Development of ZrO2 - MoS2 composite cutting tool

for optimizing machining parameters by using FUZZY -

Technique

A project report submitted in partial fulfillment of the requirements for the Award of the
Degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

by

B ASHRITH ( A21126520002 )
U THARUN KUMAR ( A21126520049 )
B NEERAJ REDDY ( A21126520005 )
S. PREETAM RAJ ( A21126520046 )
K SUPRIYA ( A21126520023 )
N SAAHIL KUMAR ( A21126520031 )

Under the guidance of

Dr. B. PRADEEP KUMAR , Ph.D.
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

 1
ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES (A)
(Permanently Affiliated to Andhra University, Approved by AICTE, Accredited by NBA Tier-I, NAAC)
Sangivalasa, Visakhapatnam (District) Andhra Pradesh -India- 531162.

APRIL 2025
 DEPARTMENT OF MECHANICAL ENGINEERING

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES

(UGC Autonomous & Permanently Affiliated to Andhra )

CERTIFICATE

This is to certify that the Project Report entitled " Development of ZrO 2 - MoS 2
composite cutting tool for optimizing machining parameters by using FUZZY
technique" being submitted by [Link] (A21126520002), [Link] Kumar
(A21126520049) ,[Link] Reddy (A21126520005), [Link] Raj (A21126520046),
[Link] (A21126520023), [Link] Kumar (A21126520031) to the Department of
Mechanical Engineering,ANITS is a record of the bonafide work carried out by them
under the esteemed guidance of Dr. [Link] Kumar. The results embodied in the
report have not been submitted to any other University or Institute for the award of any
degree or diploma.

APPROVED BY PROJECT GUIDE

([Link] Raju) (Dr. [Link] Kumar)

Head of the Department Assistant Professor
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
ANITS, Visakhapatnam. ANITS, Visakhapatnam.
 THIS PROJECT IS APPROVED BY THE

BOARD OF EXAMINERS

INTERNAL EXAMINER:

EXTERNAL EXAMINER:
 ACKNOWLEDGEMENTS

We express immensely our deep sense of gratitude to Dr. [Link] Kumar,

Assistant Professor, Department of Mechanical Engineering, Anil Neerukonda Institute of
Technology & Sciences, Sangivalasa, Bheemunipatnam Mandal, Visakhapatnam district
for his valuable guidance and encouragement at every stage of the work made it a
successful fulfillment

We were very thankful to Prof [Link] Rama Krishna, Principal, and [Link]
Raju, Head of the Department, Mechanical Engineering Department, Anil
Neerukonda Institute of Technology & Sciences for their valuable suggestions.

We wish to thank all the staff in the department, non-teaching staff in the
workshop for their kind cooperation and support given throughout our project.

Last but not the least, we like to convey our thanks to all who have contributed
either directly or indirectly for the completion of our work.

B Ashrith (A21126520002)
U Tharun Kumar (A21126520049)
B Neeraj Reddy (A21126520005)
S Preetam Raj (A21126520046)
K Supriya (A21126520023)
N Saahil Kumar (A21126520031)
 ABSTRACT

The cutting tool plays a very important role in the machining process of a part in production. It
not only performs the cutting action but helps in getting required surface finish and
accuracy of the part. In order to perform these tasks the tool has to be strong enough to
withstand wear resistance and serve for a long period of time to produce more number of
components with the same accuracy. Machining is important in the metal manufacturing
process to achieve near-net shape, good dimensional accuracy and for aesthetic
requirements.

The experiment is to study, determine and compare the effects of various parameters such as,
cutting forces (Axial, Radial and main), surface roughness and Coefficient of Friction in
turning of Hardened steel material with the help of ZrO2-MoS2 composite cutting tool
and Tungsten carbide cutting tools. The cutting operations were carried out on a
conventional lathe machine thereby making turning operation at different cutting speeds
of 75, 150 and 225 m/min. Also feed of 0.5rev/min, 1 rev/min, 1.5rev/min. Depth of cut
0.5mm,1mm,1.5mm. Our project also deals with optimization of cutting parameters on
Hardened steel specimens in turning operation to obtain minimum cutting forces, surface
roughness and Coefficient of friction.

The adequacy of the developed model is checked using response surface method (R.S.M),By
using the mathematical model the main and interaction effect of various process
parameters on responses is studied. The developed model helps in selection of proper
machining parameters for the specific material and also helps in achieving the better
performance characteristics.
 LIST OF CONTENTS
CHAPTER 1:INTRODUCTION

Page no

1.1 Turning Operation 1

1.2 Adjustable Cutting Parameters in Turning 2
1.2.1 Speed 2
1.2.2 Feed 2
1.2.3 Depth of Cut 3
1.3 Cutting Tool for Lathe 3
1.3.1 Tool Geometry 3
1.3.1(a) Flank 3
1.3.1(b) Face 3
1.3.1(c) Back Rake Angle 4
1.3.1(d) Side Rake Angle 4
1.3.1(e) Side Cutting Edge Angle 4
1.3.1(f) End Cutting Edge Angle 4
1.3.1(g) Side Relief Angle 5
1.3.1(h) End Relief Angle 5
1.3.1(i) Nose Radius 5
1.3.1(j) Lead Angle 5
1.4 Cutting Tool Materials 5
1.5 Turning Machines 6
1.5.1 Turret Lathes 7
1.5.2 Single Spindle Automatic Screw Machines 8
1.6 Turning Dynamometer 10
1.7 Introduction to Minitab 10
1.7.1 Minitab Projects and Worksheets 11
1.7.2 Two Windows in Minitab 12
 CHAPTER 2: LITERATURE REVIEW
CHAPTER 3: DESIGN OF EXPERIMENTS

3.1 DOE Overview 16

3.1.1 Planning 16
3.1.2 Screening 17
3.1.3 Optimisation 17
3.1.4 Verification 18
3.2 Advantages and Disadvantages of DOE 18
3.3 Taguchi method 19
3.3.1 Advantages and disadvantages of Taguchi Method 19
3.3.2 Why is Taguchi Method Used 19
3.4 Introduction about Matlab 19
3.4.1 Key Features of Matlab 20
3.4.2 Applications of Matlab 20
3.4.3 Advantages of Matlab 20
3.4.4 Disadvantages of Matlab 21
3.5 Fuzzy Logic Technique
3.5.1 Applications of Mechanical Engineering 21
3.5.2 Advantages of Fuzzy Logic Technique 21
3.6 Design of Experiments 22
3.6.1 Creating Taguchi Design 22
3.7 Input Cutting Parameters of Tungsten Carbide 25
3.8 Input Cutting Parameters of ZrO2-MoS2 26

CHAPTER 4: EXPERIMENTAL SET UP AND MACHINING

4.1 Selection of Process Variables 27
4.2 Selection of Levels 27
4.3 Design of Experiments 28
4.4 Selection of Material 28
4.5 Ball Milling of ZrO₂–MoS₂ 30
4.6 Compaction of ZrO₂–MoS₂ 30
4.7 Sintering Process 31
4.8 Shaping of Cutting Tool 32
4.9 Cutting Tool Geometry and Rationale 33
5.1 Tool Signature and Post Shaping Processes 34
5.2 Vickers Hardness Test 35
5.3 Clamping of Workpiece 37
5.4 Coefficient of Friction 38
5.5 Sample Calculation 38

CHAPTER 5: RESULTS AND ANALYSIS

5.6 MATLAB 32
5.7 Design of Experiments (DOE) Using Minitab 33
5.8 Analysis of Variance Using Taguchi Method 33

CHAPTER 6: RESULTS AND DISCUSSIONS

6.1 Development of Mathematical Model 36
6.2 Different Terms Used in Response Surface Methodology 37
6.3 Graphs Obtained 38
6.3.1 Contour Plots 38
6.4 Experimental Table for Tungsten Carbide 39
6.5 Tungsten Carbide Results 46
6.5.1 Taguchi Analysis : Fx(Axial)(N), Fy(Radial)(N) , Fz (Main)(N),
COF, Surface Roughness versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm) 46
6.5.2 Regression Analysis : Fx(Axial)(N) versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.5.3 Regression Analysis : Fy(Radial)(N) versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.5.4 Regression Analysis : Fz (Main)(N) versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.5.5 Regression Analysis : Surface Roughness versus Cutting Speed ( m/min),
 Feed ( mm / rev) , DOC ( mm)
6.5.6 Regression Analysis : COF versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.6 ZrO2 - MoS2 RESULTS
6.6.1 Taguchi Analysis : Fx(Axial)(N), Fy(Radial)(N) , Fz (Main)(N),
COF, Surface Roughness versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.6.2 Regression Analysis : Fx(Axial)(N) versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.6.3 Regression Analysis : Fy(Radial)(N) versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.6.4 Regression Analysis : Fz (Main)(N) versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.6.5 Regression Analysis : Surface Roughness versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
6.6.6 Regression Analysis : COF versus Cutting Speed ( m/min),
Feed ( mm / rev) , DOC ( mm)
CHAPTER 7: CONCLUSIONS
CHAPTER 8: BIBLIOGRAPHY / REFERENCES
 LIST OF TABLES
Page no
Table 3.1 Input Cutting Parameters of Tungsten Carbide 25
Table 3.2 Input Cutting Parameters of ZrO₂–MoS₂ Cutting Tool 26
Table 4.1 Selection of Process Variables 27
Table 4.2 Cutting Tool Geometry and Rationale 32
Table 4.3 Tool Signature and Post Shaping Processes 33
Table 6.1 Experimental Results 47
Table 6.2 Estimated Model Coefficients for SN ratio for Tungsten Carbide 48
Table 6.3 Model Summary 48
Table 6.4 Analysis of Variance for SN Ratio for Tungsten Carbide 48
Table 6.5 Estimated Model Coefficient for Means 49
Table 6.6 Model Summary 49
Table 6.7 Analysis of Variance for Means for Tungsten Carbide 50
Table 6.8 Response Table for Signal To Noise Ratios 50
Table 6.9 Response Table For Means 51
Table 6.10 Coefficients 52
Table 6.11 Modal Summary 52
Table 6.12 Analysis of Variance 52
Table 6.13 Regression Equation Coefficients 53
Table 6.14 Modal Summary 53
Table 6.15 Analysis of Variance 54
Table 6.16 : Fits and Diagnostics for Unusual Observations
Table 6.17 : Coefficients
Table 6.18 : Model Summary
Table 6.19 :Analysis of Variance
Table 6.20 : Fits and Diagnostics for Unusual Observations
Table 6.21 : Coefficients
Table 6.22 : Model Summary
Table 6.23 : Analysis of Variance
Table 6.24 : Fits and Diagnostics for Unusual Observations
Table 6.25 : Coefficients
Table 6.26 : Model Summary
Table 6.27 : Analysis of Variance
Table 6.28 : Estimated Model Coefficients for SN ratios
Table 6.29 : Model Summary
Table 6.30 : Analysis of Variance for SN ratios
Table 6.31 : Estimated Model Coefficients for Means
Table 6.32 : Model Summary
Table 6.33: Analysis of Variance for Means
Table 6.34 : Response Table for Signal to Noise Ratios
Table 6.35 : Response Table for Means
Table 6.36 : Coefficients
Table 6.37 : Model Summary
Table 6.38 : Analysis of Variance
Table 6.39 : Coefficients
Table 6.40 : Model Summary
Table 6.41 : Analysis of Variance
Table 6.42 : Fits and Diagnostics for Unusual Observations
Table 6.43 : Coefficients
Table 6.44 : Model Summary
Table 6.45 :Analysis of Variance
Table 6.46 : Fits and Diagnostics for Unusual Observations
Table 6.47 : Coefficients
Table 6.48 : Model Summary
Table 6.49 : Analysis of Variance
Table 6.50 : Coefficients
Table 6.51 : Model Summary
Table 6.52 : Analysis of Variance
 LIST OF FIGURES
Figure 1.1 Adjustable Parameters in Turning Operation 1
Figure 1.2 Geometry of Tool 4
Figure 1.3 Engine Lathe 7
Figure 1.4 turret lathe 8
Figure 1.5 Single Spindle Automatic Screw Lathe 9
Figure 1.6 Turing Dynamometer 10
Figure 1.7 Environment in minitab software 12
Figure 3.1 Creating a Taguchi Design in minitab 23
Figure 3.2 Selection of Factors & Levels 23
Figure 3.3 Selection of Available Taguchi Designs in minitab 24
Figure 3.4 Selection of Taguchi Design in minitab 24
Figure 3.5 Taguchi Design: Factors in Minitab 25
Figure 3.8 Interface of the minitab After Imputing the Values 25
Figure 4.1 Ball- Milling Machine 29
Figure 4.2 Powder Obtained after ball milling 29
Figure 4.3 Compacting the mixture of Zro2-Mos2 30
Figure 4.4 Compacted powder is kept in a mold for sintering 31
Figure 4.5 Sintering machine 32
Figure 4.6 Shaped cutting tool 32
Figure 4.7 Vickers Hardness Testing Machine 36
Figure 4.8 Clamping of the workpiece 37
Figure 5.1 MatLab 39
5.1.1MatLab 39
5.1.2 MatLab 39
Figure 5.2 Surface and Rule in Axial Force For Tungsten Carbide 40
Figure 5.3 Surface and Rule un Radial Force for Tungsten Carbide 40
Figure 5.4 Surface and Rule in Axial Force For Tungsten Carbide 41
Figure 5.5 Surface Roughness Tungsten Carbide
Figure 5.6 FX Zro2-Mos2 51
Figure 5.7 FY Zro2-Mos2 52
Figure 5.8 FZ Zro2-Mos2 52
 Figure 5.9 Surface Roughness of FZ Zro2-Mos2 53
Figure 5.10 COF Zro2-Mos2
Figure 5.11 Analysis Of Variance using taguchi Method
5.11.2 Analysis Of Variance using taguchi Method
5.11.3 Analysis Of Variance using taguchi Method
5.11.4 Analysis Of Variance using taguchi Method
Figure 6.1 Residual Plots for SN Ratio
Figure 6.2 Main Effects Plot for SN Ratio
Figure 6.3 Residual Plot for SN Ratio
 CHAPTER 1
INTRODUCTION

1.1 TURNING OPERATION

Metal is removed from the outer diameter of a rotating cylindrical workpiece in turning.
The diameter of the workpiece is reduced, usually to a specified dimension, and a smooth
finish is produced on the metal. Often, the workpiece is turned so that adjacent sections
are given different diameters. Cylindrical parts are produced by turning, a machining
operation that involves the use of a single-point cutting tool. In its basic form, an external
surface is machined to achieve the desired shape and size.

● With the workpiece rotating.

● With a single-point cutting tool and

● With the cutting tool feeding parallel to the axis of the workpiece

and at a distance that will remove the outer surface of the work.

Figure 1.1: Adjustable parameters in turning operation

Taper turning and contour turning are specialized techniques in machining. Taper turning
involves positioning the cutter path at an angle to the work axis, creating a tapered shape
with a gradual decrease or increase in diameter. Contour turning, on the other hand,
involves varying the distance of the cutter from the work axis to produce a desired shape

1
or profile. Multiple-tool setups are often employed in these processes, allowing each tool
to operate independently and increasing efficiency and productivity. These techniques are
widely used in various industries, including aerospace, automotive, and industrial
manufacturing, to produce complex parts and components with high precision and
accuracy.
1.2. ADJUSTABLE CUTTING PARAMETERS IN TURNING

Adjustable cutting parameters in turning include cutting speed, feed rate, and depth of cut.
Cutting speed affects tool life, surface finish, and material removal rate, while feed rate
impacts surface finish, material removal rate, and tool life.

Depth of cut determines the amount of material removed in a single pass, affecting
material removal rate, tool life, and surface finish. Adjusting these parameters can
optimize tool life, improve surface finish, and increase productivity, but requires
consideration of workpiece material, tool material, and machine capability to achieve
optimal results.

1.1.1 Speed:
Speed always refers to the spindle and the workpiece. When it is stated in revolutions per
minute (rpm) it defines the speed of rotation. But, the important feature for a particular
turning operation is the surface speed, or the speed at which the workpiece material is
moving past the cutting tool. It is simply the product of the rotating speed times the
circumference of the workpiece before the cut is started. It is expressed in meter per
minute (m/min), and it refers only to the workpiece. Every different diameter on a
workpiece will have a different cutting speed, even though the rotating speed remains the
same.

Here, v is the cutting speed in turning in m/min,

D is the initial diameter of the workpiece in mm,
N is the spindle speed in r.p.m.

2
1.1.2 Feed:
Feed always refers to the cutting tool, and it is the rate at which the tool advances along
its cutting path. On most power-fed lathes, the feed rate is directly related to the spindle
speed and is expressed in mm (of tool advance) per revolution (of the spindle), or
mm/rev.
Fm= f x N (mm/min)
Here,
Fm is the feed in mm per minute,
f - Feed in mm/rev and
N - Spindle speed in r.p.m.

3
1.1.3 Depth of Cut:
Depth of cut is the thickness of the layer being removed from the workpiece in a single
pass, measured in millimeters (mm). It's the distance from the uncut surface to the cut
[Link] a layer is removed from both sides of the workpiece, the diameter is
reduced by twice the depth of cut. This means that if the depth of cut is x mm, the
diameter will be reduced by 2x mm.

1.2 CUTTING TOOLS FOR LATHES

1.2.1 Tool Geometry

Cutting tool geometry is crucial for effective machining, with key angles including rake
angles, end relief angles, and side relief angles. Rake angles control chip flow and impact
tool life, surface finish, and cutting forces, while relief angles prevent tool rubbing and
reduce friction.
1.3.1(a) Flank
The flank of a single-point tool refers to the flat surfaces adjacent to the cutting edge,
with the side flank facing the direction of tool feed and the end flank passing over the
newly machined surface. The flank surfaces play a crucial role in preventing tool rubbing
and reducing friction, which can impact tool life, surface finish, and cutting forces.

1.3.1(b) Face
The flat surface of a single point tool through which the workpiece rotates during turning
operation. On a typical turning setup, the face of the tool is positioned upwards.

4
 Fig 1.2: Geometry of tool

1.3.1(c) Back rake angle

If viewed from the side facing the end of the workpiece, it is the angle formed by the face
of the tool and a line parallel to the floor. A positive back rake angle tilts the tool face
back, and a negative angle tilts it forward and up

1.3.1(d)( Side rake angle

If viewed from behind the tool looking down the length of the tool holder, it is the angle
formed by the face of the tool and the centre line of the workpiece. A positive side rake
angle tilts the tool face down toward the floor, and a negative angle tilts the face up and
toward the workpiece.

1.3.1(e) Side cutting edge angle

If viewed from above looking down on the cutting tool, it is the angle formed by the side
flank of the tool and a line perpendicular to the workpiece centreline. A positive side
cutting edge angle moves the side flank into the cut, and a negative angle moves the side
flank out of the cut.

1.3.1(f) End cutting edge angle

If viewed from above looking down on the cutting tool, it is the angle formed by the end

5
flank of the tool and a line parallel to the workpiece centreline. Increasing the end cutting

6
edge angle tilts the far end of the cutting edge away from the workpiece.

1.3.1(g) Side relief angle

If viewed from behind the tool looking down the length of the tool holder, it is the angle
formed by the side flank of the tool and a vertical line down to the floor. Increasing the
side relief angle tilts the side flank away from the workpiece.

1.3.1(h) End relief angle

If viewed from the side facing the end of the workpiece, it is the angle formed by the end
flank of the tool and a vertical line down to the floor. Increasing the end relief angle tilts
the end flank away from the workpiece.

1.3.1(i) Nose radius:

It is the rounded tip on the cutting edge of a single point tool. A zero degree nose radius
creates a sharp point of the cutting tool.

1.3.1(j) Lead angle:

It is the common name for the side cutting edge angle. If a tool holder is built with
dimensions that shift the angle of an insert, the lead angle takes this change into
consideration. The back rake angle affects the ability of the tool to shear the work
material and form the chip. It can be positive or negative. Positive rake angles reduce the
cutting forces resulting in smaller deflections of the workpiece, tool holder, and machine.
If the back rake angle is too large, the strength of the tool is reduced as well as its
capacity to conduct heat. In machining hard work materials, the back rake angle must be
small, even negative for carbide and diamond tools. The higher the hardness, the smaller
will be the back rake angle. For high-speed steels, back rake angle is normally chosen in
the positive range.

1.3 CUTTING TOOL MATERIALS

The classes of cutting tool materials currently in use for machining operation are high-
speed tool steel, cobalt-base alloys, cemented carbides, ceramic, and polycrystalline cubic
boron nitride and polycrystalline diamond. Different machining applications require

7
different cutting tool materials. The Ideal cutting tool material should have all of the

8
following characteristics:

● Harder than the work it is cutting

● High temperature stability

● Resists wear and thermal shock

● Impact resistant

● Chemically inert to the work material and cutting fluid

To effectively select tools for machining, a machinist or engineer must have specific
information about:

● The starting and finished part shape

● The workpiece hardness

● The material's tensile strength

● The material's abrasiveness

● The type of chip generated

● The work holding setup

● The power and speed capacity of the machine

tool Some common cutting tool materials are described below:

1.4 TURNING MACHINES

The turning machines are, of course, every kind of lathe. Lathes used in manufacturing
can be classified as engine, turret, automatics, and numerical control etc. They are heavy
duty machine tools and have a power drive for all tool movements. They commonly range
in size from 12 to 24 inches swing and from 24 to 48 inches centre distance, but swings
up to 50 inches and centre distances up to 12 feet are not uncommon.

9
 Fig 1.3: Engine lathe

1.4.1 Turret Lathes

In a turret lathe, a longitudinally feed able, hexagon turret replaces the tailstock. The
turret, on which six tools can be mounted, can be rotated about a vertical axis to bring
each tool into operating position, and the entire unit can be moved longitudinally, either
annually or by power, to provide feed for the tools. When the turret assembly is backed
away from the spindle by means of a capstan wheel; the turret indexes automatically at
the end of its movement, thus bring each of the six tools into operating position. The
square turret on the cross slide can be rotated manually about a vertical axis to bring each
of the four tools into operating position. On most machines, the turret can be moved
transversely, either manually or by power, by means of the cross slide, and longitudinally
through power or manual operation of the carriage. In most cased, a fixed tool holder also
is added to the back end of the cross slide; this often carries a parting tool. Through these
basic features of a turret lathe, a number of tools can be set on the machine and the

10
quickly be brought successively into working position so that a complete part can be
machined without the necessity for further adjusting, changing tools, or making
measurements.

Figure 1.4: Turret lathe

1.4.2 Single-Spindle Automatic Screw Machines

There are two common types of single-spindle screw machines, One, an American
development and commonly called the turret type (Brown & Sharp), is shown in the
following figure 1.5. The other is of Swiss origin and is referred to as the Swiss type. The
Brown & Sharp screw machine is essentially a small automatic turret lathe, designed for
bar stock, with the main turret mounted on the cross slide. All motions of the turret, cross
slide, spindle, chuck, and stock-feed mechanism are controlled by cams. The turret cam is
essentially a program that defines the movement of the turret during a cycle. These
machines usually are equipped with an automatic rod feeding magazine that feeds a new
length of bar stock into the collect as soon as one rod is completely used

11
 Fig 1.5: Single spindle automatic screw lathe

this speckle image can be related to the surface characteristics. The degree of correlation
of two speckle patterns produced from the same surface by two different illumination
beams can be used as a roughness parameter. Monochromatic plane wave with an angle
of incidence with respect to the normal to the surface; multi-scattering and shadowing
effects are neglected. The photo-sensor of a CCD camera placed in the focal plane of a
Fourier lens is used for recording speckle patterns. Assuming Cartesian coordinates x,y,z,
a rough surface can be represented by its ordinates Z (x,y) with respect to an arbitrary
datum plane having transverse coordinates (x,y,z). Then the rms value of surface
roughness can be defined and calculated roughness values.
a. Inductance method: An inductance pickup is used to measure the distance between the
surface and the pickup. This measurement gives a parametric value that may be used to
give a comparative roughness. However, this method is limited to measuring magnetic
materials.
b. Ultrasound: A spherically focused ultrasonic sensor is positioned with a non normal
incidence angle above the surface. The sensor sends out an ultrasonic pulse to the
personal computer for analysis and calculation of roughness parameters

12
1.5 Turning dynamometer
A machine tool dynamometer is a multi-component dynamometer that is used to measure
forces during the use of the machine tool. Empirical calculations of these forces can be
cross-checked and verified experimentally using these machine tool dynamometers

Fig 1.6: Turning Dynamometer

With advances in technology, machine-tool dynamometers are increasingly used for the
accurate measurement of forces and for optimizing the machining process. These multi-
component forces are measured as an individual component force in each co-ordinate,
depending on the coordinate system used. The forces during machining are dependent on
depth of cut, feed rate, cutting speed, tool material and geometry, material of the
workpiece and other factors such as use of lubrication/cooling during machining.
Turning dynamometers may be strain gauge or piezoelectric type and may be of one, two
or three dimensions capable of monitoring all of PX, PY and PZ. For ease of manufacture
and low cost, strain gauge type turning dynamometers are widely used and preferably of 2
– D (dimension) for simpler construction, lower cost and ability to provide almost all the
desired force values.

1.6 INTRODUCTION TO MINITAB

Minitab is a statistics package. It was developed at the Pennsylvania State University by

researchers Barbara F. Ryan, Thomas A. Ryan, Jr., and Brian L. Joiner in 1972. Minitab

13
began as a light version of OMNITAB, a statistical analysis program by NIST. It can be
used for learning about statistics as well as statistical research. Statistical analysis
computer applications have the advantage of being accurate, reliable, and generally faster
than computing statistics and drawing graphs by hand. Minitab is relatively easy to use
once you know a few fundamentals.

Minitab is distributed by Minitab Inc, a privately owned company headquartered in State

14
College, Pennsylvania, with subsidiaries in Coventry, England(Minitab Ltd.), Paris, France
(Minitab SARL) and Sydney, Australia (Minitab Pty.). Today, Minitab is often used in
conjunction with the implementation of six sigma,CMMI and other statistics-based process
improvement methods. Minitab 16, the latest version of the software, is available in 7
languages: English, French, German, Japanese, Korean, Simplified Chinese, & Spanish.

Minitab is statistical analysis software. It can be used for learning about statistics as well
as statistical research. Statistical analysis computer applications have the advantage of
being accurate, reliable, and generally faster than computing statistics and drawing graphs
by hand. Minitab is relatively easy to use once you know a few fundamentals.

Minitab Inc. produces two other products that complement Minitab 16: Quality Trainer,
an eLearning package that teaches statistical tools and concepts in the context of quality
improvement that integrates with Minitab 16 to simultaneously develop the user's
statistical knowledge and ability to use the Minitab software and Quality Companion 3,
an integrated tool for managing Six Sigma and Lean Manufacturing projects that allows
Minitab data to be combined with management and governance tools and documents.

Minitab has two main types of files, projects and worksheets. Worksheets are files that
are made up of data; think of a spreadsheet containing variables of data. Projects are made
up of the commands, graphs and worksheets. Every time you save a Minitab project you
will be saving graphs, worksheets and commands. However each one of the elements can
be saved individually for use in other documents or Minitab projects. Likewise you can
print projects and its elements.

1.6.1 Minitab Project and Worksheets

Minitab has two main types of files, projects and worksheets. Worksheets are files that
are made up of data; think of a spreadsheet containing variables of data. Projects are made
up of the commands, graphs and worksheets. Every time you save a Minitab project you
will be saving graphs, worksheets and commands. However each one of the elements can
be saved individually for use in other documents or Minitab projects. Likewise you can
print projects and its elements.

The Menu bar: You can open menus and choose commands. Here you can find the built-

15
in routines.

The Toolbar: Shortcuts to some Minitab commands.

16
1.6.2 Two windows in MINITAB

1. Session Window: The area that displays the statistical results of your data analysis and
can also be used to enter commands.
2. Worksheet Window: A grid of rows and columns used to enter and manipulate the
data. Note: This area looks like a spreadsheet but will not automatically update the
columns when entries are changed.

Other windows include

● Graph Window: When you generate graphs, each graph is opened in its own

window.

● Report Window: Version 13 has a report manager that helps you organize your

results in a report.

● Other Windows: History and Project Manager are other windows. See Minitab

help for more information on these if needed

Fig 1.7: Environment in Minitab Software

17
 CHAPTER 2
LITERATURE REVIEW

S.N. Kulko [Link]. The structure and phase composition of zirconia-based nanosystems are
studied. It is shown that during mechanical activation such a nanosystem is divided into
two subsystems with the average size of structural elements differing by two orders of
magnitude. The fraction of the quasi-amorphous (X-ray amorphous) phase therewith
increases. Through varying the heating rate of this nanosystem in sintering we may
purposefully vary its shrinkage at the stage of isothermal sintering. The ceramic matrix is
made up of linear grain chains with high bond strength at grain boundaries; in so doing,
along with strictly linear elasticity the matrix exhibits micromechanical instability under
deformation. In this case, the attainable strain and ultimate stress of ceramics produced
from nanocrystalline powders greatly exceed the values for coarse-grained ceramics with
similar parameters of the porous structure.

Faqin Xie [Link]. reviewed PEO composite coatings doped with ZrO2 and MoS2 particles
were prepared on the surface of TC21 alloy using the PEO process. The morphologies and
phase compositions of the coatings were analyzed using FE-SEM, TEM, XRD refinement
and XPS. The tribological and self-lubricating properties of the coatings were investigated
through fretting wear experiments. The results indicate co-doping reduced the friction
coefficient by approximately 30 %. The co-doped coating demonstrated higher
crystallinity, whereas the ZrO2 coating contained a significant amount of amorphous
material. The wear mechanisms of the coating included three-body abrasive, adhesive, and
oxidative wear. The self-lubricating properties of the coating were derived from the
presence of MoS₂ and the destruction and deformation of the coating surface during
fretting wear.

Avinash Borgaonkar [Link]. investigated Molybdenum disulfide (MoS2) is popularly used in

tribological applications because of its excellent lubricating properties. However, its
performance needs to be further improved. In the present study, an attempt has been made
to improve the wear resistance of pure MoS2 coating by incorporating TiO2 and ZrO2
nanoparticles as a reinforcement material into the MoS2 base matrix. The composite

18
MoS2-TiO2-ZrO2 coating was applied onto the substrate surface by the bonding
technique. The tribological performance of the coated specimens was evaluated by
employing various operating conditions (such as wt% of compounding elements, contact
pressure, and sliding speed) using pin-on-disc friction and wear test rig. A statistical model
was developed to identify the significant factors affecting the friction coefficient (COF)
and wear-rate of the composite coating material. The design of experiment (DOE) was
formulated by response surface methodology (RSM) approach to cut down the number of
experiments and to develop a mathematical model between the key process parameters
such as wt% of compounding elements, contact pressures, and sliding speeds. Analysis of
variance (ANOVA) was executed for checking the adequacy of the empirical models
developed. It was discovered that the COF and wear-rate of composite MoS 2-TiO2-ZrO2
coating significantly affected by the wt% addition of ZrO 2. The SEM and optical
microscopy analyses of the worn surfaces and transfer films indicated that the tribological
properties of composite MoS2-TiO2-ZrO2 coating were significantly improved compared
to pure MoS2 coating.

Leonardo R. SILVA [Link]. investigated The purpose of this study is to investigate the
influence of cutting speed on cutting forces and surface roughness when dry precision
turning AISI 1045 steel using uncoated and coated cemented carbide tools. The results
indicated that, in general, the turning force components tend to decrease or remain
practically stable as cutting speed increases. The specific cutting force presents a similar
behaviour as long as feed rate is kept unaltered. The surface roughness produced by the
two cutting tools was significantly affected by cutting speed within the range tested.

A. H. Boussabaine [Link]. researched construction managers are interested in the direction

of movement of cash flow at valuation periods rather than its forecast value, and fuzzy set
theory applied to decision making might help in this process. Fuzzy models are
particularly suited to making decisions involving new technologies where uncertainties
inherent in the situation are complex. The problem of healthy cash flow at valuation
periods relates to the proper estimation of cash in and out flows and project progress. The
paper presents an alternative approach to cash flow analysis for construction projects. This
project is based on the assumption that cash flow at particular valuation stages of a project

19
is ambiguous. The paper discusses the weaknesses of existing methods for cash flow and
establishes the need for an alternative approach. Using an example of 30 cash flow curves,
the advantage of fuzzy cash flow analysis is demonstrated. Results of the analysis are
presented and discussed. The model can be used to analyse the cash flow curve of projects
at any progress period to make sure it is reasonable.

Raviraj Shetty [Link] reviewed This paper discusses the use of Taguchi and response
surface methodologies for minimizing the surface roughness in turning of discontinuously
reinforced aluminum composites (DRACs) having aluminum alloy 6061 as the matrix and
containing 15 vol. % of silicon carbide particles of mean diameter 25µm under pressured
steam jet approach. The measured results were then collected and analyzed with the help
of the commercial software package MINITAB15. A second-order model has been
established between the cutting parameters and surface roughness using response surface
methodology. The experimental results reveal that the most significant machining
parameter for surface roughness is steam pressure followed by feed. The predicted values
and measured values are fairly close, which indicates that the developed model can be
effectively used to predict the surface roughness in the machining of DRAC

S.K Choudhury [Link]. investigated Optimum use of the cutting tool is a growing need in
modern industries since the cost of production is directly affected by this. This paper
presents a new approach for improving the cutting tool life by using optimal values of
velocity and feed throughout the cutting process. A tool life equation has been established
from experimental data and the adhesion wear model. Optimization techniques have been
used to maximize the tool life subject to practical constraints while maintaining a constant
metal removal rate. The experimental results showed an improvement in tool life by 30%.

Raviraj Shetty [Link]. researched This paper reports on the experimental investigations
carried out under dry, oil water emulsion and steam lubricated conditions in turning of
DRACs. The measured results were then collected and analyzed with the help of the
commercial software package MINITAB15. The experiments were planned on orthogonal
arrays, made with prefixed cutting parameters and different lubricated conditions. An
analysis of variance (ANOVA) was carried out to check the validity of the proposed

20
parameters and also their percentage contributions. The results of the tests show that with
proper selection of the range of cutting parameters, it is possible to obtain better
performance under steam lubricated condition.

21
 CHAPTER 3

DESIGN OF EXPERIMENTS
3.1 Design of Experiments (DOE) Overview

In industry, designed experiments can be used to systematically investigate the process or

product variables that influence product quality. After identifying the process conditions
and product components that influence product quality, direct improvement efforts
enhance a product’s manufacturability, reliability, quality, and field performance. As the
resources are limited, it is very important to get the most information from each
experiment performed. Well designed experiments can produce significantly more
information and often require fewer runs than haphazard or unplanned experiments. A
well-designed experiment identifies the effects that are important. If there is an
interaction between two input variables
They should be included in design rather than doing a "one factor at a time" experiment.
An interaction occurs when the effect of one input variable is influenced by the level of
another input variable.
Designed experiments are often carried out in four phases: planning, screening (also
called process characterization), optimization, and verification.

3.1.1 Planning
Careful planning helps in avoiding the problems that can occur during the execution of
the experimental plan. For example, personnel, equipment availability, funding, and the
mechanical aspects of a system may affect the ability to complete the experiment. The
preparation required before beginning experimentation depends on the problem. Here are
some steps need to go through:
• Define the problem. Developing a good problem statement helps in studying the right
variables.
• Define the objective. A well-defined objective will ensure that the experiment answers
the right questions and yields practical, usable information. At this step, define the goals
of the experiment.
• Develop an experimental plan that will provide meaningful information. Review
relevant background information, such as theoretical principles, and knowledge gained

22
through observation or previous experimentation.

23
• Make sure the process and measurement systems are in control. Ideally, both the
process and the measurements should be in statistical control as measured by a
functioning statistical process control (SPC) system. Minitab provides numerous tools to
evaluate process control and analyze your measurement system.

3.1.2 Screening
In many process development and manufacturing applications, potentially influential
variables are numerous. Screening reduces the number of variables by identifying the key
variables that affect product quality. This reduction allows focusing process improvement
efforts on the really important variables. Screening suggests the “best" optimal settings
for these factors.
The following methods are often used for screening:
• Two-level full and fractional factorial designs are used extensively in industry

• Plackett-Burman designs have low resolution, but they are useful in some screening
experimentation and robustness testing.

• General full factorial designs (designs with more than two-levels) may also be useful for
small screening experiments.

3.1.3 Optimization
After identifying the vital variables by screening, there is need to determine the "best" or
optimal values for these experimental factors. Optimal factor values depend on the
process objective.
The optimization methods available in Minitab include general full factorial designs
(designs with more than two-levels), response surface designs, mixture designs, and
Taguchi designs.
• Factorial Designs Overview describes methods for designing and analyzing general full
factorial designs.
• Response Surface Designs Overview describes methods for designing and analyzing
central composite and Box-Behnken designs.
• Mixture Designs Overview describes methods for designing and analyzing simplex
centroid, simplex lattice, and extreme vertices designs. Mixture designs are a special class
of response surface designs where the proportions of the components (factors), rather than

24
their magnitude, are important.

25
• Response Optimization describes methods for optimizing multiple responses. Minitab
provides numerical optimization, an interactive graph, and an overlaid contour plot to
help to determine the "best" settings to simultaneously optimize multiple responses.
• Taguchi Designs Overview describes methods for analyzing Taguchi designs. Taguchi
designs may also be called orthogonal array designs, robust designs, or inner-outer array
designs. These designs are used for creating products that are robust to conditions in their
expected operating environment.

3.1.4 Verification
Verification involves performing a follow-up experiment at the predicted "best"
processing conditions to confirm the optimization results.

3.2 Advantages & Disadvantages of DOE

DOE became a more widely used modelling technique superseding its predecessor one-
factor-at- time (OFAT) technique. One of the main advantages of DOE is that it shows
the relationship between parameters and responses. In other words, DOE shows the
interaction between variables which in turn allows us to focus on controlling important
parameters to obtain the best responses. DOE also can provide us with the most optimal
setting of parametric values to find the best possible output characteristics. Besides from
that, the mathematical model generated can be used as a prediction model which can
predict the possible output response based on the input values. Another main reason DOE
is used is because it saves time and cost in terms of experimentation. DOE functions in
such a manner that the number of experiments or the number of runs is determined before
the actual experimentation is done. This way, time and cost can be saved as we do not
have to repeat unnecessary experiment runs. Most usually, experiments will have error
occurring. Some of them might be predictable while some errors are just out of control.
DOE allows us to handle these errors while still continuing with the analysis. DOE is
excellent when it comes to prediction linear behaviour. However, when it comes to
nonlinear behaviour, DOE does not always give the best results.

3.3 Taguchi Method

The Taguchi Method is a statistical approach to quality improvement that focuses on

26
designing robust systems and processes to minimize variation and optimize performance.
Developed by Dr. Genichi Taguchi, it uses a special design of experiments (DOE) technique
with orthogonal arrays to systematically study the effects of multiple variables with a reduced
number of experiments. Central to the method is the use of signal-to-noise (S/N) ratios to
identify settings that improve consistency and quality, making products or processes less
sensitive to uncontrollable factors (noise). This method is widely used in engineering,
manufacturing, and product design.

3.3.1 Advantages and Disadvantages of Taguchi Method

The Taguchi Method offers several advantages, including reduced experimental effort through
the use of orthogonal arrays, making it cost-effective and efficient for optimizing complex
processes. It enhances product quality by focusing on robustness—minimizing the effect of
uncontrollable variations—while the use of signal-to-noise ratios helps identify optimal
settings for consistent performance. However, the method also has limitations. It may
oversimplify complex interactions between factors, and its emphasis on additive models
might not accurately capture nonlinear relationships. Additionally, interpreting results can be
challenging without proper statistical knowledge, and it may not be ideal for all types of
experimental designs.

3.4 Introduction about Matlab

MATLAB (Matrix Laboratory) is a high-level programming language and environment

specifically designed for numerical computation and data analysis. Developed by
MathWorks, MATLAB is widely used in various fields, including engineering, physics,
signal processing, and data science.

3.4.1 Key Features of MATLAB

1. Matrix operations: MATLAB is optimized for matrix operations, making it ideal for
linear algebra and numerical computations.

2. High-level programming language: MATLAB's syntax is easy to learn and use,

allowing users to focus on problem-solving rather than programming details.

3. Built-in functions: MATLAB has an extensive library of built-in functions for various

27
tasks, including data analysis, visualization, and machine learning.

4. Visualization tools: MATLAB provides a range of visualization tools, including plots,

charts, and graphs, to help users understand and communicate complex data insights.

5. Interoperability: MATLAB can integrate with other programming languages, such as

C, C++, Java, and Python, and can also interface with external hardware and software.

3.4.2 Applications of MATLAB

1. Numerical analysis: MATLAB is widely used for numerical analysis, including linear
algebra, optimization, and signal processing.

2. Data analysis and visualization: MATLAB's data analysis and visualization

capabilities make it an ideal tool for data scientists and analysts.

3. Machine learning and deep learning: MATLAB provides a range of machine

learning and deep learning tools, including neural networks and support vector machines.

4. Control systems: MATLAB is used in control systems engineering to design, analyze,

and simulate control systems.

5. Image and video processing: MATLAB's image and video processing capabilities
make it a popular choice for applications such as computer vision and image analysis.

3.4.3 Advantages of MATLAB

1. Ease of use: MATLAB's syntax and built-in functions make it easy to learn and use,
even for users without extensive programming experience.

2. High-performance computing: MATLAB's optimized matrix operations and built-in

functions enable fast and efficient computations.

3. Extensive community: MATLAB has a large and active community, providing access
to a wealth of resources, including tutorials, documentation, and user-contributed code.

3.4.4 Disadvantages of MATLAB

1. Cost : MATLAB can be expensive, especially for individual users or small

organizations.
2. Steep Learning Curve : MATLAB has a unique syntax and programming paradigm,

28
 which can be challenging for beginners to learn.

3. Limited Support for Certain Data Types : MATLAB is primarily designed for
numerical computations and may not be the best choice for working with certain data
types, such as text or categorical data.

4. Interpreted Language : MATLAB is an interpreted language, which can result in

slower execution times compared to compiled languages.

3.5 Fuzzy Logic Technique

The fuzzy logic technique is a computational approach based on "degrees of truth" rather than
the conventional binary logic (true or false, 0 or 1). Originally introduced by Lotfi A. Zadeh
in 1965, fuzzy logic enables reasoning with uncertain, imprecise, or vague information ,
characteristics often encountered in real-world engineering systems.

In mechanical engineering, fuzzy logic is particularly valuable for systems that are complex,
nonlinear, or difficult to model mathematically. It allows the development of intelligent
control strategies that can handle a wide range of operating conditions without requiring
precise mathematical models.

3.5.1 Applications in Mechanical Engineering

1. Fuzzy logic has been successfully applied in various mechanical engineering domains,
including but not limited to:
2. Automated HVAC systems for maintaining optimal temperature and humidity levels.
3. Intelligent robotics for adaptive navigation and control.
4. Condition monitoring and fault diagnosis in rotating machinery.
5. CNC machine tool control for precision and adaptive operations.

3.5.2 Advantages of the Fuzzy Logic Technique

The adoption of fuzzy logic in mechanical engineering systems offers a range of significant

29
benefits, particularly in handling complexity, uncertainty, and nonlinear behavior. The key
advantages are as follows:

1. Robustness to Uncertainty : Fuzzy logic provides effective solutions in situations

where system inputs are imprecise, noisy, or uncertain. It mimics human reasoning by
allowing partial truths, making it highly adaptable to real-world conditions.
2. No Requirement for Accurate Mathematical Models : Unlike traditional control
methods that depend on precise mathematical modeling, fuzzy logic systems can be
designed based on heuristic knowledge and expert experience, reducing the
complexity of system analysis and development.
3. Improved System Flexibility : Fuzzy logic controllers can easily accommodate
changes in system behavior and operating conditions without requiring major
redesign, offering high adaptability in dynamic environments.
4. Ease of Implementation : Fuzzy systems are relatively simple to implement and
interpret, especially when expert knowledge is available. Rule-based logic can be
developed and fine-tuned with minimal computational effort.
5. Enhanced Control in Nonlinear Systems : Many mechanical systems exhibit
nonlinear characteristics. Fuzzy logic is particularly well-suited for such systems,
where conventional linear control strategies may not be effective or feasible.
6. Human-like Decision Making : Fuzzy logic mimics the decision-making process of
humans, enabling more intuitive and intelligent system responses. This is especially
valuable in systems requiring autonomous control or real-time adjustments.
7. Cost-Effective Solution: Due to its simplicity and reduced dependency on complex
mathematical formulations, fuzzy logic can be a cost-effective control strategy in both
design and implementation phases.

3.6 Design of Experiments

3.6.1 Creating Taguchi Design

If any factor has more than two levels, use Minitab's general complete
factorial design option. Using this, designs with up to 15 variables may be produced. There
must be at least two levels for each element, but no more than 100 levels.

30
 Fig 3.1 Creating a Taguchi Design in Minitab

Fig 3.2: Selection of Factors & Levels

1. From the Number of factors, choose a number from 3.

2. Select the 3-level Design (2 to 13 Factors).

3. Now Click on Display Available Options.

4. Selection of Available Taguchi Designs in Minitab

31
 Fig 3.3: Selection of Available Taguchi Designs in Minitab

5. A window will appear showing all the available Taguchi Designs (with number of Factors)

6. Now Select 2-4 Design with 3 level L9 Orthogonal Array and Click OK.

Fig 3.4: Selection of Taguchi Design in Minitab

7. Now Click Designs and select L9 3 ^ 3, and click on OK.

32
 Fig 3.5 Taguchi Design: Factors in Minitab Figure

8. Now Click Factors and a new window will appear showing the factors and their level
values.

9. Double click on the Cells to edit and change the factors i.e., Factors A, B, C to Cutting
Speed, Feed, Depth of Cut.

10. Now double click on the Level Values cells to change the values and change cutting
speed values to 75, 150, 225, Feed to 0.5,1.0,1.5 Depth of cut to 0.5,1.0,1.5. Now click
OK

Fig 3.8: Interface of the Minitab After Inputting the Values

33
 3.7 Input Cutting Parameters of Tungsten Carbide

[Link]. Speed Feed DOC

1 75 0.5 0.5
2 75 1 1
3 75 1.5 1.5
4 150 0.5 1
5 150 1 1.5
6 150 1.5 0.5
7 225 0.5 1.5
8 225 1 0.5
9 225 1.5 1
T able
3.1: Input Cutting Parameters of Tungsten Carbide

34
3.8 Input Cutting Parameters of ZrO2 - MoS2 composite cutting tool

Sno speed feed d.o.c

1 75 0.5 0.5
2 75 1 1
3 75 1.5 1.5
4 150 0.5 1
5 150 1 1.5
6 150 1.5 0.5
7 225 0.5 1.5
8 225 1 0.5
9 225 1.5 1

Table 3.2: Input Cutting Parameters of ZrO2 - MoS2 composite cutting tool

35
 CHAPTER 4

EXPERIMENTAL SETUP AND MACHINING

The project was done in 3 stages.

● Design of experiments was done using a full factorial method.

● Cycle time was calculated by machining the workpiece on lathe machine

● Analysis of results was done using MINITAB 17.1.30.

4.1 Selection of process variables

● A total of three process variables and 3 levels are selected for the experimental

procedure.

● The deciding process variables are

▪ Speed

▪ Feed

▪ Depth of cut

● Speed of the spindle, i.e. the speed at which the spindle rotates the tool.

● Feed is the rate at which the material is removed from the workpiece.

● Depth of cut is the depth up to which the tool emerges in one cycle.

4.2 Selection of levels:

● Since it is a three level design by observing the parameters taken in various

projects the levels of the factors are designed as follows

FACTORS LEVEL1 LEVEL LEVEL3

2

36
 [Link](RPM) 75 175 225
FEED(MM/ 0.5 1 1.5
REV)
D.O.C(MM) 0.5 1 1.5

Table 4.1: Selection of process variables

4.3 Design of Experiments

● Design of experiments was done using a full factorial method.

● Design of experiments (DOE) or experimental design is the design of any

information-gathering exercises where variation is present, whether under the

full control of the experimenter or not.

4.4 Selection of material

By studying various projects Hardened steel material is selected for machining operation.
The composition of Hardened steel material is:

● Zirconium Oxide(ZrO2) – 90%

● Molybdenum Disulphide(MoS2) - 10%

The dimensions of the workpiece used are length 200mm*30 dia

4.5 Ball Milling of ZrO₂–MoS₂ Composite Powder (90:10 Ratio)

Introduction:

Ball milling is a widely used powder processing technique to achieve fine, homogeneous

37
mixtures. It involves the use of a rotating container filled with milling media (e.g., ceramic or
steel balls) and the target materials. The repeated collision and shearing forces promote
particle refinement and uniform distribution.

Materials and Composition:

● Zirconium Dioxide (ZrO₂) – 90 wt.%

(Provides high hardness, thermal stability, and wear resistance)

● Molybdenum Disulfide (MoS₂) – 10 wt.%

(Acts as a solid lubricant, reducing friction during cutting operations)

Method:

1. Powders of ZrO₂ and MoS₂ were weighed accurately in the 90:10 ratio.
2. The powders were loaded into a planetary ball mill along with ceramic balls as the
milling media.
3. Milling parameters:

○ Speed: 250 rpm

○ Duration: 8 hours

○ Ball-to-powder weight ratio (BPR): ~10:1

○ Dry milling or milling under inert gas (optional for MoS₂ to prevent oxidation)

4. After milling, the mixture was collected, sieved if necessary, and used for
compaction/sintering.

38
 Fig 4.1 : Ball - milling machine

Outcome:

● A uniform and fine composite powder.

● Even dispersion of MoS₂ within the ZrO₂ matrix.
● Enhanced material performance for cutting tool applications.

Fig 4.2 : Powder obtained after ball milling

4.6 Compaction of ZrO₂–MoS₂ Powder

After ball milling, the homogeneously mixed ZrO₂–MoS₂ powder (in a 90:10 weight ratio)
was subjected to uniaxial compaction to form a solid pre-sintered structure known as a green
body.

39
The powder was placed into a steel die designed according to the required shape and
dimensions of the cutting tool. A hydraulic press was used to apply a pressure of 200 MPa
uniformly across the powder. The pressure was maintained for a short duration (typically 30–
60 seconds) to ensure proper packing of particles. No binder was used, relying purely on
mechanical interlocking under pressure. The compacted body (green body) was carefully
removed from the die to avoid cracking or deformation.

Fig 4.2 : Compacting the mixture of ZrO₂–MoS₂ Powder

Purpose:

To reduce porosity and increase contact between powder particles, as well as to

provide sufficient strength for handling and transfer to the sintering furnace, the
compacted green body was formed. This process also aimed to achieve better
densification during the subsequent sintering stage. At this point, the green body
remained fragile but successfully retained a shape and dimensions close to the final
[Link] of ZrO₂–MoS₂ Composite

After compaction, the green body (pressed powder) undergoes sintering—a high-temperature
heat treatment that enhances the material's density, strength, and structural integrity.

4.7 Sintering Process:

40
The compacted green body was placed in a high-temperature furnace. The furnace was
gradually heated to a temperature of 1200°C at a controlled heating rate (e.g., 5–10°C/min) to
avoid thermal shock or cracking. The sintering temperature of 1200°C was maintained for a
specific duration (typically 1–2 hours) to allow sufficient particle bonding and densification.
To prevent oxidation of MoS₂, sintering was carried out in a controlled atmosphere such as:
Inert gas (e.g., argon) Or vacuum environmentAfter sintering, the furnace was allowed to cool
down slowly to room temperature.

Fig 4.3 : Compacted powder is kept in a mold for sintering

What Happens During Sintering:

The individual powder particles, especially ZrO₂, diffuse and bond at contact points, forming
necks and reducing porosity. MoS₂ remains dispersed in the matrix, preserving its solid
lubricating property. The material transforms from a loosely packed powder to a dense, solid
body that behaves as a single cohesive component.

41
 Fig 4.4 : Sintering machine

Result:

Improved mechanical strength, dimensional stability, and wear resistance. Formation of a

durable composite cutting tool material with a balance of hardness and lubrication.

4.8 Shaping of the Cutting Tool

After sintering, the ZrO₂–MoS₂ composite was precisely ground to achieve the final cutting
tool geometry. These specific angles and dimensions were carefully selected to optimize
cutting performance, tool life, and surface finish.

Fig 4.5 : Shaped cutting tool

4.9 Cutting Tool Geometry and Rationale

42
 Parameter Value Reason for Selection

Back Rake Angle -6° Negative rake improves edge strength and is ideal for
brittle ceramic tools.

Side Rake Angle -6° Enhances rigidity, reduces chipping in hard materials.

End Relief Angle 7° Prevents tool rubbing on the workpiece; ensures clearance
behind the cutting edge.

Side Relief Angle 7° Allows the tool to cut without interference or drag;
supports chip flow.

End Cutting Edge 12° Reduces cutting forces and distributes load over a wider
Angle area.

Side Cutting Edge 12° Helps direct chips away from the workpiece and improves
Angle heat dissipation.

Nose Radius 0.6 Small enough to reduce cutting resistance; large enough
mm to improve surface finish.

Table 4.2 : Cutting Tool Geometry and Rationale

These parameters are well-suited for ceramic-based tools like ZrO₂–

MoS₂ composites, which are hard and wear-resistant but can be brittle. Negative rake angles
enhance edge durability, while relief angles reduce friction and allow smoother machining.

43
The chosen nose radius provides a balance between sharpness and surface quality, minimizing
tool marks on the finished product. This combination of geometry ensures high wear
resistance, improved heat management, reduced tool chipping, and a better finish on the
machined surface.

4.10 Tool Signature and Post-Shaping Processes

Code Meaning

S
Insert shape: Square (four usable cutting edges)

U
Clearance angle: 7° (commonly used for general turning operations)

M
Tolerance class: Universal (general-purpose tolerance)

N
Type of cutting edge: Single-sided insert with no chipbreaker

12
Insert size: 12 mm inscribed circle

04
Insert thickness: 4 mm

06
Nose radius: 0.6 mm

Table 4.3 : Tool Signature and Post-Shaping Processes

4.11 Tool Signature: SMUN 120406

The tool used for cutting was designated as SMUN 120406, which follows the ISO insert
designation system. Each part of this code provides specific information about the insert's
shape, clearance, tolerance, and other characteristics:This insert is well-suited for medium-

44
duty turning applications, providing a good balance between strength and cutting
performance, especially when combined with the ZrO₂–MoS₂ composite body.

Post-Shaping Processes

After the primary shaping to define cutting angles, grinding and clipping were performed for
fine adjustments and to meet dimensional tolerances.

1. Grinding

To achieve high dimensional accuracy and a smooth surface finish on the cutting edges. A
precision grinding wheel was used to refine the tool geometry, sharpen the cutting edges, and
remove surface irregularities from the sintered body. Ensures uniform contact with the
workpiece, reduces tool wear, and enhances cutting performance by improving edge quality.

2. Clipping

To smooth or slightly chamfer sharp edges or corners of the tool to prevent edge chipping
during machining. Small sections of the edge or corners were clipped (beveled) using a
grinding or chamfering tool. Improves tool strength, reduces chances of brittle fracture, and
contributes to better tool life especially important for ceramic-based tools like ZrO₂–MoS₂.

4.12 Vickers Hardness Test

The Vickers Hardness Test is a widely recognized method for determining the hardness of
materials by assessing their resistance to plastic deformation. Developed in 1921 by Smith
and Sandland at Vickers Ltd., this test is particularly useful due to its accuracy and
applicability to a wide range of materials, including metals, alloys, ceramics, and even thin
sections or coatings.

The test involves pressing a diamond-shaped indenter, designed as a square-based pyramid

with an angle of 136° between opposite faces, into the surface of the material under a specific
load. The load is maintained for a standard duration, typically between 10 to 15 seconds.
Once the load is removed, the diagonals of the resulting square-shaped indentation are
measured using a high-precision microscope.

45
 Fig 4.6 :Vickers Hardness Testing Machine

Test Procedure:

A diamond pyramid indenter with an angle of 136° between opposite faces is pressed into the
material's surface using a specific force. The load applied is measured in kilograms or grams
(in this case, 200 grams or 2 N). After the load is removed, the diagonal lengths of the
indentation are measured with a microscope. The Vickers hardness number (HV) is then
calculated using the formula.

HV=2F⋅sin⁡(θ/2)d2HV = \frac{2F \cdot \sin(\theta / 2)}

{d^2}HV=d22F⋅sin(θ/2)

Where:

F = applied force (in newtons)

d = average diagonal length of the indentation (in millimeters)

θ = 136° (angle of the diamond indenter)

The Vickers Hardness Number (VHN or HV) is then calculated using the formula:

HV=1.854×Fd2\text{HV} = \frac{1.854 \times F}{d^2}HV=d21.854×F

46
Where:

● HV = Vickers Hardness Number

● F = Applied load in kilograms-force (kgf) as 2N and mass of 200gm.
● d = Average length of the two diagonals of the indentation in millimeters (mm)

One of the key advantages of the Vickers Hardness Test is that it employs a single scale for
all types of materials and loads, which simplifies comparison and reporting. The test is highly
accurate and is especially valuable for microhardness testing of small components, thin films,
and surface-hardened layers. However, it requires careful surface preparation and precise
measurement of the indentation, which can be time-consuming compared to other hardness
tests.

In mechanical engineering, the Vickers Hardness Test is extensively used in material

selection, quality control, failure analysis, and evaluation of surface treatments such as heat
treatment, nitriding, or coating processes. Its precision and versatility make it an essential tool
in both industrial and research applications.

4.13 Clamping of the workpiece

The workpiece is clamped to the machine by using standard 3 jaw chuck.

Fig 4.7: Clamping of the workpiece

The tool used for turning is High Speed Steel. Initially these tools are fixed in the tool turret
using a tool holding fixture.

47
4.14 COEFFICIENT OF FRICTION

COF(coefficient of friction) = Tan( α + tan^-1 (Fy/Fz))

Fx = Axial force
Fy = Radial Force
Fz = Tangential Force
These forces are calculated by the Dynamometer machine.
α is Back rack angle

4.15 SAMPLE CALCULATION

Fy = Radial Force = 110N

Fz = Tangential Force = 165N
α = Back rake angle = -6

COF = Tan( -6 + tan^(-1)(100/165))

COF = Tan(-6 + 0.5880026)
COF = 1.18818581

48
 CHAPTER 5
RESULTS AND ANALYSIS

5.1 MATLAB
In this Matlab we apply Fuzzy Technique and enter the matter/table in the following steps
for both Tungsten Carbide And ZrO2-MoS2.

Fig 5.1 Fig 5.1.1

49
 Fig 5.1.2

Step 1 : Enter Fuzzy in the command of the Matlab and the Add variables on input side and
output side required no.
Step 2 : Now open the Membership function Editor and enter the values of the required
function of the input and output variables including ranges and the L M H ranges.
Step 3 : Go to the rules editor and mention the rules for the

Tungsten Carbide Results in MATLAB

Fig 5.2 Surface and Rule in Axial Force for Tungsten Carbide

Fig 5.3 Surface and Rule in Radial Force for Tungsten Carbide

50
Fig 5.4 Surface and Rule in Axial Force in Tungsten Carbide

51
Fig 5.5 Surface and Rule in Surface Roughness in Tungsten Carbide

ZrO2-MoS2 Results in MATLAB

Fig 5.6 Surface and Rule in Axial Force for ZrO2-MoS2

Fig 5.7 Surface and Rule in Radial Force for ZrO2-MoS2

52
 Fig 5.8: Surface and Rule in Main Force for ZrO2-MoS2

Fig 5.9 Surface and Rule in Surface Roughness for ZrO2-MoS2

53
 Fig 5.10 Surface and Rule in COF for ZrO2-MoS2

These are the Surface viewers and Rules viewers we get in the MATLAB of the
Tungsten Carbide and ZrO2-MoS2 at various parameters based on the inputs and output
which gives us better visualization and get any parameter results based on the rules
with we provide to

5.2 Design of experiments (DOE) using MINITAB

Design of experiments (DOE) is a methodology for studying any response that varies as a
function of one or more independent variables or knobs. By observing the response under
a planned matrix of knob settings, a statistically valid mathematical model for the
response can be determined. The resulting model can be used for a variety of purposes: to
select optimum levels for the knobs; to focus attention on the crucial knobs and eliminate
the distractions caused by minor or insignificant knobs; to provide predictions for the
response under a variety of knob settings; to identify and reduce the response’s sensitivity
to troublesome knobs and interactions between knobs; and so on. Clearly, DOE is an
essential tool for studying complex systems and it is the only rigorous replacement for the

54
inferior but unfortunately still common practice of studying one variable at a time
(OVAT).

55
5.3 Analysis of variance using Taguchi Method

Step 1: Open the project file with the factors that are filled during the design of the
experiment process.

Fig 5.11.1
Step 2: Now open the Start ribbon > DOE > Taguchi > Analyze Taguchi Design...

Fig 5.11.2

56
Step 3: Now select Fx(Axial) (N) , Fy(Radial)(N) , Fz(Main)(N) , COF and Surface
Roughness and click on select.

57
 Fig 5.11.3
Step 4: Now select on the Options and select the Signal to Noise Ratio to Smaller is Better
and click OK.

Fig 5.11.4
Step 5: Now select on the Storage and select the Signal to Noise Ratios, Means,Standard
deviations, Fits, Residuals and click on OK.

58
Step 6: Now select on the Analysis of Graphs and select Four in one click on OK.

CHAPTER-6
RESULTS AND DISCUSSIONS

6.1 Development of Mathematical Models

A Second -order polynomial is employed for developing the mathematical model for
predicting weld pool geometry. If the response is well modelled by a linear function of
the independent variables then the approximating function is the first order model as
shown in Equation.

Y = β + β1 x1 + β2 x2 + …._ βx xx + ∈

A mathematical regression equation is developed for cycle time in every tool path and the
graphs are plotted.

Y = β0 + ii i2 ij i j €

● Y is the corresponding response

● Xi are the cutting parameters

● (1,2,…….k) are code levels of quantitative process variables

59
● The terms are the second order regression coefficients

● Second term is attribute to linear effect

● Third term corresponds to higher order effects

● Fourth term includes the interactive effects of the process parameters.

● And the last term indicates the experimental error.

60
6.2 Different Terms used in Response Surface Methodology Regression table

1. P-values: P- Values (P) are used to determine which of the effects in the model are
statistically significant.

● If the p-value is less than or equal to 0.5, conclude that the effect is significant.

● If the p-value is greater than 0.5, conclude that the effect is not significant.

2. Coefficients: Coefficients are used to construct an equation representing the

relationship between the response and the factors.

3. R-squared: R and adjusted R represent the proportion of variation in the response that
is explained by the model.

● R (R-Sq) describes the amount of variation in the observed responses that is

explained by the model.

● Predicted R reflects how well the model will predict future data.

● Adjusted R is a modified R that has been adjusted for the number of terms in

the model. If we include unnecessary terms, R can be artificially high. Unlike

R , adjusted R may get smaller when we add terms to the model.

4. Analysis of variance table: P-values (P) are used in analysis of variance table to
determine which of the effects in the model are statistically significant. The interaction
effects in the model are observed first because a significant interaction will influence the
main effects.

5. Estimated coefficients using uncoded units

● Minitab displays the coefficients in uncoded units in addition to coded units if the

two units differ.

● For each term in the model, there is a coefficient. These coefficients are useful to

61
construct an equation representing the relationship between the response and the
factors.

62
6.3 Graphs Obtained
6.3.1 Contour Plots

● Contour and surface plots are useful for establishing desirable response values and

operating conditions.

● A contour plot provides a two-dimensional view where all points that have the

same response are connected to

● Produce contour lines of constant responses.

● A surface plot provides a three-dimensional view that may provide a clearer

picture of the response surface..

6.4 EXPERIMENTAL TABLE FOR TUNGSTEN CARBIDE

Cutting Feed DOC Fx Fy(Radi Fz(Main) COF Surface

Speed (mm/rev) (mm) (Axial) al)(N) (N) Roughness
(m/min) (N) (μm)
75 0.5 0.5 75 125 190 0.539361334 2.1
75 1 1 72 123 188 0.536081397 1.98
75 1.5 1.5 70 121 185 0.535899954 1.95
150 0.5 1 65 118 181 0.533988063 1.91
150 1 1.5 63 115 178 0.528695019 1.88
150 1.5 0.5 60 113 175 0.528376232 1.87
225 0.5 1.5 59 110 169 0.533044537 1.83
225 1 0.5 57 107 162 0.541702493 1.79
225 1.5 1 55 102 158 0.528245631 1.78

Table 6.1 : Experimental Results

63
6.5 TUNGSTEN CARBIDE RESULTS

6.5.1 Taguchi Analysis: Fx (Axial)(N), Fy(Radial)(N), Fz(Main)(N), COF, Surface

Roughness(μm) versus Cutting Speed (m/min), Feed (mm/rev), DOC (mm)

Linear Model Analysis: SN ratios versus Cutting Speed (m/min), Feed (mm/rev), DOC
(mm)

Estimated Model Coefficients for SN ratios

Term Coef SE Coef T P

Constant -39.8371 0.02947 -1351.711 0.000

Cutting 75 -0.6221 0.04168 -14.926 0.004

Cutting 150 -0.0668 0.04168 -1.602 0.250

Feed (mm 0.5 -0.2075 0.04168 -4.979 0.038

Feed (mm 1.0 0.0038 0.04168 0.090 0.936

DOC (mm) 0.5 0.0173 0.04168 0.415 0.719

DOC (mm) 1.0 0.0379 0.04168 0.908 0.460

Table 6.2 : Estimated Model Coefficients for SN ratios for Tungsten Carbide

Model Summary

S R-Sq R-Sq(adj)

0.0884 99.46% 97.83%

Table 6.3: Model Summary

Analysis of Variance for SN ratios

Source DF Seq SS Adj SS Adj MS F P

64
 Cutting Speed 2 2.59784 2.59784 1.29892 166.16 0.006
(m/min)

Feed (mm/rev) 2 0.25379 0.25379 0.12690 16.23 0.058

DOC (mm) 2 0.01431 0.01431 0.00716 0.92 0.522

Residual Error 2 0.01563 0.01563 0.00782

Total 8 2.88158

Table 6.4 : Analysis of Variance for SN ratios for Tungsten Carbide

Linear Model Analysis: Means versus Cutting Speed (m/min), Feed (mm/rev), DOC
(mm)

Estimated Model Coefficients for Means

Term Coef SE Coef T P

Constant 71.5088 0.1539 464.698 0.000

Cutting 75 5.6006 0.2176 25.736 0.002

Cutting 150 0.1746 0.2176 0.802 0.507

Feed (mm 0.5) 1.7876 0.2176 8.214 0.014

Feed (mm 1.0) -0.0250 0.2176 -0.115 0.919

DOC (mm 0.5) -0.0842 0.2176 -0.387 0.736

DOC (mm 1.0) -0.2242 0.2176 -1.030 0.411

Table 6.5: Estimated Model Coefficients for Means

Model Summary

S R-Sq R-Sq(adj)

0.4616 99.80% 99.20%

Table 6.6 : Model Summary

65
Analysis of Variance for Means

Source DF Seq SS Adj SS Adj MS F P

Cutting Speed 2 194.254 194.254 97.1268 455.74 0.002

(m/min)

Feed (mm/rev) 2 18.909 18.909 9.4547 44.36 0.022

DOC (mm) 2 0.457 0.457 0.2287 1.07 0.482

Residual Error 2 0.426 0.426 0.2131

Total 8 214.046

Table 6.7 : Analysis of Variance for Means for Tungsten Carbide

Response Table for Signal to Noise Ratios

66
 Cutting
Speed Feed
Level (m/min) (mm/rev) DOC (mm)

1 -40.46 -40.04 -39.82

2 -39.90 -39.83 -39.80

3 -39.15 -39.63 -39.89

Delta 1.31 0.41 0.09

Rank 1 2 3
Ta
ble 6.8 : Response Table for Signal to Noise Ratios

Cutting
Speed Feed
Level (m/min) (mm/rev) DOC (mm)

1 77.11 73.30 71.42

2 71.68 71.48 71.28

3 65.73 69.75 71.82

Delta 11.38 3.55 0.53

Rank 1 2 3

Table 6.9 : Response Table for Means

67
 Fig 6.1 : Residual Plots for SN Ratio
The optimized process parameter range for temperature & Cutting
Forces are ; cutting speed = 100 rpm, feed = 0.5mm/rev, depth of cut = 0.75. The main
effects plot for S/N ratios temperature & Cutting forces are shown in Figure 5.6

6.5.2 Regression Analysis: Fx (Axial)(N) versus Cutting Speed (m/min), Feed (mm/rev),
DOC (mm)

Regression Equation

Fx (Axial)(N) = 84.00 - 0.10222 Cutting Speed (m/min) - 4.67 Feed (mm/rev) + 0.00
DOC (mm)

68
 Term Coef SE Coef T-Value P-Value VIF

Constant 84.00 1.91 43.91 0.000

Cutting Speed -0.10222 0.00717 -14.26 0.000 1.00

(m/min)

Feed (mm/rev) -4.67 1.07 -4.34 0.007 1.00

DOC (mm) 0.00 1.07 0.00 1.000 1.00

Table 6.10 : Coefficients

S R-sq R-sq(adj) R-sq(pred)

1.31656 97.80% 96.48% 92.51%

Table 6.11 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 385.333 128.444 74.10 0.000

Cutting Speed 1 352.667 352.667 203.46 0.000

(m/min)

Feed (mm/rev) 1 32.667 32.667 18.85 0.007

DOC (mm) 1 0.000 0.000 0.00 1.000

Error 5 8.667 1.733

Total 8 394.000

Table 6.12 : Analysis of Variance

69
6.5.3 Regression Analysis: Fy(Radial)(N) versus Cutting Speed (m/min), Feed
(mm/rev), DOC (mm)

Fy(Radial)(N) = 136.89 - 0.11111 Cutting Speed (m/min) - 5.667 Feed (mm/rev) + 0.333 DOC
(mm)

Term Coef SE Coef T-Value P-Value VIF

Constant 136.89 1.58 86.81 0.000

Cutting Speed -0.11111 0.00591 -18.81 0.000 1.00

(m/min)

Feed -5.667 0.886 -6.40 0.001 1.00

(mm/rev)

DOC (mm) 0.333 0.886 0.38 0.722 1.00

Table 6.13 : Regression Equation Coefficients

S R-sq R-sq(adj) R-sq(pred)

1.08525 98.75% 98.00% 95.14%

Table 6.14 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 465.000 155.000 131.60 0.000

Cutting Speed 1 416.667 416.667 353.77 0.000

(m/min)

Feed (mm/rev) 1 48.167 48.167 40.90 0.001

DOC (mm) 1 0.167 0.167 0.14 0.722

70
 Error 5 5.889 1.178

Total 8 470.889

Table 6.15 : Analysis of Variance

Fy(Radial)
Obs (N) Fit Resid Std Resid

9 102.000 103.722 -1.722 -2.13 R

Table 6.16 : Fits and Diagnostics for Unusual Observations

6.5.4 Regression Analysis: Fz(Main)(N) versus Cutting Speed (m/min), Feed (mm/rev),
DOC (mm)

Fz(Main)(N) = 206.56 - 0.1644 Cutting Speed (m/min) - 7.33 Feed

(mm/rev) + 1.67 DOC (mm)

Term Coef SE Coef T-Value P-Value VIF

Constant 206.56 3.05 67.69 0.000

Cutting Speed -0.1644 0.0114 -14.38 0.000 1.00

(m/min)

71
Feed (mm/rev) -7.33 1.71 -4.28 0.008 1.00

DOC (mm) 1.67 1.71 0.97 0.376 1.00

Table 6.17 : Coefficients

S R-sq R-sq(adj) R-sq(pred)

2.10026 97.84% 96.54% 92.37%

Table 6.18 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 997.50 332.500 75.38 0.000

Cutting Speed 1 912.67 912.667 206.90 0.000

(m/min)

Feed (mm/rev) 1 80.67 80.667 18.29 0.008

DOC (mm) 1 4.17 4.167 0.94 0.376

Error 5 22.06 4.411

Total 8 1019.56

Table 6.19 :Analysis of Variance

Obs Fz(Main)(N) Fit Resid Std Resid

6 175.00 171.72 3.28 2.09 R

Table 6.20 : Fits and Diagnostics for Unusual Observations

6.5.5 Regression Analysis: Surface Roughness(μm) versus Cutting Speed

72
 (m/min), Feed (mm/rev), DOC (mm)
Regression Equation

Surface = 2.2222 - 0.001400 Cutting Speed (m/min) - 0.0800 Feed

Roughness(μm) (mm/rev) - 0.0333 DOC (mm)

Term Coef SE Coef T-Value P-Value VIF

Constant 2.2222 0.0425 52.32 0.000

Cutting Speed -0.001400 0.000159 -8.80 0.000 1.00

(m/min)

Feed (mm/rev) -0.0800 0.0239 -3.35 0.020 1.00

DOC (mm) -0.0333 0.0239 -1.40 0.221 1.00

Table 6.21 : Coefficients

S R-sq R-sq(adj) R-sq(pred)

0.0292309 94.77% 91.63% 78.21%

Table 6.22 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 0.077417 0.025806 30.20 0.001

Cutting 1 0.066150 0.066150 77.42 0.000

73
 Speed (m/min)

Feed 1 0.009600 0.009600 11.24 0.020

(mm/rev)

DOC (mm) 1 0.001667 0.001667 1.95 0.221

Error 5 0.004272 0.000854

Total 8 0.081689

Table 6.23 : Analysis of Variance

Surface
Obs Roughness(μm) Fit Resid Std Resid

1 2.1000 2.0606 0.0394 2.16 R

Table 6.24 : Fits and Diagnostics for Unusual Observations

6.5.6 Regression Analysis: COF versus Cutting Speed (m/min), Feed (mm/rev), DOC
(mm)

Regression Equation

COF = 0.54527 - 0.000019 Cutting Speed (m/min) - 0.00462 Feed (mm/rev) - 0.00393
DOC (mm)

Term Coef SE Coef T-Value P-Value VIF

Constant 0.54527 0.00720 75.71 0.000

74
 Cutting Speed -0.000019 0.000027 -0.69 0.522 1.00
(m/min)

Feed (mm/rev) -0.00462 0.00405 -1.14 0.305 1.00

DOC (mm) -0.00393 0.00405 -0.97 0.376 1.00

Table 6.25 : Coefficients

S R-sq R-sq(adj) R-sq(pred)

0.0049572 35.25% 0.00% 0.00%

Table 6.26 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 0.000067 0.000022 0.91 0.500

Cutting Speed 1 0.000012 0.000012 0.47 0.522

(m/min)

Feed (mm/rev) 1 0.000032 0.000032 1.31 0.305

DOC (mm) 1 0.000023 0.000023 0.94 0.376

Error 5 0.000123 0.000025

Total 8 0.000190

Table 6.27 : Analysis of Variance

6.6 ZrO2 - MoS2 RESULTS

6.6.1 Taguchi Analysis: Fx (Axial)(N), Fy(Radial)(N), Fz(Main)(N), COF, Surface

75
 Roughness(μm) versus Cutting Speed (m/min), Feed (mm/rev), DOC (mm)
Linear Model Analysis: SN ratios versus Cutting Speed (m/min), Feed (mm/rev),
DOC (mm)

Table 6.28 : Estimated Model Coefficients for SN ratios

Term Coef SE Coef T P

Constant -37.9830 0.09092 -417.743 0.000

Cutting 75 -1.0405 0.12859 -8.092 0.015

Cutting 150 0.0912 0.12859 0.709 0.552

Feed (mm -0.2776 0.12859 -2.159 0.164

0.5

Feed (mm 0.0945 0.12859 0.735 0.539

1.0

DOC (mm) 0.1383 0.12859 1.076 0.395

0.5

DOC (mm) -0.1860 0.12859 -1.447 0.285

1.0

S R-Sq R-Sq(adj)

0.2728 97.76% 91.05%

Table 6.29 : Model Summary

Source DF Seq SS Adj SS Adj MS F P

Cutting Speed 2 5.9761 5.9761 2.98804 40.16 0.024

(m/min)

Feed 2 0.3585 0.3585 0.17924 2.41 0.293

(mm/rev)

76
 DOC (mm) 2 0.1680 0.1680 0.08400 1.13 0.470

Residual 2 0.1488 0.1488 0.07441

Error

Total 8 6.6514

Table 6.30 : Analysis of Variance for SN ratios

Linear Model Analysis: Means versus Cutting Speed (m/min), Feed (mm/rev), DOC
(mm)

Term Coef SE Coef T P

Constant 56.7635 0.5873 96.658 0.000

Cutting 75 8.1539 0.8305 9.818 0.010

Cutting 150 -0.8803 0.8305 -1.060 0.400

Feed (mm 0.5 2.1890 0.8305 2.636 0.119

Feed (mm 1.0 -0.5559 0.8305 -0.669 0.572

DOC (mm) 0.5 -0.7550 0.8305 -0.909 0.459

DOC (mm) 1.0 1.1778 0.8305 1.418 0.292

Table 6.31 : Estimated Model Coefficients for Means

S R-Sq R-Sq(adj)

1.7618 98.43% 93.74%

Table 6.32 : Model Summary

Source DF Seq SS Adj SS Adj MS F P

77
Cutting Speed 2 360.502 360.502 180.251 58.07 0.017
(m/min)

Feed (mm/rev) 2 23.302 23.302 11.651 3.75 0.210

DOC (mm) 2 6.408 6.408 3.204 1.03 0.492

Residual Error 2 6.208 6.208 3.104

Total 8 396.420

Table 6.33: Analysis of Variance for Means

Cutting
Speed Feed
Level (m/min) (mm/rev) DOC (mm)

1 -39.02 -38.26 -37.84

2 -37.89 -37.89 -38.17

3 -37.03 -37.80 -37.94

Delta 1.99 0.46 0.32

Rank 1 2 3

Table 6.34 : Response Table for Signal to Noise Ratios

Table 6.35 : Response Table for Means

Cutting
Speed Feed
Level (m/min) (mm/rev) DOC (mm)

1 64.92 58.95 56.01

2 55.88 56.21 57.94

3 49.49 55.13 56.34

Delta 15.43 3.82 1.93

78
 Cutting
Speed Feed
Level (m/min) (mm/rev) DOC (mm)

1 64.92 58.95 56.01

2 55.88 56.21 57.94

3 49.49 55.13 56.34

Rank 1 2 3

Fig 6.2 : Main Effects Plot for SN ratio

79
 Fig 6.3 : Residual Plot for SN ratio

6.6.2 Regression Analysis: Fx (Axial)(N) versus Cutting Speed (m/min), Feed (mm/rev),
DOC (mm)

Regression Equation

Fx (Axial)(N) = 74.333 - 0.15111 Cutting Speed (m/min) - 6.333 Feed

(mm/rev) + 1.000 DOC (mm)

Term Coef SE Coef T-Value P-Value VIF

80
 Constant 74.3333 0.838870 88.61 0.000

Cutting Speed -0.1511 0.003143 -48.08 0.000 1.00

(m/min)

Feed (mm/rev) -6.3333 0.471405 -13.44 0.000 1.00

DOC (mm) 1.0000 0.471405 2.12 0.087 1.00

Table 6.36 : Coefficients

S R-sq R-sq(adj) R-sq(pred)

0.577350 99.80% 99.68% 99.19%

Table 6.37 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 832.333 277.444 832.33 0.000

Cutting 1 770.667 770.667 2312.00 0.000

Speed (m/min)

Feed 1 60.167 60.167 180.50 0.000

(mm/rev)

DOC (mm) 1 1.500 1.500 4.50 0.087

Error 5 1.667 0.333

Total 8 834.000

Table 6.38 : Analysis of Variance

81
6.6.3 Regression Analysis: Fy(Radial)(N) versus Cutting Speed (m/min), Feed
(mm/rev), DOC (mm)

Regression Equation

Fy(Radial)(N) = 124.00 - 0.1933 Cutting Speed (m/min) - 6.67 Feed (mm/rev) -

0.67 DOC (mm)

Term Coef SE Coef T-Value P-Value VIF

Constant 124.000 8.55072 14.50 0.000

Cutting Speed -0.193 0.03203 -6.04 0.002 1.00

(m/min)

Feed (mm/rev) -6.667 4.80509 -1.39 0.224 1.00

DOC (mm) -0.667 4.80509 -0.14 0.895 1.00

Table 6.39 : Coefficients

S R-sq R-sq(adj) R-sq(pred)

5.88501 88.47% 81.55% 60.10%

Table 6.40 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 1328.83 442.94 12.79 0.009

Cutting Speed 1 1261.50 1261.50 36.42 0.002

82
 (m/min)

Feed (mm/rev) 1 66.67 66.67 1.92 0.224

DOC (mm) 1 0.67 0.67 0.02 0.895

Error 5 173.17 34.63

Total 8 1502.00

Table 6.41 : Analysis of Variance

Fy(Radial)
Obs (N) Fit Resid Std Resid

9 79.00 69.83 9.17 2.09 R

Table 6.42 : Fits and Diagnostics for Unusual Observations

6.6.4 Regression Analysis: Fz(Main)(N) versus Cutting Speed (m/min), Feed (mm/rev),
DOC (mm)
Regression Equation

Fz(Main)(N) = 177.44 - 0.1667 Cutting Speed (m/min) - 6.00 Feed (mm/rev) +

1.33 DOC (mm)

Term Coef SE Coef T-Value P-Value VIF

Constant 177.444 5.09114 34.85 0.000

Cutting Speed -0.167 0.01907 -8.74 0.000 1.00

(m/min)

Feed (mm/rev) -6.000 2.86098 -2.10 0.090 1.00

DOC (mm) 1.333 2.86098 0.47 0.661 1.00

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 Table 6.43 : Coefficients

S R-sq R-sq(adj) R-sq(pred)

3.50397 94.18% 90.69% 78.06%

Table 6.44 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 994.17 331.389 26.99 0.002

Cutting Speed 1 937.50 937.500 76.36 0.000

(m/min)

Feed (mm/rev) 1 54.00 54.000 4.40 0.090

DOC (mm) 1 2.67 2.667 0.22 0.661

Error 5 61.39 12.278

Total 8 1055.56

Table 6.45 :Analysis of Variance

Obs Fz(Main)(N) Fit Resid Std Resid

9 138.00 132.28 5.72 2.19 R

Table 6.46 : Fits and Diagnostics for Unusual Observations

6.6.5 Regression Analysis: COF versus Cutting Speed (m/min), Feed (mm/rev), DOC
(mm)

Table 6.13.1: Regression Equation

84
 COF = 0.5800 - 0.000630 Cutting Speed (m/min) - 0.0268 Feed (mm/rev) -
0.0055 DOC (mm)

Term Coef SE Coef T-Value P-Value VIF

Constant 0.580020 0.0230856 25.12 0.000

Cutting Speed -0.000630 0.0000865 -7.29 0.001 1.00

(m/min)

Feed -0.026821 0.0129730 -2.07 0.094 1.00

(mm/rev)

DOC (mm) -0.005484 0.0129730 -0.42 0.690 1.00

Table 6.47 : Coefficients

Table 6.13.2: Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.0158886 92.00% 87.21% 74.63%

Table 6.48 : Model Summary

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 0.0145221 0.0048407 19.18 0.004

Cutting Speed 1 0.0133980 0.0133980 53.07 0.001

(m/min)

Feed (mm/rev) 1 0.0010790 0.0010790 4.27 0.094

DOC (mm) 1 0.0000451 0.0000451 0.18 0.690

Error 5 0.0012622 0.0002524

85
 Total 8 0.0157843

Table 6.49 : Analysis of Variance

6.6.6 Regression Analysis: Surface Roughness(μm) versus Cutting Speed (m/min), Feed
(mm/rev), DOC (mm)

Regression Equation

Surface = 2.0467 - 0.002511 Cutting Speed (m/min) - 0.0833 Feed

Roughness(μm (mm/rev)
) - 0.0000 DOC (mm)

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 2.0467 0.0800 25.58 0.000

Cutting Speed - 0.000300 -8.38 0.000 1.00

(m/min) 0.002511

Feed -0.0833 0.0450 -1.85 0.123 1.00

(mm/rev)

DOC (mm) -0.0000 0.0450 -0.00 1.000 1.00

Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.0550757 93.64% 89.82% 79.56%

Analysis of Variance

Source DF Adj SS Adj MS F-Value P-Value

Regression 3 0.223233 0.074411 24.53 0.002

86
 Cutting 1 0.212817 0.212817 70.16 0.000
Speed (m/min)

Feed 1 0.010417 0.010417 3.43 0.123

(mm/rev)

DOC (mm) 1 0.000000 0.000000 0.00 1.000

Error 5 0.015167 0.003033

Total 8 0.238400

87
 CHAPTER 7

CONCLUSION
ZrO2 - MoS2 Cutting Tool is fabricated to machine the hardened steel workpiece at
various performance measures in comparison with Tungsten Carbide.
For ZrO2 - MoS2 the cutting process parameters are Speed [75, 150, 225] , Feed [1.5,
1.0, 0.5] and Depth of Cut [1.5, 1.0, 0.5] then the optimization is done of these
combinations, from the Taguchi method in minitab.
In Tungsten Carbide at S3 F3 D2 at this we get the optimized parameters which gives us
fx as 55N, fy as 102N, fz as 158N, cof as 0.5282 and Surface Roughness(μm) 1.78

88
 CHAPTER 8

BIBLIOGRAPHY/REFERENCES
[1] Jiayu He, Faqin Xie, Preparation and friction wear performance of ZrO2/MoS2 PEO
composite coating

[2] J. Tribol. Mar 2022, Tribological Investigation of Composite MoS 2-TiO2-ZrO2

Coating Material by Response Surface Methodology Approach

[3] J. Tribol. Jun 2021 Enhancement of Dry Sliding Tribological Characteristics of

Perforated Zirconia Toughened Alumina Ceramic Composite Filled With Nano MoS 2 in
High Vacuum

[4] Karin Kandananond, 2009, “Characterization of FDB Sleeve Surface Roughness

Using the Taguchi Approach”. European Journal of Scientific Research ISSN 1450-
216X Vol.33 No.2 (2009), pp.330-337.

[5] Sehgal A.K, Agarwal Anuj and Agarwal Amit, 2009, “Surface Roughness
Optimization in an End Milling Operation based on Taguchi Design of Experiment: A
Comparative Analysis”. International Conference on Advances in Industrial Engineering
Applications, pp.1-6.

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