Journal of Engineering Research and Studies

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Research Paper

OPTIMIZATION OF MILLING PROCESS PARAMETERS OF EN33 USING TAGUCHI PARAMETER DESIGN APPROACH
Mr. Dhole N.S. 1, Prof. Naik G.R 2, Mr. Prabhawalkar M.S. 3
1

Address for Correspondence

Rajendra Mane College of Engineering & Tech., (Ambav), Devrukh, MH, India. 2 K.I.T.s College of Engineering, Kolhapur 3 Rajendra Mane College of Engineering & Tech., (Ambav), Devrukh, MH, India. ABSTRACT
To remain competitive in the todays competitive market the manufacturers rely on their engineers and production personnel to quickly and effectively set up manufacturing processes for new products to achieve good quality. Due to this surface finish & dimensional accuracy becomes very important. The knowledge of cutting forces developing in the various machining processes under given cutting factors is of great importance, being a dominating criterion of material machinability, to both: the designer-manufacturer of machine tools, as well as to user. Furthermore, their prediction helps in the analysis of optimization. This paper discusses about Taguchi method which involves reducing the variation in a process through robust design of experiments. The overall objective of the method is to produce high quality product at low cost to the manufacturer. Taguchi developed a method for designing experiments to investigate how different parameters affect the mean and variance of a process performance characteristic that defines how well the process is functioning. The experimental design proposed by Taguchi involves using orthogonal arrays to organize the parameters affecting the process and their appropriate levels. The experiments are conducted using L-18 orthogonal array on EN 33 material as suggested by Taguchi. Signal-to-Noise (S/N) ratio and Pareto Analysis of Variance (ANOVA) will be employed to analyze the effect of milling parameters on cutting force. Main effects of process parameters on the quality characteristics can be analyzed. KEY WORDS: EN33, Optimization, milling process parameters, Taguchi method, orthogonal array, ANOVA

1. INTRODUCTION With the more precise demands of modern engineering products and competition to provide good quality, the surface finish together with dimensional accuracy plays a very important role. It has been observed that surface texture greatly influences the functioning of the machined parts. Manufacturing involves various processes to turn raw materials to finished products to be used for a variety of purposes. Whatever may be the manufacturing process used, it is not possible to produce perfectly smooth surface. Hence, the improved qualities of product and the economics of the manufacturing operation are very important consideration to produce product having the functional and visual appeal. The selection of optimum cutting conditions (depth of cut, feed rate and cutting speed) is an important element of process planning for every machining operation. Machine tool operators select the cutting conditions based on their experience or using data from machining databases or tool catalogs. These values usually do not guarantee an optimum outcome. Inspite of major advancements in metal cutting practices, the metal cutting industries continues to suffer from one major drawback of not running the machine tools at their optimum operating condition. Metal cutting is one of the most widely used production processes in an industry. The process is very flexible & parts with complex geometry & fine tolerances can be produced. The cutting forces generated in metal cutting have a direct influence on tool wear or failure, quality of machined surface, heat generation and accuracy of the workpiece. Force measurement in metal cutting is essential requirement as it is related to machine part design, tool design, power consumptions, vibrations, part accuracy etc. It is the purpose of the measurement of cutting force to be able to understand the cutting mechanism such as

the effects of cutting variables on the cutting force, the machinability of the work piece, the process of chip formation, chatter and tool wear. The knowledge of cutting forces developing in the various machining processes under given cutting factors is of great importance, being a dominating criterion of material machinability, to both: the designer-manufacturer of machine tools, as well as to user. Furthermore, their prediction helps in the analysis of optimization problems in machining economics, in adaptive control applications, in the formulation of simulation models used in cutting databases. 2. METHODOLOGY 2.1 Design of Experiment (DOE): Design of experiments (DOE) is a statistical technique introduced by Sir R. A. Fisher in England in the early 1920s. Design of Experiment (DOE) is a structured and organized method that is used to determine the relationship between the different factors of input variables that affects a process and the output or response of that process. Design of Experiment involves designing a set of experiments, in which all relevant factors are varied systematically. When the results of these experiments are analyzed, they help to identify optimal conditions, the factors that most influence the results, and those that do not, as well as details such as the existence of interactions and synergies between factors. When applied to product or process design, the technique helps to seek out the best design among the alternatives. 2.2 Taguchis Robust Design Method Using Taguchis Robust design methodology products can be produced quickly and at low cost. The idea behind robust design is to improve the quality of a product by minimizing the effects of variation without eliminating the causes. Robust design is a design that has minimum sensitivity to

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Journal of Engineering Research and Studies variations in uncontrollable factors. Taguchi's approach to quality control applies to the entire process of developing and manufacturing a product from the initial concept, through design and engineering, to manufacturing and production. To achieve desirable product quality by design, Taguchi suggests a three-stage process: 1. System design 2. parameter design 3. Tolerance design. 2.3 Orthogonal arrays Taguchi has developed a system of tabulated designs (arrays) that allow for the maximum number of main effects to be estimated in an unbiased (orthogonal) manner, with a minimum number of runs in the experiment. Orthogonal arrays are used to systematically vary and test the different levels of each of the control factors. Commonly used OAs include the L4, L9, L12, L18, and L27. The columns in the OA indicate the factor and its corresponding levels, and each row in the OA constitutes an experimental run which is performed at the given factor settings. Typically either 2 or 3 levels are chosen for each factor. Selecting the number of levels and quantities properly constitutes the bulk of the effort in planning robust design experiments. 2.4 Signal to noise ratio and Pareto ANOVA approach The S/N ratio developed by Dr. Taguchi is a performance measure to choose control levels that best cope with noise. The S/N ratio takes both the mean and the variability into account. In its simplest form, the S/N ratio is the ratio of the mean (signal) to the standard deviation (noise). The S/N equation depends on the criterion for the quality characteristic to be optimized. While there are many different possible S/N ratios, three of them are considered standard and are generally applicable in the situations below; Biggest-is-best quality characteristic (strength, yield), Smallest-is-best quality characteristic (contamination), Nominal-is-best quality characteristic (dimension). In addition to the Signal to Noise Ratio (S/N ratio), the obtained results have been tested using statistical Analysis of Variance (ANOVA) with Pareto chart to indicate the impact of process parameters on surface roughness. The reason of combining Pareto chart with Analysis of Variance was to detect causes applying the principle that 80 percent of the problems usually stem from 20 percent of the causes. Pareto ANOVA technique of analysis has been used in this experimentation to analyze data for process optimization in past research also. Pareto ANOVA is a simplified ANOVA method, which uses Pareto principle. It is a quick and easy method to analyze result of parameters design. It does not require an ANOVA table and therefore, does not use F-test. The calculations of these tables are done by the use of standard orthogonal arrays. The preferred parameter settings are then determined through analysis of the signal-to-noise (SN) ratio where factor levels that maximize the appropriate SN JERS/Vol.III/ Issue I/January-March, 2012/70-74

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ratio are optimal. There are three standard types of SN ratios depending on the desired performance response. 1. Smaller the better (for making the system response as small as possible):
2 1 n SNs = 10 log yi n i =1

2. Nominal the best (for reducing variability around a target):

SN

= 10 log

y S

2 2

3. Larger the better (for making the system response as large as possible):

SN

1 L = 10 log n

i =1

1 2 i

These SN ratios are derived from the quadratic loss function and are expressed in a decibel scale. Once all of the SN ratios have been computed for each run of an experiment, Taguchi advocates a graphical approach to analyze the data. In the graphical approach, the SN ratios are plotted for each factor against each of its levels. Finally, confirmation tests should be run at the optimal product settings to verify that the predicted performance is actually realized. 2. 5 Steps applied in Taguchi methods Taguchi proposed a standard procedure for applying his method for optimizing any process. The steps suggested by Taguchi are: 1. Determine the quality characteristic to be optimized: The first step in the Taguchi method is to determine the quality characteristic to be optimized. The quality characteristic is a parameter whose variation has a critical effect on product quality. 2. Identify the noise factors and test conditions: The next step is to identify the noise factors that can have a negative impact on system performance and quality. 3. Identify the control parameters and their alternative levels: The third step is to identify the control parameters thought to have significant effects n the quality characteristic. Control (test) parameters are those design factors that can be set and maintained. The levels (test values) for each test parameter must be chosen at this point. 4. Design the matrix experiment and define the data analysis procedure: The next step is to design the matrix experiment and define the data analysis procedure. First, the appropriate orthogonal arrays for the noise and control parameters to fit a specific study are selected. 5. Conduct the matrix experiment: The next step is to conduct the matrix experiment and record the results. 6. Analyze the data and determine the optimum levels for control factors: After the experiments have been conducted, the optimal test parameter configuration within the experiment design must be determined. To analyze the results, the Taguchi method uses a statistical

Journal of Engineering Research and Studies measure of performance called signal to noise (S/N) ratio. 7. Predict the performance at these levels: The final step is an experimental confirmation run using the predicted optimum levels for the control parameters being studied. 3. EXPERIMENTAL PROCEDURE The objective of the paper is to obtain an optimal setting of milling process parameters (cutting speed, feed rate, depth of cut and tool material) resulting in an optimal value of the cutting force when machining EN33 steel. The effects of the selected milling process parameters on cutting force and the subsequent optimal settings of the parameters have been accomplished using Taguchis parameter design approach. The results indicate that the selected process parameters significantly affect the selected machining characteristics. The following process parameters were thus selected for the present work: Cutting speed (A), feed rate (B), depth of cut (C), tool material (D) work material EN33 steel, and environment dry cutting. Table A shows the selected process parameters with their values at 3 levels. As shown in table B, total 18 experiments are carried out. Cutting force is measured using milling dynamometer. Cutting force being a lower the

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better type of machining quality characteristic, the S/N ratio for this type of response was used. The mean response refers to the average value of the performance characteristic for each parameter at different levels. The average values of cutting force for each parameter at levels 1, 2 and 3 are calculated and it is shown in table C. The lower the better quality characteristics for cutting force should be taken for obtaining optimum cutting performance. The greater S/N ratio corresponds to the smaller variance of the output characteristic around the desired value. It is evident from the above graph that cutting force is minimum at the third level of cutting speed (A), first level of feed (B) and the first level of depth of cut (C) the second level of tool material. Figure A shows the effect of process parameters on S/N ratio for cutting force. The table D shows results of ANOVA for cutting force. It can be found that cutting speed, feed rate, depth of cut, and tool cutter material has significant cutting parameters that affect the cutting force. Therefore, based on S/N and ANOVA analysis, optimal cutting parameter for cutting force are cutting speed at level3, the feed rate at level1, depth of cut at level1 and tool cutter material at level 2.The optimal parameters and their level as given below in table E.

Table A. Process parameters with their values at 3 levels.

Parameters designation Level 1 A 1005 B 0.1 C 005 D H.S.S A - Cutting speed (mm/min) B Feed rate (mm/tooth) C Depth of cut (mm) D- Tool material Process parameters Level 2 Level 3 2010 3140 015 02 0.1 0.15 Carbide uncoated Carbide coated (Tia1N)

Table B. L18 Orthogonal array

Exp. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 A 1 1 1 2 2 2 3 3 3 1 1 1 2 2 2 3 3 3 End Milling Machining parameters B C D 1 1 1 2 2 2 3 3 3 1 1 2 2 2 3 3 3 1 1 2 1 2 3 2 3 1 3 1 3 3 2 1 1 3 2 2 1 2 3 2 1 1 3 3 2 1 3 2 2 1 3 3 2 1

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Journal of Engineering Research and Studies Table C. Experimental data of Cutting force

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Figure A. Effects of process parameters on S/N ratio for cutting force

Table D. ANOVA Table

Symbol A B C D Error Total Cutting parameter Cutting speed Feed rate Depth of cut Tool material Degree of freedom 2 2 2 2 9 17 Sum of square 8.64 11.35 2.97 2.66 0.57 26.19 Mean square 4.322 5.674 1.483 1.329 0.286 F test 15.10 19.82 5.18 4.64 % contribution 33.01 43.33 11.33 10.15 2.19 100

Table E: Parameters and their selected levels (optimal cutting force)

Symbol A B C D Process parameter Cutting speed Feed rate Depth of cut Tool material Optimal levels 3 (3140 mm/min) 1 (0.1 mm/tooth) 1 (0.05 mm) 2 (carbide coated)

Table F. Results of confirmation experiment for cutting force

Initial cutting parameters Optimal cutting parameters Prediction A3B1C1D2 142.95 43.10 Optimal cutting parameters Prediction A3B1C1D2 144.35 43.19

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

A2B2C2D2 178.85 45.05

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Journal of Engineering Research and Studies 4. CONFIRMATION EXPERIMENT The confirmation experiment is the final step in verifying the conclusions drawn based on Taguchis parameter design approach. The optimum conditions are set for the significant factors (the insignificant factors are set at economic levels) and a selected number of tests are run under constant specified conditions. Once the optimal design level of design parameters has been selected, the final step is to predict and verify the improvement of the quality characteristics using the optimal level of design parameter. The value of optimal cutting force is given as, FF = 142.95 N This above value of cutting force is based on calculations or prediction by using results of S/N ratio and ANOVA. The 95% confidence interval of the predicted optimal cutting force is: [FF CI] < FF <[FF + CI] i.e. 144.96< FF (N) < 140.93 The actual optimal cutting force value after confirmation experiment is given in table F. 5. CONCLUSION It was observed that cutting speed & feed rate have the major influence on the cutting force and as the cutting speed increases cutting force decreases, but as the feed rate and depth of cut increases cutting force also increases particularly for this specific test range on specified materials. Use of Tin coated carbide tool produces less cutting force than H.S.S. & uncoated carbide tools. Also it has been observed that cutting force is significantly reduced after using the selected optimum levels of parameters for all three work materials. It is a systematic and efficient approach for determining the optimum experimental configuration of design parameters for performance, quality, and cost. Principal benefits include considerable time and resource savings; determination of important factors affecting operation, performance and cost; and quantitative recommendations for design parameters, which achieve lowest cost, high quality solutions. Taguchi method is a powerful tool, which can offer simultaneous improvements in quality and cost. 6. REFERENCES
1. G. Petropoulos, I. Ntziantzias, C. Anghel, A predictive model of cutting forces in turning using Taguchi & response surface techniques, a proceeding of 1st International Conference on Experiments/Process/ System Modelling/Simulation/Optimization, Athens, 69 July, 2005 C. C. Tsao, GreyTaguchi method to optimize the milling parameters of aluminum alloy, International Journal on Advanced Manufacturing Technology (2009) 40:4148 K.-D. Bouzakis1, R. Paraskevopoulou1, G. Giannopoulos, Multi-objective optimization of cutting conditions in milling using genetic algorithms, Proceedings of the 3rd International Conference on Manufacturing Engineering (ICMEN), 1-3 October 2008, Chalkidiki, Greece Dalgobind Mahto and Anjani Kumar, Optimization of Process Parameters in Vertical CNC Mill Machines Using Taguchis Design of experiments, ARISER Vol. 4 No. 2 (2008) 61-75 5.

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E. Daniel Kirby, A parameter design study in turning operation using the Taguchi Method, the Technology Interface/Fall 2006 6. Hari Singh & Pradeep Kumar, Optimizing feed force for turned parts through the Taguchi technique, Sadhana Vol. 31, Part 6, December 2006, pp. 671681. 7. Guey-Jiuh Tzou , Ding-Yeng Chen, Chun-Yao Hsu, Application of Taguchi method in the optimization of cutting parameters for turning operations, 2006 8. Nafis Ahmad, Tomohisa Tanaka and Yoshio Saito, Optimization of cutting parameters for end milling operation by soap based genetic algorithm, Proceedings of the International Conference on Mechanical Engineering 2005 (ICME2005) 28- 30 December 2005, Dhaka, Bangladesh 9. Hari Singh, Optimizing Tool Life of Carbide Inserts for Turned Parts using Taguchis Design of Experiments Approach, Proceedings of the International MultiConference of Engineers and Computer Scientists 2008 Vol. II, IMECS 2008, 19-21 March, 2008, Hong Kong 10. Abbas Fadhel Ibraheem,. Saad Kareem Shather & Kasim A. Khalaf, Prediction of Cutting Forces by using Machine Parameters in end Milling Process, Eng.&Tech.Vol.26.No.11,2008 11. H.-S. Lu, J.-Y. Chen*, Ch.-T. Chung, The optimal cutting parameter design of rough cutting process in side mill engineering, Journal of Achievements in materials & manufacturing engineering, Vol. 29, Issue 2, August 2008.

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