Measurement 49 (2014) 205215

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Measurement
journal homepage: www.elsevier.com/locate/measurement

Optimization of surface roughness, cutting force and tool wear

of nitrogen alloyed duplex stainless steel in a dry turning
process using Taguchi method
D. Philip Selvaraj a,, P. Chandramohan b, M. Mohanraj c
a

School of Mechanical Sciences, Karunya University, Coimbatore 641114, India

Department of Mechanical Engineering, Professional Group of Institutions, Palladam 641662, India
c
Department of Mechanical Engineering, Hindusthan College of Engineering and Technology, Coimbatore 641032, India
b

a r t i c l e

i n f o

Article history:
Received 17 January 2013
Received in revised form 24 May 2013
Accepted 25 November 2013
Available online 5 December 2013
Keywords:
Duplex stainless steel
Dry turning
Taguchi method
S/N ratio
ANOVA
Optimization

a b s t r a c t
In this work, the dry turning parameters of two different grades of nitrogen alloyed duplex
stainless steel are optimized by using Taguchi method. The turning operations were carried
out with TiC and TiCN coated carbide cutting tool inserts. The experiments were conducted
at three different cutting speeds (80, 100 and 120 m/min) with three different feed rates
(0.04, 0.08 and 0.12 mm/rev) and a constant depth of cut (0.5 mm). The cutting parameters
are optimized using signal to noise ratio and the analysis of variance. The effects of cutting
speed and feed rate on surface roughness, cutting force and tool wear were analyzed. The
results revealed that the feed rate is the more signicant parameter inuencing the surface
roughness and cutting force. The cutting speed was identied as the more signicant
parameter inuencing the tool wear. Tool wear was analyzed using scanning electron
microscope image. The conrmation tests are carried out at optimum cutting conditions.
The results at optimum cutting condition are predicted using estimated signal to noise
ratio equation. The predicted results are found to be closer to experimental results within
8% deviations.
2013 Elsevier Ltd. All rights reserved.

1. Introduction
In the past few decades, the applications of stainless
steel materials have been increased enormously in various
engineering elds. The combination of good corrosion
resistance, wide range of strength levels, good formability
and aesthetically pleasing appearance have made stainless
steels as a good choice for wide range of applications. But,
their machinability is more difcult compared to other alloy steels due to low thermal conductivity, high built-up
edge (BUE) formation tendency and high deformation
hardening. Duplex stainless steel (DSS) combines the benets of both ferritic stainless steel (FSS) and austenitic
Corresponding author. Tel.: +91 9994650780; fax: +91 4222615615.
E-mail addresses: de_philip@rediffmail.com, philipselvaraj@karunya.
edu (D. P. Selvaraj).
0263-2241/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2013.11.037

stainless steel (ASS) by proper balancing of ferrite and austenite. The duplex structure improves stress-corrosion
cracking resistance, compared to ASSs, and improves the
toughness and ductility compared to FSSs [1]. Modern
DSS grades tend to be difcult to machine, by virtue of
their higher austenite and nitrogen contents. The use of
DSSs has been increased due to their high strength, higher
pitting corrosion resistance equivalent and stress corrosion
resistance [2]. DSSs are extensively being used in many
industrial sectors like desalination, chemical tankers, pressure vessels, storage tanks, machinery in the pulp and paper industry, and also in civil engineering applications.
They have higher contents of chromium and lower contents of nickel and molybdenum and they are excellent
engineering materials [3].
Agrawal et al. [4] have been studied the machining
characteristics of cast ASSs with reference to cutting force

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D. P. Selvaraj et al. / Measurement 49 (2014) 205215

requirement, tool rake-face wear and chip characteristics.

It has been reported that the composition of stainless steel
work piece material inuences the machinability. The wear
mechanisms when turning X5CrMnN18 ASS materials
were catastrophic failure at tool nose due to high cutting
forces and sharp edge chipping. The addition of nitrogen
to ASS increases the strength and decreases the machinability [5]. In powder metallurgy produced DSSs, the
machining difculties are increased due to the presence
of more hard oxide particles, high strength and work hardening rate [6]. The surface roughness values were found to
decrease with increasing cutting speed when turning AISI
304 ASS. This can be attributed to the presence of BUE at
lower cutting speeds. The poor performance of the tool
was due to higher inuence of the heat on the cutting tool
and less efcient heat dissipation at the lower cutting
speeds [7]. Similarly, Ciftci [8] investigated the machining
characteristics of ASS using chemical vapor deposition
coated carbide cutting tools. His results reported that cutting speed is highly inuencing the surface roughness values. In another work, Senthikumar et al. [9] evaluated the
tool life of alumina based ceramic cutting tool for machining hardened martensitic stainless steel (MSS). It has been
reported that the ank wear affects the tool life at lower
cutting speed, whereas, crater wear or notch wear affects
the tool life at higher cutting speed. Noordin et al. [10]
recommended higher insert radius, low feed rate and low
depth of cut to obtain better surface nish under dry turning operation. The ank wear rate of Cubic Boron Nitride
(CBN) tool was more compared to Polycrystalline Cubic
Boron Nitride (PCBN) tool while machining MSS due to
more abrasion and diffusion [11]. Krolczyk et al. [12]
developed a mathematical model using response surface
method (RSM) to predict the surface roughness of DSS in
dry turning. The cutting parameters considered were cutting speed, feed rate and depth of cut. They found that
the feed rate is the main inuencing factor on the surface
roughness. Bouzid Sai et al. [13] investigated the residual
stresses, microstructure, surface roughness and micro
hardness of carbon steels and DSS materials during milling
operations. They found that a high value cutting speed
with less feed rate has improved the quality of the machining surface. Depth of cut has less inuence on the surface
characteristics.
Muthukrishnan and Davim [14] optimized the machining parameters of Al/SiC metal matrix composites using
ANOVA and ANN analysis and reported that feed rate has
high physical inuence on the surface roughness. Similarly,
Palanikumar [15] used Taguchi method to optimize the
drilling parameters of glass ber-reinforced plastics composites. It has been reported that feed rate was the more
inuential parameter than spindle speed. In another work,
Mandal et al. [16] applied Taguchi method and regression
analysis to assess the machinability of AISI 4340 steel with
newly developed Zirconia Toughened Alumina ceramic inserts. Their results reported that the main contributing factors for the tool ank wear are depth of cut and the cutting
speed. The feed rate has less inuence on the ank wear.
Similarly, Asiltrk and Akkus [17] conducted dry turning
tests on hardened AISI 4140 steel (51 HRC) with coated
carbide cutting tools. They used Taguchi method to opti-

mize the cutting parameters. Their results reported that

the feed rate has the more signicant effect on surface
roughness (Ra- roughness average and Rz-average maximum height of the prole). The cited literatures conrmed
that limited investigations have been carried out on the
machining characteristics of nitrogen alloyed DSS. Hence,
an attempt has been made in this work to optimize the cutting parameters to minimize the surface roughness, cutting
force and tool wear during dry turning operations of nitrogen alloyed DSS.
2. Taguchi method
Taguchi method is widely used for optimizing industrial/production processes. The Taguchi design optimization method can be divided into three stages: (a) system
design, (b) parameter design and (c) tolerance design.
Among the three stages, the parameter design stage is considered to be the important stage [1820]. The steps followed in the Taguchi parameter design are: selecting the
proper orthogonal array (OA); running experiments based
on the OA; analyzing data; identifying the optimum condition; and conducting conrmation runs [21]. Many
researchers have been used Taguchi method to optimize
the various machining operations like turning, end milling,
drilling, etc. in various alloys [2228].
3. Experimental details and data analysis
The experiments are designed using Taguchis design of
experiment method. This research work was carried out at
Centre for Research in Design and Manufacturing engineering (CRDM), Karunya University, Coimbatore, India. The
experimental data are analyzed by using the signal to noise
ratio (S/N ratio) and the analysis of variance (ANOVA). The
S/N ratio analysis is used to nd out the optimum machining conditions. The ANOVA analysis is used to nd the percentage contribution of the cutting speed and feed rate on
surface roughness, cutting force and tool wear.
3.1. Work piece material
The work piece materials selected for investigation are
the cast DSS ASTM A 995 grade 5A and grade 4A with the
compositions as shown in Table 1. The mechanical properties of the material investigated are given in Table 2. The
diameter and length of the work piece used in the experimentation are 80 mm and 300 mm, respectively. One end
of the work piece is held in a chuck and other end is supported with a tailstock. Generally the length-to-diameter
ratio used is 3:16:1, while machining with the tail stock
to prevent deection. The length-to-diameter ratio of the
specimen used in this work is 3.75:1, which falls within
the acceptable range.
3.2. Experimental procedure
The turning tests are conducted on a medium duty Kirloskar Turn master-35 Lathe with a variable speed between 100 and 1500 rpm and a power rating of 2.2 kW.

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D. P. Selvaraj et al. / Measurement 49 (2014) 205215

Table 1
Chemical composition of ASTM A 995 grade 5A and 4A DSS (wt%).
Alloy

Si

Mn

Cr

Ni

Mo

Cu

Fe

5A
4A

0.028
0.028

0.67
0.65

0.87
0.71

0.005
0.006

0.028
0.027

25.10
22.16

6.63
5.66

4.16
3.33

0.14

0.17
0.24

Bal.
Bal.

Table 2
Mechanical properties of ASTM A 995 grade 5A and 4A DSS.
Alloy

Tensile
strength (MPa)

Yield strength
(MPa)

Elongation
(%)

Hardness
(BHN)

5A
4A

741
732

546
595

32.2
30.2

223
212

The cutting tools used are carbide inserts (Taegu Tec make)
coated with TiC and TiCN with a specication of SNMG
120408 MT TT5100. The inserts are clamped on a pin and
hole type tool holder (Taegu Tec make) with a specication
of PSBNR 2525M12. The surface roughness is measured
using a TR-100 surface roughness tester. Cutting force is
measured using Kistler piezoelectric dynamometer (model
9257B). Cutting force measurements are interfaced with a
computer using data acquisition system. The tool wear is
observed using scanning electron microscope (SEM) JEOL
JSM-6390 model. The schematic diagram of the experimental set-up is depicted in Fig. 1. Dry machining is more
popular in manufacturing as a means of reducing overhead
costs and protecting the environment [29]. It has great signicance for the factors of both economics and environment [30]. Hence, the experiments were carried out
under dry condition (without using cutting uid).

3.3. Experimental plan

The cutting parameters for turning operation are cutting speed, feed rate and depth of cut. The inuence of cutting speed and feed rate are more signicant compared to
depth of cut [12,13,27]. Hence, cutting speed and feed rate
are selected as the main cutting parameters in this study.
Depth of cut was maintained at constant value in the turning operation [31] and in the milling operation [32]. For
turning DSS material using carbide cutting tool, the cutting
speed range is 80120 m/min as per the standard published by International Molybdenum Association (IMOA

Chuck

1999). The feed rate range is selected based on the availability of the range of feed in the machine utilized for
experimentation. The depth of cut is taken constant as
0.5 mm based on the investigation reported by Thakur
et al. [31]. The experiments are planned using the Taguchis OA. The machining tests were conducted according
to a 3-level and 2-factor L9 OA. The experiments were conducted at three different cutting speeds (80, 100 and
120 m/min) with three different feed rates (0.04, 0.08
and 0.12 mm/rev) and a constant depth of cut (0.5 mm).
The cutting parameters and their levels are indicated in
Table 3. The experimental layout for the L9 OA is shown
in Table 4.
3.4. Analysis of the S/N ratio
The S/N ratio is the ratio of the mean to the standard
deviation. It is used to measure the quality characteristic
deviating from the desired value. The S/N ratio (g) is given
by the following equation discussed by Yang and Tarng
[21].

g 10 log M:S:D

Here, M.S.D is the mean square deviation for the output

characteristic. To obtain optimal cutting performance,
the-lower-the-better quality characteristic for surface
roughness, cutting force and tool wear must be taken.
The M.S.D. for the-lower-the-better quality characteristic
of surface roughness, cutting force and tool wear can be given by the following equations discussed by Yang and
Tarng [21].

M:S:D

m
1X
S2
m i1 i

M:S:D

m
1X
F2
m i1 i

M:S:D

m
1X
T2
m i1 i

Tailstock

Work Piece

Here, m is the number of tests, Si, Fi and Ti are the values of

the surface roughness, cutting force and tool wear, respec^ ) has been
tively for the ith test. The estimated S/N ratio (g
used to predict and verify the quality characteristic at the
^ at the optimal level
optimal level. The estimated S/N ratio g

Tool

Table 3
Cutting parameters and their levels.

Kistler
Dynamometer
Charge
amplifier

Computer

Fig. 1. Schematic diagram of experimental set-up.

Symbol

Cutting parameters

Level 1

Level 2

Level 3

V
F

Cutting speed (m/min)

Feed rate (mm/rev)

80
0.04

100
0.08

120
0.12

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D. P. Selvaraj et al. / Measurement 49 (2014) 205215

Table 4
Experimental layout using an L9 orthogonal
array.
Experimental
number

1
2
3
4
5
6
7
8
9

Table 5
Experimental results for surface roughness and S/N ratio of 5A and 4A grade
DSS.

Cutting parameter
level
Cutting
speed (A)

Feed
rate (B)

1
1
1
2
2
2
3
3
3

1
2
3
1
2
3
1
2
3

S.
no.

1
2
3
4
5
6
7
8
9

of the design parameters can be calculated by the following equation discussed by Yang and Tarng [21].

g^ gm

o
X

gi  gm

i1

Here, gm is the total mean S/N ratio, gi is the mean S/N

ratio at the optimal level, and o is the number of the main
design parameters that affect the quality characteristic.
3.5. Analysis of the variance
ANOVA is carried out to identify the design parameters
that signicantly affect the response. The total sum of the
squared deviations (SST) is calculated by using the following equation discussed by Yang and Tarng [21].

SST

n
X
gi  gm 2

Cutting
Speed
(m/min)

80
80
80
100
100
100
120
120
120

Feed rate
(mm/rev)

0.04
0.08
0.12
0.04
0.08
0.12
0.04
0.08
0.12

Surface
roughness Ra
(lm)

S/N ratio (dB)

5A
Grade

4A
Grade

5A
Grade

4A
Grade

1.20
1.25
1.32
1.05
1.17
1.25
1.16
1.24
1.30

0.60
0.68
0.85
0.53
0.57
0.64
0.58
0.60
0.76

1.58
1.94
2.41
0.42
1.36
1.94
1.29
1.87
2.28

4.44
3.35
1.41
5.51
4.88
3.88
4.73
4.44
2.38

Table 6
Experimental results for cutting force and S/N ratio of 5A and 4A grade DSS.
S.
no.

1
2
3
4
5
6
7
8
9

Cutting
speed
(m/min)

Feed rate
(mm/rev)

80
80
80
100
100
100
120
120
120

0.04
0.08
0.12
0.04
0.08
0.12
0.04
0.08
0.12

Cutting force
Fc (N)

S/N ratio (dB)

5A
Grade

4A
Grade

5A
Grade

4A
Grade

44.5
53.6
58.9
36.9
44.1
50.9
35.2
38.7
46.5

33.2
39.3
45.8
28.2
34.4
38.1
25.7
28.8
35.6

32.97
34.58
35.40
31.34
32.89
34.13
30.93
31.75
33.35

30.42
31.89
33.22
29.00
30.73
31.62
28.20
29.19
31.03

i1

Here, n is the number of experiments, gi is the mean S/N

ratio for the ith experiment and gm is the total mean S/N
ratio. The two sources of the SST are: the sum of the
squared deviations (SSd) due to each design parameter
and the sum of the squared error (SSe).
4. Results and discussion
The experimental results of surface roughness, cutting
force and tool wear with their corresponding S/N ratio
are shown in Tables 57, respectively for 5A and 4A Grade
DSS. The mean S/N ratio for cutting speed at level 1 is calculated by averaging the S/N ratios for the experiments 1
3. The mean S/N ratio for feed rate at level 1 is calculated
by averaging the S/N ratios for the experiments 1, 4 and
7. Similarly, the mean S/N ratio for cutting speed and feed
rate at levels 2 and 3 are calculated.
4.1. S/N ratio and ANOVA results
The S/N response table for surface roughness, cutting
force and tool wear of 5A and 4A grade DSS are shown in
Tables 8 and 9, respectively. The S/N response graph for
surface roughness of 5A and 4A grade DSS is depicted in
Fig. 2. In the S/N response graph, V1 stands for cutting

Table 7
Experimental results for tool wear and S/N ratio of 5A and 4A grade DSS.
S.
no.

1
2
3
4
5
6
7
8
9

Cutting
speed
(m/min)

Feed rate
(mm/rev)

80
80
80
100
100
100
120
120
120

0.04
0.08
0.12
0.04
0.08
0.12
0.04
0.08
0.12

Tool wear Vb
(mm)

S/N ratio (dB)

5A
Grade

4A
Grade

5A
Grade

4A
Grade

0.113
0.122
0.134
0.146
0.184
0.204
0.268
0.329
0.353

0.102
0.115
0.130
0.141
0.176
0.201
0.252
0.319
0.348

18.94
18.27
17.46
16.71
14.70
13.81
11.44
9.66
9.04

19.83
18.79
17.72
17.02
15.09
13.94
11.97
9.92
9.17

speed at level 1 (80 m/min), V2 stands for cutting speed

at level 2 (100 m/min), V3 stands for cutting speed at level
3 (120 m/min), F1 stands for feed rate at level 1 (0.04 mm/
rev), F2 stands for feed rate at level 2 (0.08 mm/rev) and F3
stands for feed rate at level 3 (0.12 mm/rev). The greater
S/N ratio corresponds to the smaller variance of the output
characteristic around the desired value. From Fig. 2, the
higher S/N ratio for surface roughness of 5A and 4A grade
are obtained at cutting speed level 2 and feed rate level

D. P. Selvaraj et al. / Measurement 49 (2014) 205215

Table 8
S/N response table for surface roughness, cutting force and tool wear for 5A
grade DSS.
Cutting parameter

Mean S/N ratio (dB)

Maxmin

Level 1

Level 2

Level 3

1.98
1.10

1.24
1.72

1.81
2.21

0.74
1.11

Cutting force
Cutting speed
Feed rate

34.32
31.75

32.79
33.07

32.01
34.29

2.31
2.54

Tool wear
Cutting speed
Feed rate

18.22
15.77

15.07
14.21

10.05
13.44

8.17
2.33

Surface roughness
Cutting speed
Feed rate

Table 9
S/N response table for surface roughness, cutting force and tool wear for 4A
grade DSS.
Cutting parameter

Mean S/N ratio (dB)

Maxmin

Level 1

Level 2

Level 3

3.07
4.89

4.76
4.22

3.85
2.56

1.69
2.33

Cutting force
Cutting speed
Feed rate

31.84
29.21

30.45
30.60

29.47
31.96

2.37
2.75

Tool wear
Cutting speed
Feed rate

18.78
16.27

15.35
14.60

10.35
13.61

8.43
2.66

Surface roughness
Cutting speed
Feed rate

The S/N response graph for tool wear of 5A and 4A grade

DSS is shown in Fig. 4. From Fig. 4, the higher S/N ratio for
tool wear of 5A grade are obtained at cutting speed level 1
and feed rate level 1. Hence the optimal cutting parameters
for tool wear of 5A and 4A grade DSS are the cutting speed
at level 1 (80 m/min) and the feed rate at level 1 (0.04 mm/
rev).
Similarly, Table 10 shows that the ANOVA results of
surface roughness, cutting force and tool wear of 5A grade
DSS. It was observed that the feed rate is the more signicant cutting parameter affecting the surface roughness.
The cutting parameters inuencing the surface roughness
are feed rate followed by cutting speed. ANOVA results
showed that feed rate and cutting speed are affecting the
surface roughness of 5A grade DSS by approximately 64%,
and 31%, respectively. It was observed that the cutting
speed and the feed rate are the signicant cutting parameters affecting the cutting force. The feed rate and cutting
speed affecting the cutting force of 5A grade DSS by
approximately 53% and 45%, respectively. It was observed
that the cutting speed is the more signicant and the feed
rate is the less signicant cutting parameter affecting the
tool wear. The cutting speed and the feed rate affect the
tool wear of 5A grade DSS by approximately 92%, and 7%,
respectively.
Similarly, Table 11 shows that the ANOVA results of
surface roughness, cutting force and tool wear of 4A grade

Fig. 3. S/N graph for cutting force-5A and 4A grade DSS.

Fig. 2. S/N graph for surface roughness-5A and 4A grade DSS.

1. Therefore, the optimal cutting parameters for surface

roughness of 5A and 4A grade DSS are the cutting speed
at level 2 (100 m/min) and the feed rate at level 1
(0.04 mm/rev).
The S/N response graph for cutting force of 5A and 4A
grade DSS is shown in Fig. 3. From Fig. 3, the higher S/N
ratio for cutting force of 5A and 4A grade are obtained at
cutting speed level 3 and feed rate level 1. Therefore, the
optimal cutting parameters for cutting force of 5A and 4A
grade DSS are the cutting speed at level 3 (120 m/min)
and the feed rate at level 1 (0.04 mm/rev).

209

Fig. 4. S/N graph for tool wear 5A and 4A grade DSS.

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D. P. Selvaraj et al. / Measurement 49 (2014) 205215

Table 10
Results of the ANOVA for surface roughness, cutting force and tool wear for 5A grade DSS.
Cutting parameter

Degrees of freedom

Surface roughness
Cutting speed
Feed rate
Error
Total

Sum of squares

2
2
4
8

0.9015
1.8567
0.1581
2.9163

0.4507
0.9283
0.0395

11.40
23.49

30.91
63.67
5.42
100

Cutting force
Cutting speed
Feed rate
Error
Total

2
2
4
8

8.2854
9.6825
0.2911
18.2590

4.1427
4.8412
0.0727

56.92
66.52

45.38
53.03
1.59
100

Tool wear
Cutting speed
Feed rate
Error
Total

2
2
4
8

101.8719
7.9206
0.8721
110.6646

50.93595
3.96030
0.218025

DSS. The feed rate and cutting speed affecting the surface
roughness of 4A grade DSS by about 63% and 31%, respectively. The feed rate and cutting speed affect the cutting
force of 4A grade DSS by about 56% and 42%, respectively.
The cutting speed and the feed rate affect the tool wear of
4A grade DSS by about 91% and 9%, respectively.

Mean square

F ratio

233.62
18.1644

Contribution (%)

92.05
7.16
0.79
100

parameters for tool wear of 5A and 4A grade DSS are the

cutting speed at level 1 (80 m/min) and the feed rate at level 1 (0.04 mm/rev). It is denoted as V1F1. The experimental results are closer to the predicted values within 8%
deviations.
4.3. Effect of cutting speed and feed rate on surface roughness

4.2. Comparison of predicted and experimental results at the

optimal cutting conditions
The results at optimum cutting condition are predicted
using estimated signal to noise ratio equation discussed by
Yang and Tarng [21]. The predicted and experimental surface roughness, cutting force and tool wear of 4A and 5A
grade DSS using the optimal cutting parameters are compared in Tables 12 and 13, respectively. The optimal cutting parameters for surface roughness of 5A and 4A grade
DSS are the cutting speed at level 2 (100 m/min) and the
feed rate at level 1 (0.04 mm/rev). It is denoted as V2F1 in
the Tables 12 and 13. The optimal cutting parameters for
cutting force of 5A and 4A grade DSS are the cutting speed
at level 3 (120 m/min) and the feed rate at level 1
(0.04 mm/rev). It is denoted as V3F1. The optimal cutting

The inuence of cutting speed on surface roughness of

5A and 4A grade DSS is illustrated in Fig. 5, for three different feed rates. When cutting speed increases the surface
roughness value decreases up to 100 m/min. However, further increase in cutting speed increases the surface roughness values. The increasing cutting speed from 80 to
100 m/min reduces the surface roughness value due to
the reduction in BUE formation tendency. However, further
increase in cutting speed from 100 to 120 m/min, increases
the surface roughness due to the increase in cutting tool
nose wear at higher cutting speeds. Similar trend was reported in turning operation of ASS [8].
The inuence of feed rate on surface roughness of 5A
and 4A grade DSS is shown in Fig. 6, for three different cutting speeds. The increasing feed rate increases the surface

Table 11
Results of the ANOVA for surface roughness, cutting force and tool wear for 4A grade DSS.
Cutting parameter

Degrees of freedom

Sum of squares

Surface roughness
Cutting speed
Feed rate
Error
Total

2
2
4
8

4.2927
8.6334
0.7112
13.6373

2.14635
4.3167
0.1778

12.07
24.28

31.48
63.31
5.21
100

Cutting force
Cutting speed
Feed rate
Error
Total

2
2
4
8

8.50954
11.3442
0.2564
20.1101

4.25475
5.67210
0.06410

66.38
88.49

42.31
56.41
1.28
100

Tool wear
Cutting speed
Feed rate
Error
Total

2
2
4
8

53.91495
5.42235
0.08455

637.67
64.13

90.60
9.11
0.29
100

107.8299
10.8447
0.3382
119.0128

Mean square

F ratio

Contribution (%)

D. P. Selvaraj et al. / Measurement 49 (2014) 205215

Table 12
Comparison between predicted and experimental results for surface
roughness, cutting force and tool wear of 5A grade DSS at optimum cutting
condition.
Optimal cutting parameters
Prediction

Experiment

Surface roughness
Level
Surface roughness (lm)
S/N ratio (dB)

V2F1
1.08
0.66

V2F1
1.05
0.42

Cutting force
Level
Cutting force (N)
S/N ratio (dB)

V3F1
34.36
30.72

V3F1
35.2
30.93

Tool wear
Level
Tool wear (mm)
S/N ratio (dB)

V1F1
0.105
19.54

V1F1
0.113
18.94

Table 13
Comparison between predicted and experimental results for surface
roughness, cutting force and tool wear of 4A grade DSS at optimum cutting
condition.
Optimal cutting parameters
Prediction

Experiment

Surface roughness
Level
Surface roughness (lm)
S/N ratio (dB)

V2F1
0.52
5.76

V2F1
0.53
5.51

Cutting force
Level
Cutting force (N)
S/N ratio (dB)

V3F1
25.38
28.09

V3F1
25.7
28.20

Tool wear
Level
Tool wear (mm)
S/N ratio (dB)

V1F1
0.098
20.22

V1F1
0.102
19.83

ness. The surface roughness can be minimized by employing the combination of lower level feed rate (0.04 mm/rev)
with medium level cutting speed (100 m/min).
4.4. Effect of cutting speed and feed rate on cutting force
The inuence of cutting speed on cutting force of 5A
and 4A grade DSS is shown in Fig. 7, for three different feed
rates. The cutting force decreases with increasing cutting
speed. Higher cutting force is required at lower cutting
speed due to the higher coefcient of friction between
the tool and work piece, results. At higher cutting speeds,
the temperature generation rate is higher which makes
the material soft at the cutting zone, which helps in removing the material at lower cutting forces. As the cutting
speed increases, the chip gets thinner and cutting forces reduced. The decrease in cutting force is due to reduction in
contact area and partly due to the drop in shear strength in
the ow zone as the temperature increases with increase
in cutting speed [31].
The inuence of feed rate on cutting force of 5A and 4A
grade DSS is shown in Fig. 8, for three different cutting
speeds. The cutting force is increased with increasing feed
rate at all the selected cutting speeds. As the feed rate is increased, the amount of material in contact with the tool
also increases. This implies an increased tool-work contact

Fig. 6. Feed rate vs. surface roughness-5A and 4A grade DSS.

Fig. 5. Cutting speed vs. surface roughness-5A and 4A grade DSS.

roughness due to the increase in friction between work

piece and tool interface and increases the temperature in
the cutting zone. Hence, the shear strength of the material
reduces and behaves in a ductile fashion [31]. The sticky in
nature of DSS is the cause for the increased surface rough-

211

Fig. 7. Cutting speed vs. cutting force-5A and 4A grade DSS.

212

D. P. Selvaraj et al. / Measurement 49 (2014) 205215

length. Due to this, the value of cutting force also increases.

In addition to increased contact length, the force resisting
deection is high, which is due to the higher amount of
material in contact with the tool. This also contributes to
an increase in cutting forces. The minimum cutting force
can be obtained by employing the combination of lower level feed rate (0.04 mm/rev) with higher level cutting speed
(120 m/min).
4.5. Effect of cutting speed and feed rate on tool wear
The inuence of cutting speed on tool wear of 5A and
4A grade DSS is shown in Fig. 9, for three different feed
rates. The tool wear increases with the increase in cutting
speed. Increase in cutting speed will increase the cutting
temperature at the cutting edge of the tool. The higher cutting temperature causes the tool to lose its strength and
plastic deformation occurs. Therefore, the extent of tool
wear and cutting edge deformation increases. The tool
wear was signicantly increased with increase in cutting
speed.
The inuences of feed rate on tool wear of 5A and 4A
grade DSS is depicted in Fig. 10, for three different cutting
speeds. The tool wear increases with increase in feed rate.
The larger the feed, the greater is the cutting force per unit
area of chip-tool contact on the rake face and work-tool
contact on the ank face. However, it has been observed
that the effect of changes in feed rate on tool wear is relatively lesser than that of proportionate changes in cutting
speed. The minimum tool wear was obtained by employing
the combination of lower feed rate (0.04 mm/rev) with
lower cutting speed (80 m/min).

Fig. 9. Cutting speed vs. tool wear-5A and 4A grade DSS.

Fig. 10. Feed rate vs. tool wear-5A and 4A grade DSS.

4.6. Tool wear analysis

The worn surfaces of the cutting tool inserts used in the
machining processes of the 5A and 4A grade DSS work
piece material are examined using SEM. Figs. 11 and 12
illustrate the SEM images of the worn tool inserts used
for machining 5A and 4A grade DSS, respectively. It is observed that wear predominantly occurred in three regions
during the tests, at the depth of cut line, rake surface and
the cutting edge. The SEM images in Fig. 11ac are examined at three different cutting conditions. The lowest wear

Fig. 8. Feed rate vs. cutting force-5A and 4A grade DSS.

was observed on the edge of the cutting tool used at

80 m/min cutting speed and 0.04 mm/rev feed rate
(Fig. 11a). The tool wear at the cutting edge is 0.113 mm.
The tool wear is extended on the cutting tool used at
100 m/min cutting speed and 0.08 mm/rev feed rate
(Fig. 11b). The tool wear at the cutting edge is 0.184 mm.
More wear was observed on the rake surface of the tool.
The highest wear was observed on the cutting tool used
at 120 m/min and 0.12 mm/rev feed rate (Fig. 11c).
Similarly, the less tool wear was observed on the edge
of the cutting tool used at 80 m/min cutting speed and
0.04 mm/rev feed rate (Fig. 12a). The tool wear at the cutting edge is 0.102 mm. The tool wear is extended on the
cutting tool used at 100 m/min cutting speed and
0.08 mm/rev feed rate (Fig. 12b). The tool wear at the cutting edge was 0.176 mm. More wear was observed on the
rake surface of the tool. The highest wear was observed
on the cutting tool used at 120 m/min and 0.12 mm/rev
feed rate (Fig. 12c). More wear was observed on the ank
and rake surface of the tool. The tool wear at the cutting
edge was 0.348 mm.
Tool wear is generally inuenced by abrasion, diffusion, thermal softening and notching. It was observed
from Figs. 11a and 12a, there is less wear on the cutting
edge ank face and rake surface at a cutting speed of
80 m/min, a feed rate of 0.04 mm /rev and a depth of

D. P. Selvaraj et al. / Measurement 49 (2014) 205215

Fig. 11. SEM images of tool inserts used for machining 5A grade DSS
(d = 0.5 mm), (a) V = 80 m/min and f = 0.04 mm/rev, (b) V = 100 m/min
and f = 0.08 mm/rev and (c) V = 120 m/min and f = 0.12 mm/rev.

cut of 0.5 mm. It was due to the abrasive action of micro

hard particle present in the material and plastic deformation. At this cutting speed, the cutting tool temperature was lower compared to the cutting speeds of
100 m/min and 120 m/min. Hence, abrasion is the major
factor inuencing the tool wear at lower cutting speed. It
was also observed from Figs. 11b and 12b, the wear rate
increases and there were more wear on the cutting edge,
ank face and rake surface at a cutting speed of 100 m/
min, a feed rate of 0.08 mm/rev and a depth of cut of
0.5 mm. Micro chipping was observed on the ank face
and rake surface. It was observed from Figs. 11c and
12c, the wear rate further increased, at a cutting speed
of 120 m/min, a feed rate of 0.12 mm/rev and a depth

213

Fig. 12. SEM images of tool inserts used for machining 4A grade DSS
(d = 0.5 mm), (a) V = 80 m/min and f = 0.04 mm/rev, (b) V = 100 m/min
and f = 0.08 mm/rev and (c) V = 120 m/min and f = 0.12 mm/rev.

of cut of 0.5 mm. Micro chipping and notch wear

were observed on the rake surface and ank face. At this
cutting speed, the cutting tool temperature was
higher compared to cutting speeds of 80 m/min and
100 m/min. The major factors such as diffusion, thermal
softening and notching inuencing the tool wear at
120 m/min cutting speed. Hence, tool wear is mainly
due to abrasion at lower cutting speed and due to diffusion, thermal softening and notching at higher cutting
speed. The results conrmed that the ank wear, rake
wear and notch wear were quite severe at higher cutting
speed [9].

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D. P. Selvaraj et al. / Measurement 49 (2014) 205215

4.7. Effect of work piece material on surface roughness,

cutting force and tool wear
The surface roughness, cutting force and tool wear values for 4A grade DSS are lower compared to 5A grade DSS
due to the difference in chemical compositions, which
leads to the difference in the formation of micro grains
[4]. The 4A grade DSS material has lower strength and lower hardness compared to 5A grade DSS. The lower percentage of molybdenum presents in 4A grade DSS decreases the
strength and hardness [8]. Lower cutting force is required
for shearing 4A grade DSS leads to good surface nish
and less tool wear compared to 5A grade DSS.
4.8. Comparison between dry and wet turning operation
The comparison of surface roughness and cutting force
values of machined work piece during dry and wet turning
of 4A and 5A grade DSSs are depicted in Figs. 13 and 14,
respectively. The result reveals that the surface roughness
and the cutting force values of wet turning operation are
reduced by about 510% compared to the dry turning operation. The application of cutting uid reduces chip friction

Fig. 13. Comparision of surface roughness between dry and wet turning
of 4A and 5A grade DSS.

during wet turning. Lower friction at the tool-chip interface can lead to lower cutting temperature which results
in less tool wear and better surface nish. Moreover, low
friction at the tool-chip interface will reduce the tool-chip
contact length which in turn decreases the cutting force
[33,34].
5. Conclusion
The Taguchi optimization method was successfully
used to identify the optimal cutting parameters of two different grades of nitrogen alloyed DSS during dry turning
operations. The following specic conclusions are made
from this work.
 A cutting speed of 100 m/min and a feed rate of
0.04 mm/rev are found to give the lowest surface
roughness for both 5A and 4A grade DSS. A cutting
speed of 120 m/min and a feed rate of 0.04 mm/rev
are found to give the lowest cutting force for both 5A
and 4A grade DSS. A cutting speed of 80 m/min and a
feed rate of 0.04 mm/rev are found to give the lowest
tool wear for both 5A and 4A grade DSS.
 ANOVA analysis indicates that the feed rate and the cutting speed were affecting the surface roughness of 5A
grade DSS by approximately 64% and 31%, respectively.
The feed rate and the cutting speed were affecting the
cutting force of 5A grade DSS by approximately 53%
and 45%, respectively. The cutting speed and the feed
rate were affecting the tool wear of 5A grade DSS by
approximately 92% and 7%, respectively.
 ANOVA analysis indicates that the feed rate and the cutting speed were affecting the surface roughness of 4A
grade DSS by about 63% and 31%, respectively. The feed
rate and the cutting speed were affecting the cutting
force of 4A grade DSS by about 56% and 42%, respectively. The cutting speed and the feed rate were affecting the tool wear of 4A grade DSS by about 91% and 9%,
respectively.
 The tool wear was due to abrasion at lower cutting
speeds and due to diffusion, thermal softening and
notching at higher cutting speeds.

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Fig. 14. Comparision of cutting force between dry and wet turning of 4A
and 5A grade DSS.

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