and depth of cut are the most influential
parameters. The optimal setting of machining parameters
achieving sustainability target in terms of minimum surface
roughness and minimum cutting power was determined.
The aim of the work reported in Huseyin Cetin et al. (2011), was
to evaluate the performances of six CFs, four different VBCFs from
sunflower and canola oils with different ratios of extreme pressure
(EP) additives, and two commercial types of CFs (semi-synthetic
244 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254

and mineral) for reducing of surface roughness, and cutting and Table 1
feed forces during turning of AISI 304L austenitic stainless steel Chemical composition (wt %) of 7075 Al alloy.

with carbide insert tool. Taguchi’s mixed level parameter design
(L18) is used for the experimental design. Cutting fluid, spindle
speed, feed rate and depth of cut are considered as machining
parameters. Regression analyses are applied to predict surface
roughness, and cutting and feed forces. ANOVA is used to deter-
mine effects of the machining parameters and CFs on surface
roughness, cutting and feed forces. In turning of AISI 304L, effects of
feed rate and depth of cut are found to be more effective than CFs
and spindle speed on reducing forces and improving the surface
finish. Performances of VBCFs and commercial CFs are also
compared and results generally show that sunflower and canola
based CFs perform better than the others.
The work of Fratila and Caizar (2011) outlines the Taguchi
optimization methodology, which is applied to optimize the cutting
parameters in face milling when machining AlMg3 (EN AW 5754)
with HSS (high speed steel) tool under semi-finishing conditions in
order to get the best surface roughness and the minimum power
consumption. Beside the conventional flood lubrication, the
investigations include the minimal quantity lubrication and the dry
milling. These environment-friendly cutting techniques are
considered two practical ways to the cleaner manufacturing in the
context of the sustainable production. The parameters evaluated
are the cutting speed, the depth of cut, the feed rate and the cooling
lubrication techniques (cutting fluid flow). The appropriate
orthogonal array, signal to noise (S/N) ratio and Pareto analysis of
variance (ANOVA) are employed to analyze the effect of the
mentioned parameters on the good surface finish (surface rough-
ness). Using Taguchi method for the design of experiments (DOE), it
is investigated the significant influence and the parameters inter-
action effect with minimum number of trials as compared with
a full factorial design.
The above literature reviews show that so far no efforts have
been made toward optimization of machining parameters for
minimizing power consumption and maximizing tool life during
machining of Al Alloy SiC particle composites. Al alloyeSiC metal
matrix composite are increasingly being used in manufacturing
especially in automobile and aerospace industries. However, it
poses a difficult machining problem due to its material properties.
The environmental impact of using this material is rarely discussed
especially with regards to energy consumption. The poor machin-
ability of Al alloyeSiC metal matrix composite leads to lower
material removal rate and longer machining time, hence higher
power consumption. Therefore the environmental impact of using
this material needs to be optimized. So there is a strong case for
focusing on this metal matrix composite.
In the present work, an attempt has been made to evaluate the
contribution of cutting parameters during machining of 7075 Al
alloy 15 wt% SiC (particle size 20e40 mm) composite on the power
consumption and tool life by using response surface methodology.
Optimum values of cutting parameters to minimize the power
consumption and maximize tool life have been found out by
desirabilityanalysis.
Material Zn Mg Cu Cr Si Fe Al
Wt% 5.62 2.52 1.63 0.22 0.06 0.18 89.77
3.2. Computer numerical control (CNC) turning machine
The basic objective behind the use of CNC turning machine is the
reduction in the cost of production and the improvement in
product quality. Machining by CNC turning can be done to very
precise limits, which normally is very difficult by a conventional
Lathe Table 2. Also, a range of cutting speed, feed and depth of cut
can be selected on CNC turning machine. Any combination of
cutting speed, feed and depth of cut is possible on CNC turning
machine, whereas on conventional lathe only a particular combi-
nation of cutting speed, feed and depth of cut is possible. CNC
Turning Machine (Model TC 20) is used for experiments. Machine is
shown in Fig. 1.
3.3. Turning inserts
The following tool holders and inserts were used for turning.
Details of these are shown in Table 3.
3.4. Selection of process parameters and their ranges
The process parameters that may affect the machining charac-
teristics of parts machined by CNC turning machine have been
identified, based on literature review. The identified process
parameters are:
 Cutting tool related parameters: tool material, tool geometry,
type of coating, grade and insert condition.
 Machining parameters: cutting speed, feed, depth of cut and
nose radius.
The ranges of process parameters for the experiment are
decided on the basis of literature survey and the results of pilot
experiments conducted using one parameter at a time approach.
3.5. Selection of the levels of parameters based on preliminary
investigation
Results of pilot experiments are utilized for deciding the levels
of parameters for cutting speed, feed and depth of cut for con-
ducting design of experiments in CNC turning of 7075 Al alloy 15 wt
% SiC (20e40 mm) composites, as depicted in Table 4. Based on
literature survey (Cheung et al., 2002; Manna and Bhattacharayya,
2005; Ciftci et al., 2004) and availability, cutting inserts of three
different nose radius are chosen.

Table 2
3. Machining Parameters of CNC turning machine.

Parameter Specifications
3.1. Material
Distance between centers 575 mm
Swing over telescopic cover 500 mm
The chemical composition of 7075 Al alloy was analyzed by Spindle speed range 40e4000 rpm
electron probe microscopic analysis (EPMA). It is as shown in Positioning accuracy
Table 1. X-axis þ/ 0.005 mm
7075 Al alloye15 wt% SiC (particle size 20e40 mm) composites Z-axis þ/ 0.0075 mm
Main motor 7.5 kW
are fabricated by stir casting process under, controlled conditions.
 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254
4. Design of experiments
Designs of experiments are considered as very useful strategy
for deriving clear and accurate conclusions from the experimental
observations. In this phase of experimentation a design of experi-
mentation technique versus Response Surface Methodology has
been used for studying the influence of four process parameters
(cutting speed, feed, depth of cut and nose radius) on two different
responses in machining of 7075 Al alloy SiC composites. Face
centered central composite design is preferred in this case. Thirty
experiments are performed at three different levels. Design expert
software has been used for design of experiments and analysis of
results.
5. Response surface methodology (RSM)
Box and Wilson (1951) have proposed response surface meth-
odology for the optimization of experiments. According to, Myers
and Montgomery (1995) the RSM is an empirical modeling
approach for the determination of relationship between various
process parameters and responses with the various desired criteria
and searching the significance of these process parameters on the
coupled response It is a sequential experimentation strategy for
building and optimizing the model.
5.1. Face centered central composite Design (FCCD)
Montgomery (2001) mentioned that, a face-centered CCD, is
used whenever the region of operability encompasses the full
region of interest as described by the variable ranges or when non
allowable operating conditions exist at only one of the extremes of
the design region. The face-centered CCD requires only three levels
of each experiment variable, making it the simplest variety of CCD
Table 3
Details of inserts and tool holders.
Turning tool holder Type of insert Clearance angle (degree)
PCLNL 2525 Carbide insert 0
M12 KT 809 CNMG
120404EM
120408EM
120412EM
Grade 6615
245
Fig. 1. CNC turning machine.
to carry out as well as the least prone to corruption due to sources
of experimental error associated with setup and operation.
6. Planning of experimentation
Turning of AA7075e15 wt% SiC Particles (20e40 mm) composite
is carried out by tungsten carbide inserts on CNC turning machine
as per the plan of experiments tabulated in Table 5.
Adequate model is selected for these responses. Analysis of
variance (ANOVA) is performed in order to statistically analyze the
results. Significant process parameters are identified. Interaction
effects of process parameters were studied.
7. Results
In experimental investigations, the results depend, to a large
extent, on the way in which data is collected. The most preferred
method of experimentation utilized by the researchers is face
centered central composite design. This measures the response of
every possible combination of factors and the factor levels. These
responses are analyzed to provide information about every main
effect and every interaction effect. Values of responses viz power
consumption and tool life is measured. These are shown in Table 5.
Experimental results during turning of AA7075e15 wt% SiC
Particles (20e40 mm) composites have been analyzed and
discussed here.
7.1. Analysis of variance (ANOVA)
In order to statistically analyze the results, ANOVA is performed.
Pooled versions of ANOVA for power consumption and tool life of
AA7075e15 wt% SiC Particles (20e40 mm) composites are given in
Tables 6 and 7.
Back rake angle (degree) Nose radius (r) mm Feed (f) mm/rev Depth of cut (mm)
7 fmin ¼ 0.15 fmax ¼ 0.60 apmin ¼ 1.0 apmax ¼ 6.0
0.4
0.8
1.2
246 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254

Table 4 Table 6
Process parameters with their values at three levels. Pooled ANOVA-power consumption [AA7075e15 wt% SiC (20e40 mm)].

Factors Process parameters Level 1 Level 2 Level 3 Source Sum of squares DF Mean squares F value Prob > F
A Cutting speed (m/min) 90 150 210 Model 1.968Eþ006 9 2.187Eþ005 205.08a <0.0001 significant
B Feed (mm/rev) 0.15 0.2 0.25 A 1.093Eþ006 1 1.093Eþ006 1025.32a <0.0001
C Depth of cut (mm) 0.2 0.4 0.6 B 1.359Eþ005 1 1.359Eþ005 127.45a <0.0001
D Nose radius (mm) 0.4 0.8 1.2 C 6.483Eþ005 1 6.483Eþ005 608.01a <0.0001
D 29443.56 1 29443.56 27.61a <0.0001
A2 10068.01 1 10068.01 9.44a 0.0060
C2 14974.68 1 14974.68 14.04a 0.0013
1. The Model F-value of 19.82 implies the model is significant. AB 22801.00 1 22801.00 21.38a 0.0002
There is only a 0.01% chance that a “Model F-Value” this large AC 18769.00 1 18769.00 17.60a 0.0004
CD 4225.00 1 4225.00 3.96a 0.0604
could occur due to noise.
Residual 21324.54 20 1066.23
2. Values of “Prob > F” less than 0.0500 indicate model terms are Lack of fit 19020.54 15 1268.04 2.75 0.1344 not significant
significant. In this case A, B, C, D, C2, D2, BD, CD are significant Pure error 2304.00 5 460.80
model terms. Cor total 1.989Eþ006 29
3. The “Lack of Fit F-value” of 3.89 implies there is a 7.01% chance a
Significant at 95% confidence interval.
that a “Lack of Fit F-value” this large could occur due to noise.
Non-significant lack of fit is good e we want the model to fit.
1. The Model F-value of 205.08 implies the model is significant.
There is only a 0.01% chance that a “Model F-Value” this large
Std. dev. 32.65 R-squared 0.9893 could occur due to noise.
Mean 1496.53 Adj R-squared 0.9845 2. Values of “Prob > F” less than 0.0500 indicate model terms are
C.V. 2.18 Pred R-squared 0.9712 significant. In this case A, B, C, D, A2, C2, AB, AC are significant
PRESS 57244.37 Adeq precision 59.786 model terms.
3. The “Lack of Fit F-value” of 2.75 implies the Lack of Fit is not
significant relative to the pure error. There is a 13.44% chance
that a “Lack of Fit F-value” this large could occur due to noise.
Non-significant lack of fit is good e we want the model to fit.
4. The “Pred R-squared” of 0.9712 is in reasonable agreement with
the “Adj R-squared” of 0.9845. “Adeq precision” measures the
Std. dev. 0.62 R-squared 0.8830
signal to noise ratio. A ratio greater than 4 is desirable. Your Mean 3.18 Adj R-squared 0.8385
ratio of 59.786 indicates an adequate signal. This model can be C.V. 19.36 Pred R-squared 0.7615
used to navigate the design space. PRESS 16.26 Adeq precision 19.341

Table 5
Face centered central composite design for four variables at three levels.
4. The “Pred R-squared” of 0.7615 is in reasonable agreement with
Std Run Block Cutting Feed (B) Depth of Nose Power Tool life the “Adj R-squared” of 0.8385. “Adeq precision” measures the
speed mm/rev cut (C) mm radius consumption (min) signal to noise ratio. A ratio greater than 4 is desirable. Your
(A) m/min (D) mm (Wh)
ratio of 19.341 indicates an adequate signal. This model can be
1 28 Block 1 90 0.15 0.20 0.40 1012 6.5 used to navigate the design space.
2 14 Block 1 210 0.15 0.20 0.40 1334 6.0
3 10 Block 1 90 0.25 0.20 0.40 1098 4.5
4 13 Block 1 210 0.25 0.20 0.40 1640 2.5
5 30 Block 1 90 0.15 0.60 0.40 1338 4.2 7.2. Regression coefficient for second order equations
6 27 Block 1 210 0.15 0.60 0.40 1790 1.3
7 20 Block 1 90 0.25 0.60 0.40 1390 1.5
The regression coefficients of the second order equations are
8 7 Block 1 210 0.25 0.60 0.40 1976 0.8
9 24 Block 1 90 0.15 0.20 1.20 1046 4.4
obtained by using the experimental data (Table 5). The regression
10 22 Block 1 210 0.15 0.20 1.20 1406 2.5 equations for the response characteristics as a function of four input
11 17 Block 1 90 0.25 0.20 1.20 1176 3.5
12 2 Block 1 210 0.25 0.20 1.20 1680 1.5
13 18 Block 1 90 0.15 0.60 1.20 1382 2.7 Table 7
14 6 Block 1 210 0.15 0.60 1.20 1948 1.1 Pooled ANOVA-Tool life [AA7075e15 wt% SiC (20e40 mm)].
15 16 Block 1 90 0.25 0.60 1.20 1488 2.3
16 8 Block 1 210 0.25 0.60 1.20 2160 0.6 Source Sum of squares DF Mean squares F value Prob > F
17 29 Block 1 90 0.20 0.40 0.80 1344 4.5 Model 62.21 8 7.53 19.82a <0.0001 significant
18 5 Block 1 210 0.20 0.40 0.80 1776 3.8 A 10.89 1 10.89 28.68a <0.0001
19 11 Block 1 150 0.15 0.40 0.80 1372 3.3 B 8.96 1 8.96 23.60a <0.0001
20 19 Block 1 150 0.25 0.40 0.80 1584 2.1 C 18.20 1 18.20 47.93a <0.0001
21 26 Block 1 150 0.20 0.20 0.80 1272 2.4 D 6.72 1 6.72 17.70a 0.0004
22 1 Block 1 150 0.20 0.60 0.80 1608 1.2 C2 9.45 1 9.45 24.89a <0.0001
23 3 Block 1 150 0.20 0.40 0.40 1492 5.4 D2 2.17 1 2.17 5.71a 0.0263
24 4 Block 1 150 0.20 0.40 1.20 1512 3.1 BD 2.18 1 2.18 5.73a 0.0261
25 12 Block 1 150 0.20 0.40 0.80 1536 4.4 CD 2.64 1 2.64 6.95a 0.0154
26 23 Block 1 150 0.20 0.40 0.80 1536 4.3 Residual 7.97 21 0.38
27 21 Block 1 150 0.20 0.40 0.80 1488 4.1 Lack of fit 7.38 16 0.46 3.37 0.0701 not significant
28 9 Block 1 150 0.20 0.40 0.80 1512 3.7 Pure error 0.59 5 0.12
29 25 Block 1 150 0.20 0.40 0.80 1512 3.7 Cor total 68.18 29
30 15 Block 1 150 0.20 0.40 0.80 1488 3.6 a
Significant at 95% confidence interval.
 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254 247

process parameters considered in these experiments are given Table 8

below. The insignificant coefficient terms (identified from ANOVA) Confidence interval.

have been omitted from the equations. Equations (1) and (2) are Factor Coefficient DF Standard 95% CI low 95% CI high VIF
regression equations for power consumption and tool life estimate error
respectively. Intercept 1503.66 1 9.87 1483.06 1524.25
Cutting speed (A) 246.44 1 7.70 230.39 262.50 1.0
Power consumption ¼ þ767:45609  4:05630*A Feed (B) 86.89 1 7.70 70.83 102.94 1.0
Depth of cut (C) 189.78 1 7.70 173.72 205.83 1.0
 149:72222*B þ 1676:97357*C Nose radius (D) 40.44 1 7.70 24.39 56.50 1.0
A2 54.06 1 17.59 17.36 90.77 2.09
þ 19:86111*D þ 0:015018*A2 C 2
65.94 1 17.59 102.64 29.23 2.09
AB 37.75 1 8.16 20.72 54.78 1.0
 1648:38710*C 2 þ 12:58333*A*B AC 34.25 1 8.16 17.22 51.28 1.0
þ 2:85417*A*C þ 203:12500*C*D CD 16.25 8.16 0.78 33.28 1.0

(1) DF-Degree of freedom.

CI-Confidence interval.
VIF-Variance inflation factor.

Tool life ¼ þ12:82446  0:012963*A  28:86111*B

Fig. 8 indicates the influence of cutting speed and depth of cut
þ 24:03875*C  15:18201*D  41:41129*C 2
on tool life. The increase in depth of cut first increases then
þ 4:95968*D2 þ 18:43750*B*D þ 5:07813*C*D decreases the tool life in machining of AA7075e15 wt% SiC (20e
(2) 40 mm) composites.
Fig. 9 shows the influence of cutting speed and nose radius on
tool life. From the figure, it is seen that the tool life is less at high
7.3. Analysis of power consumption for [AA7075/15 wt% SiC (20e
value of nose radius. In order to promote the maximum tool life it is
40 mm)] composite
necessary to carry out turning at a lower level of cutting speed, feed
and depth of cut.
Confidence Interval results of Table 8 show that standard error
of process parameters for power consumption is with in limits i.e.
7.5. Desirability function approach
around 5%.
Normal plot vs. Residuals displays the residual data where 98%
For improving productivity and minimizing power consump-
of residuals should fall with in 3 sigma. This experimental data is
tion, optimization of process parameters is an important criterion.
well with in three 3 sigma (Fig. 2).
Different optimization techniques have been used by many
researchers. In the present work, the multi response optimization
7.3.1. Effect of process parameters on power consumption
analysis has been carried out for achieving the minimum power
Power is consumed for turning the composite rod. Movement of
consumption and the maximum tool life in machining of AA7075e
tool holder also consumes power. Figs. 3e5 depict the surface plot
15 wt% SiC (20e40 mm) composite using developed mathematical
of power consumption as per experimental conditions tabulated in
model. For optimizing the process parameters, desirability function
Table 5. Fig. 3 represents the surface plot of power consumption
based approach is used.
with respect to varying cutting speed and feed. The figure shows
Optimization steps using desirability function analysis in the
that the power consumption increases with the increase in cutting
response surface methodology are as under;
speed. The power consumption is little affected by increase in feed.
Fig. 4 shows the influence of cutting speed and depth of cut on
Step 1: Calculate the individual desirability index (di) for the
power consumption. Cutting speed has most significant effect on
corresponding responses using the formula proposed by the
the power consumption. The increase in depth of cut increases the
power consumption in machining of AA7075e15 wt% SiC (20e40)
composites. Fig. 5 indicates the influence of cutting speed and Normal Plot of Residuals
nose radius on power consumption. From the figure, it is seen that
nose radius is not having much effect on the power consumption.
From these figures, it is seen that the lower power consumption 99
Normal % Probability

could be achieved only at lower level of cutting speed and depth of

95
cut. This is because less resistance is faced by tool at lower values. 90
80
7.4. Analysis of tool life for [AA7075e15 wt% SiC (20e40 mm)] 70
composite 50

30
Confidence Interval results of Table 9 show that standard error 20
of process parameters for tool life is with in limits i.e. around 5%.
10
Normal plot vs. Residuals displays the residual data where 98% 5
of residuals should fall with in 3 sigma. This experimental data is
well with in three 3 sigma (Fig. 6). 1

7.4.1. Effect of process parameters on tool life

Fig. 7 represents the surface plot of tool life with respect to -2.28 -1.14 -0.01 1.12 2.26
varying cutting speed and feed. The figure shows that the tool life Studentized Residuals
decreases with the increase in cutting speed. The increase in feed
sharply decreases the tool life. Fig. 2. Normal plot of residuals e power consumption.
248 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254

1928.8 1844.61
Power consumption (Watt.hr)

Power consumption (Watt.hr)

1762.14 1701.16

1595.47 1557.72

1428.8 1414.28

1262.14 1270.83

210.00 210.00
0.25 1.20
180.00 180.00
0.23 1.00
150.00 150.00
0.20 0.80
Cutting Speed 120.00 0.18 Cutting Speed 120.00 0.60
Feed Nose radius
90.00 0.15 90.00 0.40

Fig. 3. Effect of cutting speed and feed on power consumption. Fig. 5. Effect of cutting speed and nose radius on power consumption.

!r
1 y  ymin
Derringer and Suich (1980). In this case there are two forms of y  ymax
di ¼ ; ymin  y  ymax ; r0 (3)
the desirability functions according to the response ymin  ymax
0 y  ymax
characteristics.
Where the ymin represents the lower tolerance limit of y, the ymax
represents the upper tolerance limit of y and r represents the
7.5.1. The-smaller-the better weight. If the corresponding response is expected to be closer to the
Smaller the better characteristic is applied to determine the target, the weight can be set to the larger value; otherwise, the
individual desirability values for power consumption since objec- weight can be set to the smaller value.
tive is to minimize power consumption. The value of y is expected
to be the smaller the better. When the by is less than a particular 7.5.2. The-larger-the better
criteria value, the desirability value equals to 1; if the y exceeds Larger the better characteristic is applied to determine the
a particular criteria value, the desirability value equals to 0. The individual desirability values for tool life since objective is to
desirability function of the-smaller-the-better can be written as maximize the tool life. The value of y is expected to be the larger
given in Equation (3): the better. When the y exceeds a particular criteria value, which
can be viewed as the requirement, the desirability value equals to 1;
if the y is less than a particular criteria value, which is unaccept-
able, the desirability value equals to 0. The desirability function of
the larger-the better can be written as given in Equation (4):
!r
0 y  ymin
1962.26 y  ymax
di ¼ ; ymin  y  ymax; r  0 (4)
ymin  ymax
Power consumption (Watt.hr)

1744.15 1 y  ymin
1526.03
where the ymin represents the lower tolerance limit of y, the ymax
1307.92 represents the upper tolerance limit of y and r represents the
1089.81 weight.

Table 9
Confidence interval.

Factor Coefficient DF Standard 95% CI low 95% CI high VIF

estimate error
210.00
0.60 Intercept 3.07 1 0.19 3.31 4.09
180.00 Cutting speed (A) 0.78 1 0.15 1.08 0.48 1.0
0.50 Feed (B) 0.71 1 0.15 1.01 0.40 1.0
150.00 Depth of cut (C) 1.01 1 0.15 1.31 0.70 1.0
0.40
Nose radius (D) 0.61 1 0.15 0.91 0.31 1.0
Cutting Speed 120.00 0.30 C2 1.66 1 0.33 2.35 0.97 2.09
Depth of cut D2 0.79 1 0.33 0.10 1.48 2.09
90.00 0.20
BD 0.37 1 0.15 0.048 0.69 1.0
CD 0.41 0.15 0.086 0.73 1.0
Fig. 4. Effect of cutting speed and depth of cut on power consumption.
 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254 249

Normal Plot of Residuals

4.63144
99
3.5389

2.44636

T ool life ( m in)

95
1.35383
90
Normal % Probability

0.26129
80
70

50
210.00
30 0.60
180.00
20 0.50
150.00
10 0.40
Cutting speed (m/min) 120.00
5 0.30
Depth of cut (mm)
90.00 0.20

1
Fig. 8. Effect of cutting speed and depth of cut on tool life.

The calculated total sum of square values is used to measure the

-2.18 -1.19 -0.20 0.79 1.77
relative influence of the parameters.
Studentized Residuals
Step 5: Calculate the predicted optimum condition. Once the
Fig. 6. Normal plot of residuals e tool life. optimal level of the design parameters has been selected, the
final step is to predict and verify the quality characteristics using
the optimal level of the design parameters.
Step 2: Compute the composite desirability (dG). The individual
desirability index of all the responses can be combined to form
The optimization analysis is carried out using DESIGN-EXPERT
a single value called composite desirability (dG) by the following
software. In recent years, desirability function approach is used
Equation (5):
by some of the researchers like Derringer and Suich (1980), Dhupal
rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
  et al. (2008) and Jinshan et al. (2007) for finding the optimal
dG ¼ 1 d2 ...di
dw1 w2 wi (5) solutions using multi performance objective. In the present work,
single objective optimization is carried out using desirability based
method. The optimization is carried out in two steps: (1) Obtaining
where di is the individual desirability of the property Yi, wi is the
the desirability for the response and (2) The maximization of
weight of the property “Yi” in the composite desirability and w is
desirability and identifying the optimal value. In desirability based
the sum of the individual weights.
approach, different solutions are obtained. The solution with high
desirability is preferred.
Step 3: Determine the optimal parameter and its level combi-
nation. The higher composite desirability value implies better
7.6. Multi response optimization of process parameters for
product quality. Therefore, on the basis of the composite desir-
minimum power consumption and maximum tool life
ability (dG), the parameter effect and the optimum level for each
controllable parameter are estimated.
Desirability analysis is carried out to minimize the power
Step 4: Perform ANOVA for identifying the significant parame-
consumption and maximize the tool life while allowing process
ters. ANOVA establishes the relative significance of parameters.

5.18441 5.88351

4.44274 5.11409

3.70108 4.34467
T ool life ( m in)
T ool life ( m in)

2.95941 3.57524

2.21774 2.80582

210.00 210.00
0.25 1.20
180.00 180.00
0.23 1.00
150.00 150.00
0.20 0.80
Cutting speed (m/min) 120.00 0.18
Cutting speed (m/min) 120.00 0.60
Feed (mm/rev) Nose radius (mm)
90.00 0.15 90.00 0.40

Fig. 7. Effect of cutting speed and feed on tool life. Fig. 9. Effect of cutting speed and nose radius on tool life.
250 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254

parameters to vary from lower limit to upper limit. Table 10 shows Table 11
the constraints used for optimization of process parameters. Multi response optimization solutions.

Importance of tool life is twice as compared to importance of power Solution Cutting Feed Depth Nose Power Tool Desirability Selection
consumption since wear of tools in turning the 7075 Al alloyeSiC no speed (mm) of cut radius consumption life
composites is more and tools are very costly. Main objective of (m/min) (mm) (mm) (Wh) (min)

Optimization is to reduce the cost of these tools. 1 90.00 0.15 0.20 0.42 1017.5 6.59 0.998 Selected
2 91.33 0.15 0.20 0.40 1018.21 6.66 0.998
A Multi response optimization solution for minimum power
3 92.33 0.15 0.20 0.40 1019.28 6.66 0.998
consumption and maximum tool life is given in Table 11. Solution 4 90.00 0.15 0.20 0.40 1019.78 6.64 0.998
with maximum value of desirability is considered best. In the present 5 92.40 0.15 0.20 0.42 1020.61 6.51 0.997
case any solution, out of solution 1, 2, 3 or 4 can be selected. As per
solution 1 the optimum values of cutting speed, feed, depth of cut
and nose radius are 90 m min1, 0.15 mm/rev, 0.20 mm and 0.42 mm. process parameters is selected, the final step is to predict and verify
the improvement of the performance characteristics using the
6:59 þ 6:66 þ 6:66 þ 6:64 þ 6:51
Arithmetic mean ¼ optimum level of the process parameters. The confirmation
5 experiment is conducted at the optimum test conditions to verify
¼ 6:612 the quality characteristics for turning AA7075e15 wt% SiC (20e40)

sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ð6:59  6:612Þ2 þð6:66  6:612Þ2 þð6:66  6:612Þ2 þð6:64  6:612Þ2 þð6:51  6:612Þ2
Experimental standard deviation ¼
5
¼ 0:05706

0:05706
Standard uncertainty ¼ pffiffiffi ¼ 0:0255 ¼ 2:55% composite, as recommended by the investigation. The summary of
5 the results obtained from the confirmation tests are detailed below.
Errors in measurement have been considered. Arithmetic mean, Validation experiment was conducted for the combined objective
experimental standard deviation and standard uncertainty are with the obtained best levels of parameters. The values for power
calculated as per guide to the expression of uncertainty in consumption and tool life from validation experiment are 1117 Wh
measurement, International Organization for Standardization and 6.6 min respectively (Table 11). After multi objective optimi-
(1993). The value of Standard uncertainty is ¼ 2.55%. zation the values of machining parameters obtained are: cutting
Fig. 10 shows composite desirability of power consumption and speed e 90.00 (m/min), feed e 0.15 (mm), depth of cut e 0.20 (mm)
tool life. This value of desirability has been obtained by using and nose radius e 0.40 (mm). When these values of machining
equation (5). The plot has been obtained by design expert software. parameters are put in equation no 3 and 4, the corresponding
As per this plot composite desirability value is 0.902, which is good values of power consumption and tool life are 1291 Wh and
enough to predict the values of process parameters for multi 5.14 min respectively.
response optimization i.e. for minimum power consumption and The percent reduction in power consumption and improvement
maximum tool life. tool life with the application of design of experiments is calculated
Fig. 11 shows the contour graph of power consumption at from the validated result and the best values during experiments
maximum desirability value. As per this plot after the multi response as:
optimization, the predicted value of power consumption is 1017 Wh. 1291  1116
Fig. 12 shows the contour graph of tool life at maximum desir- The % reduction in power consumption  100
1291
ability value. As per this plot after the multi response optimization ¼ 13:55%
the predicted value of tool life is 6.59 min.
6:6  5:14
The % increment in tool life  100 ¼ 22:12%
7.7. Confirmation test 6:6
Non-cutting operations consumed most of the energy in
The purpose of the confirmation test is to validate conclusions machining; keeping machines powered up but not cutting
drawn during the analysis phase. Once the optimum level of the contributes to energy waste and must be minimized where
Table 10 possible. The critical parameters for the optimum tool-life for
Constraints used for multi response optimization of process parameters during minimum energy are the power required to start the machine tool
turning of [AA7075e15 wt% SiC (20e40)] composite. and put it in an idle condition, the power consumed for positioning
Response Constraint Lower Upper Lower Upper Importance the tool, energy needed for feed back and control systems. Reduc-
limit limit weight weight tion in energy consumption leads to lower emission hence support
Cutting In range 90 210 1 1 3 sustainable machining processes.
speed (m/min)
Feed (mm/rev) In range 0.15 0.25 1 1 3 8. Discussions
Depth of In range 0.2 0.6 1 1 3
Cut (mm)
Nose radius (mm) In range 0.4 1.2 1 1 3 8.1. Macro-scale observation and micro-scale mechanisms for
Power Minimize 1112 2160 1 1 2 power consumption and tool life
consumption
(watts)
The power consumption increases as cutting speed increase. This
Tool life (min) Maximize 0.6 6.5 1 1 4
is quite obvious because as cutting speed increases, the material
 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254 251

DESIGN-EXPERT Plot
0.25
Desirability
Desirability
X = A: Cutting Speed
Y = B: Feed 0.515

Actual Factors
0.23
C: Depth of cut = 0.20 0.612
D: Nose radius = 0.42

0.708

B: Feed
0.20

0.805

0.18 0.902

Predi c 1.00
0.15
90.00 120.00 150.00 180.00 210.00

A: Cutti ng Speed

Fig. 10. Composite desirability of power consumption and tool life.

removal rate also increases forcing the system to spend more power.
As cutting speed increases, the heat generated at the tool workpiece
interface also increases. With a significant portion of heat generated
entering in to the workpiece material, this increased heat generated
leads to softening of the aluminum matrix. In Al alloy/SiC
machining, significant amount of energy is spent in removing the
hard abrasive particle reinforcements from the “sticky” matrix. The
SiC particles are pulled out of the matrix rather than being sheared.
Moreover as the cutting tool wears, there is a clear trend indicating
greater power consumption. Tool wear will determine the
maximum cutting speed that would result in a reasonable tool life.
As increasing the cutting speed beyond a limit will lead to very rapid
tool wear and prove economically unviable.
Large tool nose radii only give finer surface finish, but compa-
rable tool wear compared to small nose radius tools. The reason is
that since nose radius is more, the area of contact of nose with
composite will be more and large number of SiC particles will come
in contact with the nose. It will offer additional resistance during
the turning process, resulting in excess wear. When cutting with
a large nose radius tool, the chip thickness varies between zero and
a maximum value, which tends to plow a large portion of the chips
rather than shearing it. This plowing process results in increased
stresses and deformation of the layer being cut, consequently are
causing a temperature rise. The length of the active part of the
cutting edge and volume of the tool edge in contact with the,
material increases. This results in a higher probability of a greater

DESIGN-EXPERT Plot
0.25
Power consumption
Power consumption
X = A: Cutting Speed
Y = B: Feed
1515.96
Actual Factors
0.23
C: Depth of cut = 0.20
D: Nose radius = 0.42
1416.27
B: Feed

0.20
1117.18 1216.88 1316.57

0.18

P re d i c 1 0 1 7 .5 0
0.15
90.00 120.00 150.00 180.00 210.00

A: Cutti ng Speed

Fig. 11. Contour graph of power consumption at maximum desirability value.

252 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254
DESIGN-EXPERT Plot
0.25
Tool lif e
X = A: Cutting Speed
Y = B: Feed
Actual Factors
0.23
C: Depth of cut = 0.20
D: Nose radius = 0.42
B: Feed
0.20
0.18
5.97892
P re d i c 6 .5 9
0.15
90.00
Fig. 12. Contour graph of tool life at maximum desirability value.
number of abrasive particles coming into contact with, and
abrading, the cutting tool material, which leads to severe wear and
hence lower tool life (Manna and Bhattacharayya, 2005).
8.2. Literature’s approaches
Bhattachary et al. (2009), estimated the effect of cutting
parameters on surface finish and power consumption during high
speed machining of AISI 1045 steel using Taguchi design and
ANOVA. Their observations are as under;
i. Conflicting results were obtained when measuring the power
consumption with other levels of the same contributing
factors reduced the power consumption.
ii. Cutting speed was once again observed to be most significant
factor to reduce the power consumption during these
machining trials with a contribution is 77.4%, followed by the
depth of cut (13.2%). The feed rate has no significant affect on
the power consumption and thus should be set at a level
which is most appropriate and most economical.
iii. Higher cutting speeds provide for higher surface finish, but
will lead to higher power consumption. Thus a compromise
must be arrived depending upon the accuracy requirements
on the part to be machined and economic requirements. At
lower depth of cut and at lower cutting speed, formation of
built-up-edge is found and this lead to a higher machine
power consumption.
Abhang and Hameedullah (2010) carried work on Power
Prediction Model for Turning EN-31 Steel Using Response Surface
Methodology. Their observations are as under;
i. Response surface method is found to be a successful tech-
nique to perform trend analysis of power consumption in
metal cutting with respect to various combinations of design
variables (metal cutting speed, feed rate, depth of cut and tool
nose radius).
ii. The first order, second order and exponential models are
found to be adequately representing metal cutting power
Tool life
3.52988
4.14214
4.7544
5.36666
120.00 150.00 180.00 210.00
A: Cutti ng Speed
with experimental results. Second order model is more
precise than the first order model in predicting the power
consumption during machining.
iii. The models developed in the research produces smaller
errors and have satisfactory results. Therefore the proposed
models can be used to predict the corresponding power
consumption in metal cutting of EN-31 steel at different
parameters in turning.
iv. The smallest the values of the cutting speed, feed rate, depth
of cut and tool nose radius, the lowest is the metal cutting
power consumption. The counter plots show the safe zone for
minimum power consumption. Thus, from the model equa-
tions and counter plots a designer can select the best
combination of cutting variables for achieving optimum or
minimum metal cutting power consumption during turning
steel. This eventually may reduce the machining time, oper-
ator efforts, cost and save the cutting tools.
Aggarwal et al. (2008) investigated into the effects of cutting
speed, feed rate, depth of cut, nose radius and cutting environment
in CNC turning of AISI P-20 tool steel. Their observations are as
under;
i. The analysis of the results for power consumption shows that
the techniques, RSM and Taguchi methodology, give similar
results. Taguchi’s technique revealed that cryogenic envi-
ronment is the most significant factor followed by cutting
speed and depth of cut. The 3D surface plots of RSM also
revealed that cryogenic environment has very significant
effect in reducing power consumption. The lowest value of
power consumption in the given range of parameters as
depicted by ramp function graphs are dry environment
(858.07 Wh), wet environment (1479.87 Wh) and cryogenic
environment (658.79 Wh).
ii. Significance of interactions and square terms of parameters is
more clearly predicted in RSM. The RSM shows significance of
all possible combinations of interactions and square terms. In
Taguchi’s technique only three interactions (AB, AC and BC)
are normally studied. Where A is cutting speed, B is feed, C is
 R.K. Bhushan / Journal of Cleaner Production 39 (2013) 242e254
depth of cut. Also square of parameters are analyzed in RSM
whereas none of them is done in Taguchi’s technique. This is
owing to the fact that in Taguchi’s design, interactions
between control factors are aliased with their main effects.
iii. Time required for conducting experiments using RSM tech-
nique was almost twice as that needed through Taguchi’s
technique. It is attributed to the fact that 180 (30  2, 30  2,
30  2) were performed using face centered central
composite design for three (dry, wet and cryogenic) cutting
environments whereas only 81 (27  3) experiments were
performed using L27 orthogonal array.
iv. RSM technique can model the response in terms of significant
parameters, their interactions and square terms. This facility
is not provided by Taguchi’s technique.
v. 3D surfaces generated by RSM can help in visualizing the
effect of parameters on response in the entire range
specified whereas Taguchi’s technique gives the average
value of response at given level of parameters. Also ramp
function graphs tell the exact level of parameters for
desired level of response. Thus RSM can better predict the
effect of parameters on response and is a better tool for
optimization.
8.3. Comparative benefits between our approach and literature’s
approaches
i. We have favored face-centered central composite design
(CCD) because, the face-centered CCD requires only three
levels of each experiment variable, making it the simplest
variety of CCD to carry out, as well as the least prone to
corruption due to sources of experimental error associated
with setup and operation. This has reduced the cost of
experiments, as both AA7075e15 wt% SiC composite and
tungsten carbide inserts are costly.
ii. Based on the research reviewed so far it can be said that no
work has been reported about multi response optimization of
power consumption and tool life during turning of AA7075e
15 wt% SiC composite, where objective is to minimize the
power consumption and maximize tool life.
iii. As concluded by one of the researcher, RSM can better predict
the effect of parameters on response and is a better tool for
optimization, as compared to Taguchi’s technique. That is the
reason of selecting RSM for predicting the effect of process
parameters on power consumption and tool life and desir-
ability analysis for multi response optimization.
9. Conclusions
Turning experiments were conducted based on response surface
methodology for AA7075e15 wt% SiC (20e40 mm) composite using
6615 grade tungsten carbide cutting tool. The experimentally
collected data were subjected to ANOVA and desirability function
analysis for optimization of machining parameters. From this
analysis, the following conclusions are drawn for power
consumption and tool life:
1. The 3D surface plots of Response Surface Methodology (RSM)
for AA7075e15 wt% SiC (20e40 mm) composite revealed that
cutting speed is the most significant factor followed by depth of
cut, feed and nose radius.
2. Significance of interactions and square terms of parameters is
more clearly predicted in RSM. The RSM shows significance of
all possible combinations of interactions and square terms as
depicted in Tables 6 and 7.
253
3. As evident from equations (1) and (2), RSM technique can
model the response in terms of significant parameters, their
interactions and square terms.
4. 3D surfaces of power consumption generated by RSM [Figs. 3e
5] can help visualize the effect of the parameters across the
range specified.
5. 3D surfaces of tool life generated by RSM [Figs. 7e9] can help in
visualizing the effect of parameters on response in the entire
range specified.
6. Multi response optimization by desirability analysis shows that
the minimum value of power consumption (1116 Wh) during
turning of AA7075e15 wt% SiC (20e40 mm) composite can be
achieved at cutting speed of 90 m min1, feed of 0.15 mm/rev
depth of cut of 0.20 mm, and nose radius of 0.42 mm.
7. Multi response optimization by desirability analysis shows that
the maximum value of tool life (6.6 min) during turning of
AA7075e15 wt% SiC (20e40 mm) composite can be achieved at
cutting speed of 90 m min1, feed of 0.15 mm/rev depth of cut
of 0.20 mm, and nose radius of 0.42 mm.
8. When turning will be carried out at values of cutting parame-
ters obtained by multi response optimization through desir-
ability analysis route this will reduce power consumption by
13.55% and increase tool life by 22.12%.
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