MAJOR PROJECT REPORT

Experimental Investigations and Data Analysis of Surface

Roughness in CNC Turning of Aluminum KS 1295 Using
Design of Experiments
By:

Ram Kumar Sharma – 2K13/CEME/72

Ravi Kumar Sharma – 2K13/CEME/73

Rahul Kumar– 2K13/CEME/71

UNDER THE GUIDANCE OF

Dr. RANGANATH M. SINGARI

Associate Professor
Sh. K SRINIWAS
Associate Professor

Department of Mechanical Engineering

Delhi Technological University

(Formerly Delhi College Of Engineering)

ShahbadDaulatpur, Bawana Road, Delhi – 110042

 STUDENTS’ DECLARTION

We hereby certify that the work which is being presented in the minor project entitled
“Experimental Analysis of Surface Roughness in CNC Boring of Aluminum Using
Taguchi Technique”, is submitted, and in the partial fulfilment of the requirements for
Bachelors’ degree in Mechanical Engineering at Delhi Technological University is an
authentic record of our own work carried under the supervision of Dr. Ranganath M.
Singari. We have not submitted the matter embodied in this minor project for the award
of any other degree. Also, it has not been directly copied from any source without giving
its proper reference.

RAHUL KUMAR

2K13/CEME/71

RAM KUMAR SHARMA

2K13/CEME/72

RAVI KUMAR SHARMA

2K13/CEME/73
 CERTIFICATE

This is certified that the work contained in this minor project entitled “Experimental
Analysis of Surface Roughness in CNC Boring of Aluminum Using Taguchi
Technique” by Rahul kumar, Ram kumarsharma, Ravi kumarsharma is the requirement
for the partial fulfilment of the degree in Mechanical Engineering at Delhi Technological
University. This work was completed under my direct supervision and guidance. The
students have completed their work with utmost sincerity and diligence. The work
embodied in this major project has not been submitted for the award of any other degree
to the best of my knowledge.

Dr. Ranganath M. Singari

Associate Professor
Department of Mechanical Engineering
Delhi Technological University
(Formerly Delhi College of Engineering)
Shahbad ,Daulatpur, Bawana Road,

Delhi – 110042

Sh.K Srinivas
Associate Professor
Department of Mechanical Engineering
Delhi Technological University
(Formerly Delhi College of Engineering)
Shahbad ,Daulatpur, Bawana Road,

Delhi – 110042

ACKNOWLEDGEMENT
We would like to express our heartfelt gratitude to our Head of department Dr. R.S
Mishra for giving us the opportunity to work on this research work in the Metal Cutting
Laboratory at Delhi Technological University under their supervision and for their
consistent support, guidance and motivation throughout the time period of project. We
also thank our mentor [Link] M. Singari for his invaluable suggestions and giving
directions to our thoughts and ideas. We would also like to thank Sh.K Srinivas for
enthusiastically supporting us in procuring the right resources and at various stages of the
project work.

We would also like to thank our parents for giving us the motivation during the tough
patches.

RAHUL KUMAR RAM KUMAR SHARMA RAVI KUMAR SHARMA

2K13/CEME/71 2K13/CEME/72 2K13/CEME/73

 CONTENTS

1. Introduction 7
2. Surface Roughness 7
2.1. Surface Characteristics 8
2.2. Definition And Measurement 8
3. Surface Roughness Measurement 9
3.1. Traversing length 9
3.2. Sampling length 9
3.3. Centre line 9
3.4. Maximum height of the irregularity (Rmax) 10
4. Profile Roughness Parameters and their Calculations 10
4.1. Centre line average method 11
4.2. Root mean square method (Rq): 11
4.3. Peak to valley average method (Rz): 11
5. Surface roughness symbol in drawing: 12
6. Literature Review 14
7. Design of Experiments 19
7.1. Overview 19
7.2. Terminology of Experiments 20
7.3. Types Of Variables 21
7.4. Robust Design 21
8. Taguchi Method 22
8.1. Methodology 22
8.2. Signal to Noise ratio 22
9. Experimentation 24
9.1. Machine Specification 24
9.2. Tool Geometry 25
[Link] used 25
9.3. Material Used 26
[Link] Composition 26
[Link] Properties 26
[Link] 27
9.4. Tallysurf 27
10. Experimentation 29
10.1. CNC Codes 29
10.2. CNC Programme 30
10.3. Measurements 32
11. Analysis 33
11.1. Taper Turning 33
11.2. Internal Turning 38
12. Conclusion 43
12.1. Taper Turning 43
12.2 Internal Turning 43
13. Future Plan 44
14. References 44
 LIST OF FIGURES

1. Surface Characteristics 8
2. Traversing length and Sampling length 9
3. Maximum Height of Irregularity 10
4. To determine Rq (Root mean square method) 11
5. To determine Rz (Peak to Valley method) 12
6. Fish Bone Diagram 14
7. Input factors and Response Diagram 20
8. CNC BORING MACHINE FMS 24
9. Tool Geometry and Designation 25
10. Taylor Hobson Tallysurf 28
11. Final Shape of the work piece 29
12. Measurement of roughness 32
13. Main Effects plot for Means (Taper) 34
14. Main Effect plots for S/N ratio (Taper) 35
15. Residual plots for S/N ratio (Taper) 37
16. Residual plots for Means(Taper) 37
17. Main Effects plot for Means (Internal) 39
18. Main Effect plots for S/N ratio (Internal) 40
19. Residual plots for S/N ratio (Internal) 42
20. Residual plots for Means (Internal) 42

LIST OF TABLES

1. Taguchi Orthogonal Arrays and Corresponding maximum value of factors 24

2. CNC Machine Specifications 24
3. Specification of Tool employed during experiment 25
4 G and M Codes for CNC machine 29
5. Parameters And their Levels(Taper) 33
6. L27 OA for experiment along with S/N Ratios(Taper) 33
7. Analysis of Variance (ANOVA) for Means(Taper) 35
8. Analysis of Variance (ANOVA) for S/N ratio(Taper) 36
9. Response Table for S/N Ratios(Taper) 36
10. Response Table for means (Taper) 36
11. Parameters And their Levels(Internal) 38
12. L27 OA for experiment along with S/N Ratios(Internal) 38
13. Analysis of Variance (ANOVA) for Means(Internal) 40
14. Analysis of Variance (ANOVA) for S/N ratio(Internal) 41
15. Response Table for S/N Ratios(Internal) 41
16. Response Table for means (Internal) 41
 ABSTRACT

The work and study presented in this paper aims to investigate the effect of various
cutting parameters as well as nose radius on surface roughness, in CNC Boring of
Aluminum (KS 1295). The effect of cutting conditions (speed, feed and depth of cut) and
tool geometry (nose radius) on surface roughness has been studied and analyzed in
Boring. For the experimentation Taguchi’s L27 Orthogonal array has been employed in
Boring., the effect of cutting conditions (speed, feed and depth of cut) on surface
roughness has been studied. For the experimentation Taguchi’s L9 Orthogonal array has
been employed. Analysis of Variance is performed to determine the significance for each
parameter in both experiments. For Boring; The Nose Radius is identified as the most
significant parameter followed by Feed Rate. It is observed that Surface Roughness value
decreases with increase in Nose Radius and increases with increase in Feed Rate. For
Internal Turning; Feed is identified as the most significant parameter. It is observed that
Surface Roughness value increases with increase in Feed Rate.
 1. INTRODUCTION

Process modelling and optimization are two important issues in manufacturing products.
The manufacturing processes are characterized by multiplying of dynamically interacting
process variables. Modelling of surface roughness is difficult because it is affected by
different variables. The objective of the project is to optimize the process parameters in
boring operation. The process parameters affecting the characteristics of boring parts are
cutting tool parameters-tool geometry and tool material; cutting parameters- cutting
speed, feed, depth of cut, dry/wet cutting; work piece related parameter metallographic,
hardness etc. The boring process is one of the most fundamental metal removal
operations used in the manufacturing industry to increase internal dia of any hole. Surface
roughness, used to determine and evaluate the quality of a product, is one of the major
quality attributes of a machined product. Surface roughness of a machined product could
affect several of the product’s functional attributes such as contact causing surface
friction, wearing, light reflection, heat transmission, ability of distributing and holding a
lubricant, coating and resisting fatigue. Surface roughness being important quality aspects
in operations there is a need to optimize the process parameters in a systematic way to
achieve the output characteristics/responses in order to obtain better surface roughness,
the proper setting of cutting parameters is crucial before the process takes place. As a
starting point for determining cutting parameters, technologists could use the hands on
data tables that are furnished in machining data handbooks. Previously trial and error
approach was followed in order to obtain the optimal machining conditions for particular
operations. In recent times, a Design of Experiment (DOE) is implemented to select
manufacturing process parameters that could result in a better quality product.

2. SURFACE ROUGHNESS

The proper functioning and service life of a machine part depend to a considerable extent
on the quality of its surfaces. The action of a cutting tool in machining never results in
absolutely smooth and even surface of the parts, the later invariably bear some traces of
unevenness, roughness, notches, scores, lines, etc. both in the direction of primary
motion, in which the cutting is performed and in the direction of feed. Even the surfaces
which seem perfectly smooth after scrapping, lapping, etc. have a minor unevenness.
Surface Roughness is measure of the technological quality of a product and a factor that
greatly influences manufacturing cost. It describes the geometry of the machined surfaces
and combined with surface texture. Minimum Surface Roughness demand is important
due to increased customer demands for quality, less costly products, minimum friction,
maximum lubrication and minimum wear. Roughness plays an important role in
determining how a real object will interact with its environment. Roughness is often a
good predictor of the performance of a mechanical component, since irregularities in the
surface may form nucleation sites for cracks or corrosion.
 [Link] Characteristics

The standard terms which are used to explain surface characteristics are defined below:

1. Profile: profile is defined as the contour of any section through a surface.

2. Primary texture (roughness): this refers to relatively finely spaced irregularities
which result from the inherent action of the production process. These are deemed
to include transverse feed marks and the irregularities in them.
3. Secondary texture (waviness): waviness consists of those surface irregularities
which are of greater waves more or less of the same size. Waviness may be caused
by vibrations, machine or work deflection, chatter, wrapping, etc. The most clear
defined waviness appears in turning, milling, planning, broaching, and grinding.
4. Lay: Lay is defined as the direction of the predominant surface markings. this is
ordinarily determined by the production method used.
5. Flaws: Flaws are surface imperfections such as blow holes, cracks, porosity, etc.
which appear at frequent intervals and at random locations. the flaws, unless
otherwise specified, shall not be included in the surface characteristics.

Fig1. Surface characteristics[18]

[Link] and Measurement:

There are many definitions of surface roughness; all of them are based on a statistical
representation of the high frequency surface deviations (peaks and valleys) from the local
mean surface height. Filtering is used to separate the high frequency texture data from
lower frequency machining features. It is quantified by the deviations in the direction of
the normal vector of a real surface from its ideal form. If these deviations are large, the
surface is rough; if they are small, the surface is smooth. In a nutshell Roughness is
typically considered to be the high-frequency, short-wavelength component of a
measured surface.

3. SURFACE ROUGHNESS MEASUREMENT:

Synonymous with surface metrology determines surface topography, which is essential

for confirming a surface's suitability for its function. Surface measurement conceptually
includes surface shape, surface finish, surface profile roughness (Ra), or in surface area
roughness (Sa), surface texture, asperity and structural characterization.
For example, engine parts may be exposed to lubricants to prevent potential wear, and
these surfaces require precise engineering – at a microscopic level – to ensure that the
surface roughness holds enough of the lubricants between the parts under compression,
while it is smooth enough not to make metal to metal contact. For manufacturing and
design purposes, measurement is critical to ensure that the finished material meets the
design specification.
A roughness value can either be calculated on a profile (line) or on a surface (area). The
profile roughness parameter (Ra, Rq,...) are more common. The area roughness parameters
(Sa, Sq,...) give more significant values.

3.1. Traversing length:

Traversing length is the length of the profile necessary for evaluation of the surface
roughness parameters. Traversing length may include one or more sampling lengths.

3.2. Sampling length:

Sampling length is the length of the profile necessary for the evaluation of the
irregularities to be taken into account. This is also called the ‘Instrument cut-off’ in
regard to measuring instruments.

Fig2. Traversing length and Sampling length[18]

3.3. Center line:

Center line of the profile is the line parallel to the general direction of the profile for
which the areas embraced by the profile above and below the line are equal.
 3.4. Maximum height of the irregularity (Rmax):

Rmax is defined as the distance between two lines parallel to the mean line and touching
the profile at highest points within the sampling length.

Fig3. Maximum height of irregularity, mean line and effective profile[18]

4. PROFILE ROUGHNESS PARAMETERS AND THEIR

CALCULATIONS:

There are many different roughness parameters in use, but R a is by far the most common
though this is often for historical reasons not for particular merit as the early roughness
meters could only measure Ra. Other common parameters include Rz, Rq, and Rsk. Some
parameters are used only in certain industries or within certain countries. For example,
the Rkfamily of parameters is used mainly for cylinder bore linings, and the Motif
parameters are used primarily within France.

[Link] line average method:

The ‘M-system’, also known as center line average method (CLA) or Mean Line System,
expresses the arithmetical average (AA) departure of the actual surface both above and
below a mean line, within a specified sampling length. According to Indian Standard, the
surface roughness is specified in terms of CLA values denoted by R a, meaning average
roughness height, in microns. Roughness average (Ra) is the arithmetic average of the
absolute values of the roughness profile ordinates. Ordinates are summed up without
considering their algebraic signs.
 [Link] mean square method (Rq):
In this method, the rms average value is obtained by setting many equidistant ordinates
on the mean line and taking the root of the mean of the squared ordinates. The formula is
as below:

Fig4. To determine Rq (Root mean square method)[18]

4.3. Peak to valley average method (Rz):

The PVA value is obtained as the average difference between (say) five highest peaks
and equal number of deepest valleys over the sampling length measured parallel to the
mean line and not crossing the profile. This is denoted by Rz.
 Fig 5. To determine Rz(Peak to valley average method)[18]

Other parameters:

Rv: Maximum valley depth.

Rp: Maximum peak height

Rt: Maximum Height of the Profile

5. SURFACE ROUGHNESS SYMBOL IN DRAWING

Surface roughness symbol is given to convey manufacturing process related information

only. Unless written specifically on the symbol, they do not carry the surface texture type
(i.e. plated / milled / cold drawn). These symbols are given irrespective of material and its
surface condition.
The symbols to be used for lay are:
‘=’ Parallel to the line representing the surface
‘ 丄’ Perpendicular to the line representing the surface.
‘X’ Angular in both directions to the line representing the surface
‘M’ Multi directional
‘C’ Approximately circular relative to the centre
‘R’ Approximately radial relative to the centre of the surface

The latest Indian Standard method of indicating surface texture on technical drawings
suggests the practice of giving the surface roughness value directly in micron as Ra value
or by grade numbers. In earlier times surface roughness on drawing was represented by
triangles. They were classified into four groups with their R a (micrometers) values as
shown below.

8-25

1.6-8

.025-1.6

<.025

Meaning of complete surface finish symbol is as below:

a = Roughness value Ra in micro meter or grade number

b = Production method, treatment or coating
c = Sampling length
d = Direction of lay
e = Machining allowance
f = other roughness value than Ra
 6. LITERATURE REVIEW

Turning is the most significant operation in almost all the machining processes in the
industry, surface roughness of the turned product has greater effect on the quality of the
product. Surface Roughness has been found to be influenced in varying amounts by a lot
of factors such as feed rate, cutting speed, depth of cut, tool nose radius, cutting time,
work material characteristics, work hardness, unstable built-up edge.

Fig6. Fish bone Diagram depicting factors affecting Surface Roughness [4]

According to these factors, a detailed literature survey was carried out as follows,

Anupam Agarwal et al.[1] predicted a surface roughness model during hard turning of
AISI 4340 steel(69 HRC). Hard turning process has now become a viable method to
machine automotive components made of ferrous alloys with hardness above 45 HRC.
AISI 4340 medium carbon (0.4% C) high strength martensitic steel used very frequently
to manufacture critical components in aerospace engineering and automotive
transmissions. A series of longitudinal hard turning trials were performed on a Mori-Seiki
SL-25Y (4-axis) CNC lathe. The workpiece specimen used AISI 4340 steel was hardened
up to 69 HRC through heat treatment process. CBN cutting inserts (type CNMA 12 04
08S-B) having a rake angle of 0◦, clearance angle of 5◦, and a nose radius of 0.8 mm were
used. 39 trials were conducted in total.
The surface topography of the machined samples was examined by using a white light
interferometer and a reconfirmation of measurement was done using a Form Talysurf.
The machining outcome was used as an input to develop various regression models to
predict the average machined surface roughness on this material. Three regression models
– Multiple regression, Random forest, and Quantile regression were applied to the
experimental outcomes.
For the first time, the random forest regression modeling was applied to the machining
domain and an excellent correlation was found between the model and in house
experimental results, as the standard deviation of the predicted values from the 39
experimental result set was very low. The experimental outcome of 39 sets of trials
showed that the value of machined surface roughness is most significantly impacted by
the feed rate followed by the cutting speed and depth of cut. Although the feed rate was
found to play a dominant role compared to the other two parameters, it cannot be lowered
beyond a certain critical extent due to ploughing phenomena.

Upinder Kumar Yadav et al. [3] experimented and optimised machining parameters for
surface roughness in CNC turning by Taguchi [Link] work material used for the
present study was AISI 1045 medium carbon steel. This Carbon steel is suitable for shafts
and machinery parts. Taguchi’s orthogonal arrays are highly fractional designs, used to
estimate main effects using few experimental runs [Link] effect of three machining
parameters i.e. Cutting speed, feed rate and depth of cut and their interactions were
evaluated using ANOVA and with the help of MINITAB 16 statistical software. The
purpose of the ANOVA in this study was to identify the important turning parameters in
prediction of Surface roughness.
The current study was done to study the effect of machining parameters on the surface
roughness. It was concluded that the Surface roughness was mainly affected by feed rate
and cutting speed. With the increase in feed rate the surface roughness also increased &
as the cutting speed was decreased the surface roughness increased. From ANOVA
analysis, parameters making significant effect on surface roughness were feed rate and
cutting speed. The optimum setting of cutting parameters for high quality turned parts
was obtained.

IlhanAsiltürk et al.[4] presented a method to determine optimal cutting conditions and

mathematical models for surface roughness (response). The author considered three
cutting parameters affecting the response namely, cutting speed, depth of cut, and feed
rate. Taguchi method was employed to determine the optimal turning process parameters.
The experiments were performed on Taksan CNC turning machine. The material selected
was AISI 304 austenitic stainless steel and IC 3028 grade carbide inserts as the cutting
tool. For surface roughness measurement Mitutoyo SJ-201 surface roughness test was
employed. The experimentation involved turning of 27 workpieces based on L 27 standard
three level orthogonal arrays. The author had used smaller the better type of quality
characteristic as surface roughness should be least. The S/N ratios were computed for 27
trials. With this analytical model, the objective function problem can be easily solved
hence a second order model for surface roughness was obtained using RSM. Further the
suitability of model was proved by ANOVA. The signal to noise ratio main plots showed
that feed rate has strong effect on surface roughness. ANOVA for Ra and Rz indicated that
feed rate has most significant effect on surface roughness. Based on S/N ratio and
ANOVA optimal cutting parameters for Ra were found to be V=50 mm/min, f=0.15
mm/min and DOC=1.5 mm. The optimal cutting parameters for R z were found to be
V=150 mm/min, f=0.15 mm/min and DOC=1 mm. From Taguchi and RSM both
indicated that the main effect of the feed rate is the most significant factor on the
workpiece surface roughness.
The RSM was found to be effective for the identification and development of significant
relationships between cutting parameters, Significance of interactions and square terms of
parameters were more clearly predicted in RSM. RSM technique could model the
response in terms of all parameters, their interactions and square terms. This facility was
not provided by the Taguchi technique. The Response Surfaces revealed that R a increases
with increase of depth of cut, feed rate and cutting speed. The R z value decreases with
decrease in depth of cut and feed rate. The authors concluded that the ideal combination
of control factors for lowest surface roughness should consist of minimum depth of cut,
minimum feed rate and maximum cutting speed.

IlhanAsiltürk et al.[5] considered a workpiece of a particular size made of AISI 4140

grade (DIN 42CrMo4) steel was used. The hardness of the material was brought down
from 62HRC to 56-57HRC with the help of thermal treatment. The experiments were
conducted under dry cutting conditions. Al2O3 and TiC-coated inserts were used as the
cutting material. The surface roughness was measured using a Mitutoyo SJ-301P portable
device. The Taguchi method and L9 orthogonal array were used to reduce number of the
experiments. The experiments were conducted with three [Link] this experiment the
optimum cutting conditions required and S/N ratios and levels were calculated in
MINITAB 14 Program. Analysis of Variance (ANOVA) was applied to investigate
effects of cutting speed, feed rate and depth of cut on surface roughness.
Results indicated that the feed rate had the most significant effect on Ra and Rz. Variance
was not observed for the cutting speed and the depth of cut at the reliability level of 95%.
The effects of two factor interactions of the feed rate-cutting speed and depth of cut-
cutting speed appeared to be important.

Murat Sarikaya et al.[6] analysed CNC turning parameters under MQL using Taguchi
design and response surface methodology. In this study, design of experiments had been
used to analyse the effect of main turning parameters such as cutting speed (Vc), cooling
condition, depth of cut (a) and feed rate (f) on arithmetic average roughness (R a) and
average maximum height of the profile (Rz) by turning of AISI 1050 Steel. Experiments
were performed under dry cutting (DC), conventional wet cooling (CC) and MQL, which
was considered for two different amounts of oil flow rate. Boron oil and water (ratio of
Boron oil/water= 1/20) solution was used as the coolant for the conventional cooling
technique. 60 mL/h and 120 mL/h were 2 applied flow rates for two different quantities
of the lubricant at MQL condition. Cutting fluid (mineral oil-based) used in MQL was
crushed to dust through a nozzle and an air compressor at 6 bars and was delivered to the
area of workpiece-cutting [Link] results were analyzed using 3D surface graphs, signal
to noise ratios and main effect graphs of means. The surface graphs, S/N ratios and main
effect graphs demonstrated that cooling conditions are highly effective on machined
surface roughness. In the cooling conditions, MQL is a good tool in order to increase the
quality for cutting operations.
Analysis of Variance (ANOVA) demonstrated that the feed rate and the cooling
conditions had the highest influence on machined surface roughness. Nevertheless, the
depth of cut and cutting speed have no influence on the surface roughness at the
reliability level of 95%.
Mathematical models were developed using response surface methodology to formulate
the input cooling condition, cutting speed, feed rate and depth of cut to the R a and Rz.
Confirmation experiments showed that the developed mathematical models through RSM
could be used for turning of AISI 1050 steel. Also Mathematical model output showed
that the developed RSM model was statistically significant and suitable for all the cutting
conditions because of higher R2 value. The values of experimental and predicted were
found to be very close to each other implying significance of models proposed for
arithmetic average roughness (Ra) average maximum height of the profile (Rz).

Prajwalkumar M. Patil et al.[7] observed the effect of cutting parameters on the surface
roughness and hardness. The author employed Taguchi methods in the optimization of
cutting parameters namely; speed, feed and depth of cut. The turning experiments were
designed as per Taguchi’s L9 orthogonal array. The Analysis of means (ANOM) and
Analysis of variance (ANOVA) were carried out to determine the optimal parameters
level and obtain level of importance of each parameter. AISI 316 austenitic stainless steel
was selected as the work material. Turning was performed on CNC ‘Ace turn Mill
Fanuc’, lathe type LT-2XLMMC. The coated carbide insert of ISO geometry ‘CNMG
120416’ was employed for machining. The experiment was conducted with three levels
for each parameter. The surface roughness was measured using Mitutoyo Surf test model
SJ-201P and hardness was measured using Vickers hardness tester. Experimentation
involved turning of 9 workpieces based Taguchi’s L9 orthogonal array. The author
determined the S/N ratios for each of the trial. The main effect for means was plotted.
ANOM based on the S/N ratios was performed. The ANOVA based on S/N ratio was
done to determine the parameters quantitatively. From the ANOVA it was observed that
feed had maximum significance in case of Ra and Rz. Depth of cut had a major
significance in case of hardness. The main plot indicated that the ideal conditions for
least surface roughness were at speed of 150 m/mm feed rate at .20 mm/min and depth of
cut of 1.5 mm. The ideal conditions for most extreme hardness are speed of 180 m/rev
and feed rate at 0.2 mm/rev and depth of cut at 1.5 mm.
The hardness values of micro hardness profile concluded that the hardness of the turned
specimen goes on decreasing from the surface to the depth of the specimen.
The verification tests had deduced that the results obtained were accurate up to 95% of
confidence level.

Ranganath M S et al.[8]analyzed the effect of the cutting speed, feed rate and depth of cut
on surface roughness (response). The author conducted Taguchi design to perform the
analysis and optimized the results by employing Analysis of Variance (ANOVA).
RanganathM S conducted turning of Aluminum 6061 using CNMG insert of tool nose
radius 0.8 mm. The work pieces were turned on CNC turning centre LMW LL20TL3.
The surface roughness of the machined surface was measured using surtronic 3+ talysurf.
For conducting experiments L27 orthogonal array was selected. For each parameter three
levels were selected. The main effect plots for means and S/N ratios were plotted which
showed variation of individual response with the three parameters. In order to quantify
the influence of process parameters and interactions on the selected machining
characteristics, analysis of variance was performed. The ANOVA values proved that
speed is the most significant factor and thus affects the mean value of R a, the next
significant factor was depth of cut followed by feed. The response tables for S/N ratios
and the means showed that feed is the dominant factor followed by depth of cut and
speed. It was concluded that increase in cutting speed decreases the surface up to a
certain level but as speed increases beyond a certain level the surface roughness
increases. The optimal combination of process parameters for the work with regard to
minimum surface roughness were speed at 1900 rpm, depth of cut 0.25 mm and feed of
0.12 mm/rev.

Ranganath M S et al.[11] studied the effect of rake angle on surface roughness in CNC
Turning. Study aims to investigate the effect of rake angle on surface roughness in CNC
turning of Aluminium (6061) with keeping other machining parameters such as cutting
speed, feed rate and depth of cut as constant.
In this study, Taguchi's approach was used to analyze the effect of rake angle on Surface
Roughness of Aluminium 6061. Cutting tool with three different positive rake angles 16 0,
180 and 200were used to obtain an optimal setting of these parameters that may result in
good surface [Link] work pieces were turned on CNC turning centre LMW
LL20TL3. The cutting tool used was cemented carbide insert type. The geometry of the
tools selected are with the combinations of three nose radius: 0.4, 0.8, 1.2 and positive
rake angles 160, 180, 200. The surface roughness of the machined surface was measured
using Surtronic 3+ talysurf which is a portable, self contained instrument.
The pieces of work material were set so as to conduct turning process three times on a
single work piece while calculating the average roughness value, simultaneously by the
stylus of the measuring instrument. To more closely replicate typical finish turning
processes and to avoid excessive vibrations due to workplace dimensional inaccuracies
and defects, each workpiece was rough-cut just prior to the measured finish cut. Thus
simultaneously we could choose the machining zero required for generating cutting
profile with reference to our workpiece dimensions. The three different values of feed at
one depth of cut and at a single speed. ANOVA was used in the analysis of comparative
experiments, those in which only the difference in outcomes is of [Link] graphs for
variation of rake angle with surface roughness for different feed values by keeping nose
radius of the tool, cutting speed and depth of cut as constant were obtained. It was
observed that surface roughness decreases with increase in rake angle.

Ranganath M S et al [13] studied the effect of cutting parameters on MRR and surface
roughness in turning of of Aluminium (6061).Taguchi method is a powerful tool for the
design of high quality systems. The machining trials were carried out on conventional
Lathe Machine model Kirloskar Turnmaster-35. The workpiece was prepared in the form
of round bar 50 mm in diameter and 150 mm in length. The effect of cutting conditions
on material removal rate and surface roughness were studied and analyzed. Experiments
were conducted based on the Taguchi design of experiments (DOE) with orthogonal L27
array, and then followed by optimization of the results using Analysis of Variance
(ANOVA) to find minimum surface roughness and maximum MRR.
From the results it was obtained that the finish gets poor as the feed increases, thus the
average surface roughness value increased with increase in feed. The optimal process
parameters for minimum surface roughness and maximum material removal rate were
obtained. Taguchi gave a systematic, simple and efficient method to find out optimum
operating conditions.

7. DESIGN OF EXPERIMENT:

[Link]

Experiment is defined as a scientific procedure undertaken to make a discovery, test a

hypothesis or demonstrate a known fact. Experiments provide insight into cause-and-
effect by demonstrating what outcome occurs when a particular factor is manipulated.
Experiments vary greatly in goal and scale, but always rely on repeatable procedure and
logical analysis of the results. The goal of any experimental activity is to get the
maximum information about a system with the minimum number of well-designed
experiments. In the scientific method, an experiment is an empirical procedure that
arbitrates between competing models or hypotheses. Researchers also use
experimentation to test existing theories or new hypotheses to support or disprove them.
Experimentation plays an important role in technology, commercialization and product
realization activities, which consist of new product design and formulation,
manufacturing process development, and process improvement. The objective in many
cases may be to develop a robust process, that is, a process affected minimally by
external sources of variability. There are also many applications of designed experiments
in a nonmanufacturing or non-product-development setting, such as marketing, service
operations, and general business operations.
Experimentation is a vital part of the scientific method. Now there are certainly situations
where the scientific phenomena are so well understood that useful results including
mathematical models can be developed directly by applying these well-understood
principles. However, most problems in science and engineering require observation of the
system at work and experimentation to elucidate information about why and how it
works. Well-designed experiments can often lead to a model of system performance;
such experimentally determined models are called empirical models.
A well-designed experiment is important because the results and conclusions that can be
drawn from the experiment depend to a large extent on the manner in which the data were
collected.
 Fig7. Input factors and Response Diagram

In general, experiments are used to study the performance of processes and systems. The
process or system can be represented by the model shown above. We can usually
visualize the process as a combination of operations, machines, methods, people, and
other resources that transforms some input (often a material) into an output that has one
or more observable response variables. Some of the process variables and material
properties x1, x2, . . . ,xp are controllable, whereas other variables z1, z2, . . . , zq are
uncontrollable (although they may be controllable for purposes of a test).

The objectives of the experiment may include the following:

1. Determining which variables are most influential on the response y

2. Determining where to set the influential x’s so that y is almost always near the
desired nominal value
3. Determining where to set the influential x’s so that variability in y is small
4. Determining where to set the influential x’s so that the effects of the uncontrollable
variables z1, z2, . . . ,zq are minimized.

7.2. Terminology of Experiments

● FACTORS: experimental variables that can be changed independently of each

other
● LEVEL: It is the particular setting. It is the value chosen for a factor .Values may
be qualitative or quantitative.
● DESIGN: It basically means strategy to do experiments in an efficient manner.

The main uses of design of experiments are:

1. Discovering interactions among factors

2. Screening many factors
3. Establishing and maintaining quality control
4. Optimizing a process
 5. Designing robust products

Interaction occurs when the effect on the response of a change in the level of one factor
from low to high depends on the level of another factor. In other words, when an
interaction is present between two factors, the combined effect of those two factors on the
response variable cannot be predicted from the separate effects. The effect of two factors
acting in combination can either be greater (synergy) or less (interference) than would be
expected from each factor separately. Frequently there is a need to evaluate a process
with many input variables and with measured output variables. A screening experiment
tells us which input variables (factors) are causing the majority of the variability in the
output (responses), i.e., which factors are the “drivers.” A screening experiment usually
involves only two levels of each factor and can also be called characterization testing or
sensitivity analysis.
A process is “out of statistical control” when either the mean or the variability is outside
its specifications. When this happens, the cause must be found and corrected. The cause
is found efficiently using an experimental design similar to the screening design, except
that the number of levels for the factors need not be two for all the factors

[Link] Of Variables

In an experiment we have got different types of variables:

1. Independent variables: are the factors whose value we are going to manipulate.
2. Dependent variables are the responses.
3. Control variables are the ones which we wish to keep constant.
4. Random (noise) variables are the ones that we are not controlling or are not under
our control. Examples are Vibrations, voltage fluctuations etc.

[Link] Design

Robust design is an engineering methodology for improving productivity during research

and development so that high-quality products can be produced quickly and at low cost.
According to [Link] Taguchi, a robust design is one that is created with a system of
design tools to reduce variability in product or process, while simultaneously guiding the
performance towards an optimal setting. A product that is robustly designed will provide
customer satisfaction even when subjected to extreme conditions on the manufacturing
floor or in the service [Link] method is one of the important tools used for
robust design to produce high quality products quickly and at low cost.
 8. TAGUCHI DESIGN:

8.1. Methodology:

Taguchi method is based on performing evaluation or experiments to test the sensitivity

of a set of response variables to a set of control parameters (or independent variables) by
considering experiments in “orthogonal array” with an aim to attain the optimum setting
of the control parameters. Orthogonal arrays provide a best set of well balanced
(minimum) experiments. An array name indicates the number of rows and columns it has,
and also the number of levels in each of the columns. For example array L 4 (23) has four
rows and three “2 level” columns. Similarly the array L 18 (21 37) has 18 rows; one “2
level” column; and seven “3 level” columns. Thus, there are eight columns in the array
L18. The number of rows of an orthogonal array represents the requisite number of
experiments. The number of rows must be at least equal to the degrees of the freedom
associated with the factors i.e. the control variables. In general, the number of degrees of
freedom associated with a factor (control variable) is equal to the number of levels for
that factor minus one.

[Link] orthogonal arrays and corresponding maximum number of factors[20]

8.2. Signal To Noise Ratio

The concept of S/N ratio originated in the electrical engineering field .Taguchi effectively
applied this concept to establish the optimum condition from the Experiments. When an
experiment is conducted, there are numerous external factors not designed into the
experiment which influence the response. These external factors are called the noise
factors and their effect on the outcome of the quality characteristics under test is termed
“noise.” The signal to noise ratio measures the sensitivity of the quality characteristics
being investigated in a controlled manner, to those external influencing factors not under
control. The signal to noise ratio indicates the degree of the predictable performance
parameter of a product or process in the presence of noise factors.

The signal to noise ratios (S/N), which are log functions of desired output, serve as the
objective functions for optimization, help in data analysis and the prediction of the
optimum results.
There are three forms of signal to noise (S/N) ratio that are of common interest for
optimization of static problems.

1. Smaller-the-better

This is expressed as

n = -10Log10 [mean of sum of squares of measured data]

This is usually the chosen S/N ratio for all the undesirable characteristics like
“defects” for which the ideal value is zero. When an ideal value is finite and its
maximum or minimum value is defined (like the maximum purity is 100% or the
maximum temperature is 92 K or the minimum time for making a telephone
connection is 1 sec) then the difference between the measured data and the ideal
value is expected to be as small as possible. Thus, the generic form of S/N ratio
becomes,

n = -10Log10 [mean of sum of squares {of measured-ideal}]

2. Larger-the-better

This is expressed as

n = -10Log10 [mean of sum of squares of reciprocal of measured data]

This is often converted to smaller-the-better by taking the reciprocal of the

measured data and next, taking the S/N ratio as in the smaller-the-better case.

3. Nominal-the-best

This is expressed as

n = -10Log10 [Square of mean/Variance]

This case arises when a specified value is the most desired, meaning that neither a
smaller nor a larger value is desired.
 9. EXPERIMENTATION:

9.1. Machine Specifications

Fig8. CNC FINE BORING MACHINE[8]

Table2. CNC machine Specifications[8]

CNC Machine Make FMS
NO of axis 6
max boring diameter 36.0mm
Max lenth of workpiece 120mm
Max bore length 100 mm
Spindle power (KW) 10 KW
Axis motor N/M 8 N/M
Weight of machine 5000 kg
Cast bad Yes
Type of spindle A2-6
Spindle RPM 4000
[Link] Geometry
 Fig9. Tool Geometry and Designation[17]

9.2.1. Tools Used

The tool inserts used in our experiment are the following:

Table3. Specifications of tool employed during experimentation

Nose Radius (mm) Rake angle Clearance Angle Lip angle

10 7º 15º 90º

[Link] Used

Material is a precipitation hardening aluminium alloy, containing magnesium and silicon

as its major alloying elements. Originally called "KS 1295," it was developed in 1998. It
is one of the most common alloys of aluminium for manufacturing piston purpose use.

9.3.1. Chemical Composition

The alloy composition of KS 1295 is:
● Silicon 12.5% to 13.5%
● Iron 0- 0.65%
● Copper 3.4% to 3.9%
● Manganese 0.15-0.35%
● Magnesium 0.95%-1.1%
● Chromium 0.0%
● Zinc 0-0.25%
● Titanium 0-0.15%
● Other elements no more than 0.05% each, 0.15% total
● Remainder Aluminium

9.3.2. Mechanical Properties

KS 1295 has an ultimate tensile strength of at least 42,000 psi (300 MPa) and yield
strength of at least 35,000 psi (241 MPa). More typical values are 45,000 psi (310 MPa)
and 40,000 psi (275 MPa), respectively. In thicknesses of 0.250 inch (6.35 mm) or less, it
has elongation of 8% or more; in thicker sections, it has elongation of 10%. T651 temper
has similar mechanical properties. The typical value for thermal conductivity for KS
1295 at 77°F is around 152 W/m K. A material data sheet defines the fatigue limit under
cyclic load as 14,000 psi (100 MPa) for 500,000,000 completely reversed cycles using a
standard RR Moore test machine and specimen. Note that Aluminium does not exhibit a
well-defined "knee" on its S-n graph, so there is some debate as to how many cycles
equates to "infinite life". Also note the actual value of fatigue limit for an application can
be dramatically affected by the conventional de-rating factors of loading, gradient, and
surface finish.

9.3.3. Uses;
 Manufacturing of piston for automobile vehicle.
 Material used in some ultra-high vacuum (UHV) chambers
 Many parts for remote controlled model aircraft, notably helicopter rotor
components.

[Link]

These methods enable to determine a numerical value of the surface finish of any surface.
Nearly all instruments used are stylus probe type of instruments. These operate on
electrical principles. Further, these electrical instruments can be of two kinds. In first
type, they operate on the carrier-modulating principle. The movements of the stylus
exploring the surface are caused to modulate a high frequency carrier current. The second
type includes those operating on voltage-generating principle. In these the movements of
the stylus are caused to generate a voltage signal. In both these types the output has to be
amplified and the amplified output is used to operate a recording or indicating instrument.

The Taylor-Hobson Tallysurf.

The Tallysurf is an electronic instrument working on carrier modulating principle. This

instrument also gives the same information as the previous instrument, but much more
rapidly and accurately. This instrument as also the previous one records the static
displacement of the stylus and is dynamic instrument like Profilometer.
 Fig10. Taylor Hobson Tallysurf[21]

The measuring head of this instrument consists of a diamond stylus of about 0.002 mm
tip radius and skid or shoe which is drawn across the surface by means of a motorised
driving unit (gearbox), which provides three motorised speeds giving respectively x 20
and x 100 horizontal magnification and a speed suitable for average reading. A neutral
position in which the pick-up can be traversed manually is also provided. In this case the
arm carrying the stylus forms an armature which pivots about the centre piece of E-
shaped stamping as shown. On two legs of (outer pole pieces) the J5-shaped stamping
there are coils carrying an a.c. current. These two coils with other two resistances form an
oscillator. As the armature is pivoted about the central leg, any movement of the stylus
causes the air gap to vary and thus the amplitude of the original a.c. current flowing in the
coils is modulated. The output of the bridge thus consists of modulation only.

This is further demodulated so that the current now is directly proportional to the vertical
displacement of the stylus only. The demodulated output is caused to operate a pen
recorder to produce a permanent record and a meter to give a numerical assessment
directly. In recorder of this statement the marking medium is an electric discharge
through a specially treated paper which blackens at the point of the stylus, so this has no
distortion due to drag and the record strictly rectilinear one.

Now-a-days microprocessors have made available complete statistical multi-trace

systems measuring several places over a given area and can provide standard deviations
and average over area-type readings and define complete surface characterisation. These
systems lend themselves to research applications where specialised programming can
achieve autocorrelation, power spectrum analysis and peak curvature.

[Link]:
 10.1. CNC Codes:

The machine has tool movement along two directions. The Z direction is along the axis of
the machine chuck and the X axis is normal to the axis of the machine.
The machine recognizes certain pre designated codes for metal cutting operations and
other machine operations. They are G codes and M codes.
Following are the type of codes used in our program:

Table4. G and M codes for CNC machine

CODE FUNCTION
G00 Rapid positioning
G01 Linear interpolation
G21 Programming in millimeters (mm)
G90 Fixed cycle, simple cycle, for roughing (Z-axis emphasis)
G99 Feed rate per revolution
M03 Spindle on (clockwise rotation)
M05 Spindle stop
M30 End of program, with return to program top
M02 End of program
R Defines size of arc radius, or defines retract height in milling canned cycles
O Program name
S Defines speed, either spindle speed or surface speed depending on mode
T Tool selection
X Absolute or incremental position of X axis.
Z Absolute or incremental position of Z axis

10.2. Measurements :

Surface Roughness of these machined surfaces has been measured by a Surface

Roughness measuring instrument TalysurfSurtronic 3+. Surtronic 3+ is a self-contained,
portable instrument for the measurement of surface texture and is suitable for use in both
the workshop and laboratory. Parameters available for surface texture evaluation are: Ra,
Rq, Rz (DIN), Ry and Sm. The parameter evaluation and other functions of the
instrument are microprocessor based. The measurement results are displayed on an LCD
screen and can be connected to an optional printer or computer for further results.

1. The workpiece is held in the vice such that the tapered surface is made straight so
that the tapered surface is virtually horizontal and the probe moves horizontally
over the surface. The Measurement for tapered surface was recorded and the
subsequent readings were jotted down.
 Fig12. Measurement of Roughness of work piece using Talysurf.

3.4 Specifications of roughness measuring instrument:

1 100 mm traverse for measurement

2 0.05 µm straightness accuracy

3 complies with all the roughness standards

4 Low measuring speed up to 0.03mm/sec

5 Full CNC column for ease of use

6 Cost effective

7 Supports 7 different languages

8 LCD touch screen

9 LC = 0.00001mm
10 cut off length =0.8mm

11 transvrse length =4.8mm

12 12measuring length =4.0mm

13 Speed range 0.03-6.0mm/sec

14 Stylus size=22µm & 5µm diamond tip checking parameters roughness-Ra,Rz,Rmax, pitch

[Link]

11.1. BORING

Table5. Parameters and their levels

LEVELS 1 2 3
Speed (rev) 2700 3000 3300
Feed (mm/rev) 0.15 0.20 0.25
Depth (mm) 0.05 0.10 0.15
 FEED
S.n DEPTH (mm/rev. Ra Rz Rmax Sm
o (mm) RPM ) (µm) (µm) (µm) (µm)
1 0.05 2700 0.15 0.239 1.45 2.35 41.47
2 0.05 2700 0.2 0.25 1.41 2.28 45.34
3 0.05 2700 0.25 0.348 1.61 3.58 80.32
4 0.05 3000 0.15 0.223 1.38 2.97 42.62
5 0.05 3000 0.2 0.245 1.49 3.91 58.26
6 0.05 3000 0.25 0.307 1.6 4.21 68.67
7 0.05 3300 0.15 0.194 1.23 1.82 35.92
8 0.05 3300 0.2 0.236 1.4 2.38 43.92
9 0.05 3300 0.25 0.3 1.61 2.45 57.83
10 0.1 2700 0.15 0.272 1.53 2.32 34.46
11 0.1 2700 0.2 0.356 1.72 2.6 86.22
12 0.1 2700 0.25 0.439 1.69 2.98 120.68
13 0.1 3000 0.15 0.264 1.53 2.25 34.99
14 0.1 3000 0.2 0.346 1.69 2.9 90.26
15 0.1 3000 0.25 0.434 1.74 3.21 99.41
16 0.1 3300 0.15 0.224 1.48 2.23 31.48
17 0.1 3300 0.2 0.348 1.61 3.58 80.32
18 0.1 3300 0.25 0.418 1.54 2.95 109.89
19 0.15 2700 0.15 0.296 1.62 2.4 43.69
20 0.15 2700 0.2 0.412 2.02 2.92 98.67
21 0.15 2700 0.25 0.49 2.08 3.42 120.2
22 0.15 3000 0.15 0.272 1.55 2.32 46.36
23 0.15 3000 0.2 0.354 1.72 2.99 97.42
24 0.15 3000 0.25 0.406 1.89 3.26 104.21
25 0.15 3300 0.15 0.256 1.46 2.46 42.46
26 0.15 3300 0.2 0.292 1.62 3.64 78.61
27 0.15 3300 0.25 0.402 1.68 2.68 104.6
Dr. Ranganath

————— 25-05-2017 17:55:16

————————————————————

Welcome to Minitab, press F1 for help.

Executing from file: C:\Program Files (x86)\Minitab\Minitab 17\English\Macros\
[Link]

This Software was purchased for academic use only.

Commercial use of the Software is prohibited.

Results for: Worksheet 2

Taguchi Design

Taguchi Orthogonal Array Design

L27(3^3)

Factors: 3
Runs: 27

Columns of L27(3^13) Array

1 2 3

Results for: Worksheet 3

Taguchi Design

Taguchi Orthogonal Array Design

L27(3^3)

Factors: 3

1
Runs: 27

Interactions

AB
AC
BC

Taguchi Analysis: Ra, Rz, Rm, Sm versus Dc, S, F

Linear Model Analysis: SN ratios versus Dc, S, F

Estimated Model Coefficients for SN ratios

Term Coef SE Coef T P

Constant -5.15183 0.02840 -181.372 0.000
Dc 0.05 0.12809 0.04017 3.189 0.005
Dc 0.10 -0.02439 0.04017 -0.607 0.551
S 2700 -0.03110 0.04017 -0.774 0.448
S 3000 0.01636 0.04017 0.407 0.688
F 0.15 0.29410 0.04017 7.321 0.000
F 0.20 -0.08204 0.04017 -2.042 0.055

S = 0.1476 R-Sq = 77.6% R-Sq(adj) = 70.8%

Analysis of Variance for SN ratios

Source DF Seq SS Adj SS Adj MS F P

Dc 2 0.24979 0.24979 0.124896 5.73 0.011
S 2 0.01307 0.01307 0.006534 0.30 0.744
F 2 1.24378 1.24378 0.621892 28.55 0.000
Residual Error 20 0.43569 0.43569 0.021785
Total 26 1.94234

Unusual Observations for SN ratios

Observation SN ratios Fit SE Fit Residual St Resid

7 -5.011 -4.715 0.075 -0.296 -2.33 R

R denotes an observation with a large standardized residual.

Linear Model Analysis: Means versus Dc, S, F

Estimated Model Coefficients for Means

Term Coef SE Coef T P

Constant 18.7714 0.5982 31.378 0.000
Dc 0.05 -4.4430 0.8460 -5.252 0.000
Dc 0.10 1.5164 0.8460 1.792 0.088
S 2700 1.0656 0.8460 1.260 0.222
S 3000 0.3303 0.8460 0.390 0.700
F 0.15 -7.9370 0.8460 -9.381 0.000
F 0.20 1.3324 0.8460 1.575 0.131

S = 3.108 R-Sq = 86.9% R-Sq(adj) = 82.9%

Analysis of Variance for Means

Source DF Seq SS Adj SS Adj MS F P

2
Dc 2 275.45 275.45 137.723 14.25 0.000
S 2 28.74 28.74 14.368 1.49 0.250
F 2 975.52 975.52 487.758 50.48 0.000
Residual Error 20 193.25 193.25 9.663
Total 26 1472.95

Response Table for Signal to Noise Ratios

Nominal is best (10×Log10(Ybar^2/s^2))

Level Dc S F
1 -5.024 -5.183 -4.858
2 -5.176 -5.135 -5.234
3 -5.256 -5.137 -5.364
Delta 0.232 0.047 0.506
Rank 2 3 1

Response Table for Means

Level Dc S F
1 14.33 19.84 10.83
2 20.29 19.10 20.10
3 21.70 17.38 25.38
Delta 7.37 2.46 14.54
Rank 2 3 1

Main Effects Plot for Means

Main Effects Plot for SN ratios

Residual Plots for SN ratios

Residual Plots for Means

TAGUCHI FACTORS DESIGNE

A B C

1 1 1

1 1 2

1 1 3

1 2 1

1 2 2

1 2 3

3
1 3 1

1 3 2

1 3 3

2 1 1

2 1 2

2 1 3

2 2 1

2 2 2

2 2 3

2 3 1

2 3 2

2 3 3

3 1 1

3 1 2

3 1 3

3 2 1

3 2 2

3 2 3

3 3 1

3 3 2

3 3 3

FACTORS
Dc S F

0.05 2700 0.15

0.05 2700 0.20

4
0.05 2700 0.25

0.05 3000 0.15

0.05 3000 0.20

0.05 3000 0.25

0.05 3300 0.15

0.05 3300 0.20

0.05 3300 0.25

0.10 2700 0.15

0.10 2700 0.20

0.10 2700 0.25

0.10 3000 0.15

0.10 3000 0.20

0.10 3000 0.25

0.10 3300 0.15

0.10 3300 0.20

0.10 3300 0.25

0.15 2700 0.15

0.15 2700 0.20

0.15 2700 0.25

0.15 3000 0.15

0.15 3000 0.20

0.15 3000 0.25

0.15 3300 0.15

0.15 3300 0.20

0.15 3300 0.25

RESULTS

5
Ra Rz Rm Sm

0.239 1.45 2.35 41.47

0.250 1.41 2.28 45.34

0.348 1.61 3.58 80.32

0.223 1.38 2.97 42.62

0.245 1.49 3.91 58.26

0.307 1.60 4.21 68.67

0.194 1.23 1.82 35.92

0.236 1.40 2.38 43.92

0.300 1.61 2.45 57.83

0.272 1.53 2.32 34.46

0.356 1.72 2.60 86.22

0.439 1.69 2.98 120.68

0.264 1.53 2.25 34.99

0.346 1.69 2.90 90.26

0.434 1.74 3.21 99.41

0.224 1.48 2.23 31.48

0.348 1.61 3.58 80.32

0.418 1.54 2.95 109.89

0.296 1.62 2.40 43.69

0.412 2.02 2.92 98.67

0.490 2.08 3.42 120.20

0.272 1.55 2.32 46.36

0.354 1.72 2.99 97.42

0.406 1.89 3.26 104.21

0.256 1.46 2.46 42.46

0.292 1.62 3.64 78.61

6
0.402 1.68 2.68 104.60

SNRA1 MEAN1 COEF_MEANS1 COEF_SN1

-4.93473 11.3773 18.7714 -5.15183

-5.04769 12.3200 -4.4430 0.12809

-5.24449 21.4645 1.5164 -0.02439

-4.83199 11.7982 1.0656 -0.03110

-4.94478 15.9763 0.3303 0.01636

-5.02790 18.6968 -7.9370 0.29410

-5.01055 9.7910 1.3324 -0.08204

-4.99910 11.9840

-5.17245 15.5475

-4.69706 9.6455

-5.40547 22.7240

-5.53833 31.4473

-4.73971 9.7585

-5.40074 23.7990

-5.40658 26.1985

-4.64128 8.8535

-5.24449 21.4645

-5.51238 28.6995

-4.91883 12.0015

-5.40531 26.0055

-5.45448 31.5475

7
-5.02081 12.6255

-5.43082 25.6210

-5.41593 27.4415

-4.92460 11.6590

-5.22649 21.0405

-5.50251 27.3405

Main Effects Plot for Means

Data Means
Dc S F
26

24

22
Mean of Means

20

18

16

14

12

10
0.05 0.10 0.15 2700 3000 3300 0.15 0.20 0.25

8
 Main Effects Plot for SN ratios
Data Means
Dc S F
-4.8

-4.9
Mean of SN ratios

-5.0

-5.1

-5.2

-5.3

-5.4
0.05 0.10 0.15 2700 3000 3300 0.15 0.20 0.25

Signal-to-noise: Nominal is best (10×Log10(Ybar^2/s^2))

Residual Plots for SN ratios

Normal Probability Plot Versus Fits
99 0.30

90 0.15
Residual
Percent

50 0.00

-0.15
10

-0.30
1
-0.30 -0.15 0.00 0.15 0.30 -5.6 -5.4 -5.2 -5.0 -4.8
Residual Fitted Value

Histogram Versus Order

0.30
4.8
0.15
Frequency

3.6
Residual

0.00
2.4

-0.15
1.2

-0.30
0.0
-0.24 -0.12 0.00 0.12 0.24 2 4 6 8 10 12 14 16 18 20 22 24 26
Residual Observation Order

9
 Residual Plots for Means
Normal Probability Plot Versus Fits
99
5.0
90
2.5

Residual
Percent

50 0.0

10 -2.5

1 -5.0
-5.0 -2.5 0.0 2.5 5.0 10 20 30
Residual Fitted Value

Histogram Versus Order

6.0 5.0

4.5 2.5
Frequency

Residual
3.0 0.0

1.5 -2.5

0.0 -5.0
-4 -2 0 2 4 2 4 6 8 10 12 14 16 18 20 22 24 26
Residual Observation Order

General Linear Model: Ra versus Dc, S, F

Method

Factor coding (-1, 0, +1)

Factor Information

Factor Type Levels Values

Dc Fixed 3 0.05, 0.10, 0.15
S Fixed 3 2700, 3000, 3300
F Fixed 3 0.15, 0.20, 0.25

Analysis of Variance

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

Dc 2 0.04758 0.023788 37.67 0.000
S 2 0.01046 0.005229 8.28 0.002
F 2 0.09468 0.047338 74.95 0.000
Error 20 0.01263 0.000632
Total 26 0.16534

Model Summary

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

0.0251311 92.36% 90.07% 86.08%

Coefficients

10
Term Coef SE Coef T-Value P-Value VIF
Constant 0.31937 0.00484 66.03 0.000
Dc
0.05 -0.05915 0.00684 -8.65 0.000 1.33
0.10 0.02519 0.00684 3.68 0.001 1.33
S
2700 0.02530 0.00684 3.70 0.001 1.33
3000 -0.00259 0.00684 -0.38 0.709 1.33
F
0.15 -0.07048 0.00684 -10.30 0.000 1.33
0.20 -0.00393 0.00684 -0.57 0.572 1.33

Regression Equation

Ra = 0.31937 - 0.05915 Dc_0.05 + 0.02519 Dc_0.10 + 0.03396 Dc_0.15 + 0.02530 S_2700

- 0.00259 S_3000 - 0.02270 S_3300 - 0.07048 F_0.15 - 0.00393 F_0.20
+ 0.07441 F_0.25

General Linear Model: Rz versus Dc, S, F

Method

Factor coding (-1, 0, +1)

Factor Information

Factor Type Levels Values

Dc Fixed 3 0.05, 0.10, 0.15
S Fixed 3 2700, 3000, 3300
F Fixed 3 0.15, 0.20, 0.25

Analysis of Variance

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

Dc 2 0.3373 0.168633 20.77 0.000
S 2 0.1283 0.064133 7.90 0.003
F 2 0.2802 0.140078 17.25 0.000
Error 20 0.1624 0.008119
Total 26 0.9081

Model Summary

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

0.0901049 82.12% 76.75% 67.41%

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 1.6056 0.0173 92.59 0.000
Dc
0.05 -0.1411 0.0245 -5.75 0.000 1.33
0.10 0.0089 0.0245 0.36 0.721 1.33
S
2700 0.0756 0.0245 3.08 0.006 1.33
3000 0.0156 0.0245 0.63 0.533 1.33
F
0.15 -0.1356 0.0245 -5.53 0.000 1.33
0.20 0.0256 0.0245 1.04 0.310 1.33

11
Regression Equation

Rz = 1.6056 - 0.1411 Dc_0.05 + 0.0089 Dc_0.10 + 0.1322 Dc_0.15 + 0.0756 S_2700

+ 0.0156 S_3000 - 0.0911 S_3300 - 0.1356 F_0.15 + 0.0256 F_0.20
+ 0.1100 F_0.25

Fits and Diagnostics for Unusual Observations

Obs Rz Fit Resid Std Resid

2 1.4100 1.5656 -0.1556 -2.01 R
20 2.0200 1.8389 0.1811 2.34 R
21 2.0800 1.9233 0.1567 2.02 R

R Large residual

General Linear Model: Rm versus Dc, S, F

Method

Factor coding (-1, 0, +1)

Factor Information

Factor Type Levels Values

Dc Fixed 3 0.05, 0.10, 0.15
S Fixed 3 2700, 3000, 3300
F Fixed 3 0.15, 0.20, 0.25

Analysis of Variance

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

Dc 2 0.07516 0.03758 0.17 0.848
S 2 0.93161 0.46580 2.07 0.153
F 2 3.60750 1.80375 8.00 0.003
Error 20 4.50819 0.22541
Total 26 9.12245

Model Summary

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

0.474773 50.58% 35.76% 9.93%

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 2.8541 0.0914 31.24 0.000
Dc
0.05 0.029 0.129 0.23 0.823 1.33
0.10 -0.074 0.129 -0.57 0.573 1.33
S
2700 -0.093 0.129 -0.72 0.480 1.33
3000 0.259 0.129 2.01 0.059 1.33
F
0.15 -0.507 0.129 -3.93 0.001 1.33
0.20 0.168 0.129 1.30 0.208 1.33

Regression Equation

Rm = 2.8541 + 0.029 Dc_0.05 - 0.074 Dc_0.10 + 0.045 Dc_0.15 - 0.093 S_2700

+ 0.259 S_3000

12
 - 0.166 S_3300 - 0.507 F_0.15 + 0.168 F_0.20 + 0.339 F_0.25

General Linear Model: Sm versus Dc, S, F

Method

Factor coding (-1, 0, +1)

Factor Information

Factor Type Levels Values

Dc Fixed 3 0.05, 0.10, 0.15
S Fixed 3 2700, 3000, 3300
F Fixed 3 0.15, 0.20, 0.25

Analysis of Variance

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

Dc 2 4313.0 2156.5 14.15 0.000
S 2 425.9 213.0 1.40 0.270
F 2 14940.7 7470.4 49.02 0.000
Error 20 3047.6 152.4
Total 26 22727.3

Model Summary

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

12.3443 86.59% 82.57% 75.56%

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 70.31 2.38 29.59 0.000
Dc
0.05 -17.60 3.36 -5.24 0.000 1.33
0.10 6.11 3.36 1.82 0.084 1.33
S
2700 4.25 3.36 1.27 0.220 1.33
3000 1.05 3.36 0.31 0.758 1.33
F
0.15 -31.03 3.36 -9.24 0.000 1.33
0.20 5.14 3.36 1.53 0.142 1.33

Regression Equation

Sm = 70.31 - 17.60 Dc_0.05 + 6.11 Dc_0.10 + 11.50 Dc_0.15 + 4.25 S_2700

+ 1.05 S_3000
- 5.30 S_3300 - 31.03 F_0.15 + 5.14 F_0.20 + 25.89 F_0.25

13
 Interaction Plot for Ra
Data Means
2700 3000 3300

Dc
0.4
0.05
0.10
0.3 Dc 0.15

0.2
S
0.4
2700
3000
S 0.3 3300

0.2
F
0.4
0.15
0.20
0.3 F 0.25

0.2
0.05 0.10 0.15 0.15 0.20 0.25

Interaction Plot for Rm

Data Means
2700 3000 3300

3.5
Dc
0.05
3.0
0.10
Dc 0.15
2.5

3.5
S
2700
3.0
3000
S 3300
2.5

3.5
F
0.15
3.0 0.20
F 0.25
2.5

0.05 0.10 0.15 0.15 0.20 0.25

14
 Interaction Plot for Rz
Data Means
2700 3000 3300

Dc
1.8
0.05
0.10
1.6 Dc 0.15

1.4

S
1.8
2700
3000
S 1.6 3300

1.4

F
1.8
0.15
0.20
1.6 F 0.25

1.4

0.05 0.10 0.15 0.15 0.20 0.25

Interaction Plot for Sm

Data Means
2700 3000 3300

100
Dc
0.05
75
0.10
Dc 0.15
50

100
S
2700
75
3000
S 3300
50

100
F
0.15
75 0.20
F 0.25
50

0.05 0.10 0.15 0.15 0.20 0.25

15
 12. CONCLUSIONS

12.1. BORING

1. There is increase in surface roughness when speed varies from 2700 rpm to
3000 rpm and decrease in roughness as speed varies from 3000rpm to 3300.
2. The surface roughness increases with increase in feed rate.
3. There is increase in surface roughness when depth of cut varies from 0.05 to
0.10 mm and decrease in roughness as speed varies from 0.10 to 0.15 mm.
4. The surface roughness decreases with increase in nose radius.
5. The optimal combination of process parameter for minimum surface
roughness are speed at 2700 rpm, feed of 0.15 mm/rev, depth of cut of 0.05
mm and nose radius of 10.0mm.
6. From plots for S/N ratio, the ideal conditions for least surface roughness
(Ra) are speed at level 1 (2700 rev/min), feed at level 1 (0.15 mm/rev),
depth of cut at level 1 (0.05 mm).
7. ANOVA table and F-statistic value shows that the percentage contribution
of nose radius and feed are maximum followed by depth of cut.

Taguchi gives systematic simple approach and efficient method for the optimum
operating conditions.

13. FUTURE PLAN

 The scope of the project is far from dead. The material can be varied and
parameters can be changed.
 We can fix a Force dynamometer and an Infrared Pyrometer on the CNC Turret
and analyse the cutting force and temperature variation and their respective
effects on surface roughness.
 Optimization techniques such as Response Surface Methodology, Factorial
designs, Artificial Neural Networks etc. can also be employed for surface
roughness analysis. We can develop regression models for the same. There can
be a comparison between the results obtained from various techniques.
 The analysis in this project is carried out using MINITAB. The same analysis
can be performed using software like Design Expert or Mat lab etc. Analysis
obtained using various software can be compared.

16
 We can also compare the surface roughness of the material when machined on
CNC boring and when machined conventional machine .

14. REFERENCES
1. A. Agrawal, S Goel, W. B Rashidc, M. Price Prediction of surface roughness
during hard turning of AISI 4340 steel (69 HRC).ELSEVIER Applied Soft
Computing30 (2015) 279–286.
2. C. Natarajan, S. Muthu, P. Karuppuswamy (2011) Prediction and analysis of
surface roughness characteristics of a non-ferrous material using ANN in CNC
turning. International journal for Advanced Manufacturing Technology (2011)
57:1043-1051.
3. U. K Yadav, D Narang, P SharmaExperimental Investigation And Optimization
Of Machining Parameters For Surface Roughness In CNC Turning By Taguchi
Method / International Journal of Engineering Research and Applications
(IJERA) ISSN: 2248-9622 Vol. 2, Issue4, July-August 2012, pp.2060-2065.
4. I. Asilturk, S. Neseli (2011) Multi response optimisation of CNC turning
parameters via Taguchi method-based response surface analysis. ELSEVIER
Measurement 45 (2012) 785-794.
5. I. Asilturk, HarunAkkus Determining the effect of cutting parameters on
surface roughness in hard turning using the Taguchi method. ELSEVIER
Measurement 44 (2011) 1697-1704.
6. M. Sarikaya, A. Gullu Taguchi design and response surface methodology based
analysis of machining parameters in CNC turning under MQL ELSEVIER
Measurement 65 (2014) 604-616
7. P.M. Patil, R.V. Kadi, S.T. Dundur, A.S. Pol Effect of cutting Parameters on
Surface Quality of AISI 316 Austenitic Stainless Steel in CNC Turning
International Research Journal Of Engineering and Technology,Volume: 02
Issue: 04/ july-2015
8. Ranganath. M. S., Vipin, R.S. Mishra, Prateek, Nikhil Optimization of Surface
Roughness in CNC Turning of Aluminium 6061 Using Taguchi Techniques,
International JOurnal of Modern Engineering research (IJMER), volume 5,
Issue 5, May 2015,42-50.
9. Ranganath. M. S., Vipin, Harshit Surface Roughness Prediction Model for
CNC Turning of EN-8 Steel Using Response Surface Methodology,
International Journal of Emerging Technology and Advanced Engineering
Volume 5, Issue 6, June 2015.
10. Ranganath. M. S., Vipin, N Kumar, R Kumar Experimental Analysis of
Surface Roughness in CNC Turning of Aluminium Using Response Surface
[Link] Journal of Advance Research and
InnovationVolume 3, Issue 1 (2015) 45-49.
11. Ranganath. M. S., Vipin Effect of Rake Angle on Surface Roughness in CNC
Turning International Journal of Advance Research and Innovation, Volume 2,
Issue 2 (2014) 522-530

17
12. Ranganath. M. S., Vipin, S. MAurya, S. Yadav Parametric Analysis of Surface
roughness Studies in Turning Using Artificial Neural Network, International
Journal of Advance Research and Innovation volume 2, Issue 3 (2014) 676-
683.
13. Ranganath. M. S., Vipin, R.S. Mishra Effect of Cutting Parameters on MRR
and Surface Roughness in Turning of Aluminium (6061) International Journal
of Advance Research and Innovation Volume 2, Issue 1 (2014) 32-39
14. Ranganath. M. S., Vipin Optimization of Process Parameters in Turning
Operation Using Taguchi Method and Anova: A Review International Journal
of Advance Research and Innovation volume 1 (2013) 31-45.
15. U. Caydas, S. Ekici Support vector machines models for surface roughness
prediction in CNC turning of AISI 304 Austenitic stainless steel Journal of
Intelligent Manufacturing (2012) 23: 639-650.
16. G Code,Retrieved from [Link]
17. Tool Insert Designation retrieved from
[Link]
18. Surface Roughness Definitions and measurement retrieved from Elements of
Workshop Technology Vol1: Manufacturing Processes by S.K.
HajraChoudhary, A.K. HajraChoudhary and Nirjhar Roy.
19. Taguchi design, retrieved from
[Link]/courses/112101005/downloads/Module_5_Lecture_4_final.pdf.
20. A Brief Introduction to Design of Experiments Jacqueline K. Telford, retrieved
from [Link]/techdigest/td/td2703/[Link]
21. Tallysurf and other surface roughness measuring instrument, retrieved from
[Link]
metrology/

18