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Engineering
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ISSN 0976 6340(Print),
INTERNATIONAL
JOURNAL
OF MECHANICAL
ENGINEERING
AND
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
TECHNOLOGY (IJMET)
IJMET
IAEME
Vishesh Ranglani2,
Sateesh Kumar3,
ABSTRACT
A series of experiments to determine the character of surface of the alloy steel have been
conducted. The main objective of this work is to develop a holistic understanding of the effects of
feed rate, spindle speed, depth of cut and type of coolant on the surface roughness and to create a
model for the conducted study. Such an understanding can provide sapience about the shortcomings
of controlling the finish of machined surfaces when the process parameters are adjusted to obtain a
certain surface finish. The model, which includes the effect of spindle speed, cutting feed rate and
depth of cut, and any three variable interactions, predicted the surface roughness values.
Keywords: Surface Roughness, Milling, ANOVA, EN11.
1. INTRODUCTION
The evaluation of surface roughness of machined parts using a direct contact method has
limitations in handling the different geometrical parts to be measured. Surface roughness affects
many functional parameters, such as friction, wear and tear, light reflection, heat transmission,
ability of distributing and holding a lubricant, coating etc. Therefore, the desired surface finish is
usually specified and appropriate processes are required to maintain the quality. Hence, the
inspection of surface roughness of the work piece is very important to assess the quality of a
component. Alternately, optical measuring methods are applied to overcome the limitations of stylus
method, but, they are also sensitive to lighting conditions and noise. The technique proposed in this
work, requires no apriority information about the lighting conditions and source of noise. Metal
cutting is one of the most significant manufacturing processes in the area of material removal [1].
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
Black [2] defined metal cutting as the removal of metal chips from a work piece in order to obtain a
finished product with desired attributes of size, shape, and surface roughness. The imperative
objective of the science of metal cutting is the solution of practical problems associated with the
efficient and precise removal of metal from work piece. It has been recognized that the reliable
quantitative predictions of the various technological performance measures, preferably in the form of
equations, are essential to develop optimization strategies for selecting cutting conditions in process
planning [3-5].
Milling is a machining process in which the removal of metal takes place due to the cutting
action of a revolving cutter when the work is fed through it. Milling refers to the process of breaking
down, separating, sizing, or classifying aggregate material. For instance rock crushing or grinding to
produce uniform aggregate size for construction purposes, or separation of rock, soil or aggregate
material for the purposes of structural fill or land reclamation activities. Aggregate milling processes
are also used to remove or separate contamination or moisture from aggregate or soil and to produce
"dry fills" prior to transport or structural filling.
2. MATERIALS AND METHODS
2.1. RESPONSE SURFACE METHODOLOGY (RSM)
It is a collection of mathematical and statistical techniques for empirical model building. By
careful design of experiments, the objective is to optimize a response (output variable) which is
influenced by several independent variables (input variables).
Originally, RSM was developed to model experimental responses (Box and Draper, 1987),
and then migrated into the modeling of numerical experiments. The difference is in the type of error
generated by the response. In physical experiments, inaccuracy can be due, for example, to
measurement errors while, in computer experiments, numerical noise is a result of incomplete
convergence of iterative processes, round-off errors or the discrete representation of continuous
physical phenomena[6]. In RSM, the errors are assumed to be random.
The application of RSM to design optimization is aimed at reducing the cost of expensive
analysis methods (e.g. finite element method or CFD analysis) and their associated numerical noise.
The problem can be approximated with smooth functions that improve the convergence of the
optimization process because they reduce the effects of noise and they allow for the use of
derivative-based algorithms. Venter et al. (1996) have discussed the advantages of using RSM for
design optimization applications.
2.2. METHODOLOGY ADOPTED FOR THE PROPOSED DESIGN
1. To design the experiment using Design of Experiment techniques.
2. To obtain a combination of the optimal levels of the parameters in order to minimize surface
roughness with the application of response surface method (RSM).
EN 11(Fig. 10) was chosen to be the specimen material in the proposed work in order to
study the effect of four different parameters (Depth of cut, feed, spindle speed & different coolants)
on the Surface Roughness of the finished specimens using L18 orthogonal design. Therefore the
milling operations and measurements of surface roughness have been done 18 times on the work
pieces for each of the following cases. The work piece were machined by HSS cutting tool wet the
cutting conditions respectively.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
Material
Carbon (%)
EN11
0.4
Molybdenum (%)
1.0
0.23
The Rockwell hardness number was 84 HRC for the EN11 work piece material.
EN11 is a high quality, high tensile, alloy steel. It combines high tensile strength, shock
resistance, good ductility and resistance to wear. EN11 is available from stock in round bar, flat bar
and plate.
EN11 is most suitable for the manufacture of parts such as roller bearing components such as
brake, cylindrical, conical & needle rollers, producing components with enhanced wear resistance.
EN11 is capable of retaining good impact values at low temperatures; hence it is frequently specified
for harsh offshore applications such as hydraulic bolt tensioners and ship borne mechanical handling
equipment. EN11 is a high carbon alloy which is widely used in roller component such as brake,
cylindrical, conical & needle rollers due to their exception thermal resistance and ability to retain
mechanical properties at elevated service temperatures over 1000 C. However a high carbon alloy is
cut material due to their high degree of hardening and compressive strength and abrasion resistance.
The difficulty of machining EN11 results in to shorter tool life and severe surface abuse to machined
surface.
The Initial dimensions of the specimen for Milling Operation:
Length (mm) = 110.5
Breath (mm) = 20.5
Height (mm) = 20.5
In this experiment four different control factors have been taken into consideration to find out their
influence on surface roughness. All the four parameters are at three levels each. Values of variables
at different level for Milling Operation is as shown in the Table 2.
Factors
D1
F1
S1
Level 3
D2
F2
S2
D3
F3
S3
C1
C2
The degree of freedom (DF) of a three level parameter is 2 (number of levels-1) and two level
parameter is 1. The minimum required degree of freedom in the experiment is the sum of all factors.
Factors
Degree of Freedom
49
D
1
Total
7
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
Total DF for this experiment is 7 as shown in Table 3. As the degree of freedom required for
the experiment is 7 so the orthogonal array that is to be selected should have degree of freedom
higher than 7. The most suitable orthogonal array that can be used for this experiment is L18.
In this experiment, the assignment of factors was carried out using MINITAB 17 Software.
The standard L18 orthogonal array Table 4 as suggested by MINITAB using Taguchi for the
particular experiment are listed in Table 7.
Experiment
No.
Coolant
D
1.
C1
2.
C1
3.
C1
4.
C1
5.
C1
6.
C1
7.
C1
8.
C1
9.
C1
10
C2
11
C2
12
C2
13
C2
14
C2
15
C2
16
C2
17
C2
18
C2
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
Level 1
0.5
0.000025
250
C1
Level 2
1.0
0.000125
330
Level 3
1.5
0.000375
510
C2
Using the L18 orthogonal array the trial runs have been the conducted on Milling Machine
for milling operations.
Table 6: List of Hardware
S.No.
Item
Specifications
1.
Milling machine
2.
Cutting Tool
Material of the cutting tool
Multipoint
HSS It is show in Fig. 2.
3.
Venire Caliper
It is show in Fig. 3.
Surface Roughness
Measurement Device
4.
51
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
The factors (Depth of cut, Feed rate and Spindle Speed, Different Coolants) were varied at
three levels for both milling operations. The measured response was impact surface roughness.
Analysis of the results was carried out analytically as well as graphically. All the statistical
calculations and plots were generated by MINITAB 17 software.
ANOVA plots of the experimental data have been created to calculate the significance of
each factor for each response. Often, researchers choose 90%, 95%, or 99% Confidence Levels; but
since most of the researchers have chosen 95% Confidence Level, so for this research work also 95%
Confidence Level has been chosen. Thus = 0.05 was selected for all statistical calculations. The
response surface method uses the Signal-to-Noise ratio (S/N) to express the scatter around a target
value. A high value of S/N implies that the signal is much higher than the random effects of the noise
factors.
Table 7: Results of Experimental Trial Runs for Milling Operation
Experiment
No.
Depth of Cut
A
Feed Rate
B
Spindle
Speed C
Coolant
D
Ra
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11
12
13
14
15
16
17
18
0.5
0.5
0.5
1
1
1
1.5
1.5
1.5
0.5
0.5
0.5
1
1
1
1.5
1.5
1.5
0.000125
0.00025
0.000375
0.000125
0.00025
0.000375
0.000125
0.00025
0.000375
0.000125
0.00025
0.000125
0.00025
0.000375
0.000125
0.00025
0.000375
0.00025
250
330
250
330
510
250
330
510
250
330
510
250
330
510
250
330
510
250
C1
C1
C1
C1
C1
C1
C1
C1
C1
c2
c2
c2
c2
c2
c2
c2
c2
c2
0.67
0.2
0.41
0.46
0.52
0.37
0.53
0.5
0.47
0.96
0.28
0.35
0.72
0.73
0.33
0.75
0.34
0.39
The response variables measured were surface roughness, surface roughness tester TR 110P is
used to measure the surface roughness for end milling operation. The single generated value is
measure after working. Surface roughness tester TR 110P is used to measure average surface
roughness.
The experimental come out result for surface roughness (Ra) are given in the Table 7. Values
of Ra are desirable. Thus the data sequences have the smaller-the-better characteristic, the smallerthe-best methodology by using MINITABE 17 to find the result.
53
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
Level
7.151
7.622
5.807
7.621
6.199
6.046
7.181
5.324
7.008
6.972
6.357
Delta
0.951
1.576
1.374
2.296
Rank
Level
Coolant
0.4589
0.4783
0.5500
0.4271
0.5389
0.5217
0.4800
0.6033
0.4967
0.4640
0.4740
0.0433
0.0860
0.1762
3
Delta
0.0800
Rank
DF
Adj SS
Adj MS
FValue
P-Value
Model
0.174778
0.019420
0.3
0.945
Linear
0.017613
0.005871
0.10
0.960
0.003922
0.003922
0.06
0.806
0.001090
0.001090
0.02
0.897
Speed (rpm)
0.011150
0.011150
0.18
0.680
0.123873
0.041291
0.68
0.589
0.008579
0.008579
0.14
0.717
0.010444
0.010444
0.17
0.689
0.106344
0.106344
1.75
0.222
0.040513
0.013504
0.22
0.878
0.038733
0.038733
0.64
0.448
0.000926
0.000926
0.02
0.905
0.001428
0.001428
0.02
0.882
0.485800
0.060725
Lack-of-Fit
0.434600
0.062086
1.2
0.606
Pure Error
0.051200
0.051200
17
0.660578
Square
2-Way Interaction
Error
Total
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
Fig. 7: Histogram graph between frequency and Residual (response surface roughness)
In Fig. 6-7, the signal to noise ratio select for the current work was smaller to better
According to Fig. 6, at the first level of depth of cut (0.5), first level of feed rate (0.000375)
mm/rev, first spindle speed (250 rpm) and first level of different Coolants (C1 type) respectively.
The surface roughness on the machined surface was found to be minimum. At Main effects versus
order between Residual and observation.
55
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
i. The use of a standard L18 orthogonal array, with four control parameters required 2 work
pieces to conduct the experimental portion in each case.
ii. In milling of EN11 (0.4% C) by High Speed Steel tool, the cutting the combination obtained
for the optimal levels of the parameters was spindle speed (250 rpm) followed by feed
(0.000375 mm/rev) and depth of cut (0.5 mm) and Different Coolant.
CONCLUSION
The present work has successfully demonstrated the application of Response surface method
for multi objective optimization of process parameters in end milling EN11 metal based alloy. The
conclusions can be drawn from the present work are as follows
i. The highest response surface result 0.73 was observed for the experimental Process, shown in
experiment result (Table 7).
ii. The order of importance for the controllable factors to the minimum force, in sequence, is the
spindle speed, depth of cut, feed rate and different Coolant; the order to minimum surface
roughness, in sequence, is the spindle speed, feed rate, depth of cut and different coolants.
iii. However, it is observed through ANOVA that the spindle speed is the most influential
control factor among the four end milling process parameters investigated in the present
work, when minimization of cutting forces, minimization of surface roughness are
simultaneously considered.
In this research work, the material used is EN11 with 0.4% carbon. The experimentation can
also be done for other materials having more hardness to see the effect of parameters on
Surface Roughness. In each case interaction of the different levels of the factors can be
included and study can be extended. In DOE the number of trials can be repeated with the
same combinations of factors and their interactions to obtain more than one response
(Surface Roughness).
3. ACKNOWLEDGEMENTS
Students Workshop, Department of Mechanical Engineering, Shepherd School of
Engineering and Technology, SHIATS, Allahabad. New Metal Testing Laboratory, Allahabad.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 11, November (2014), pp. 47-58 IAEME
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