Int J Adv Manuf Technol (2006) 29: 940947

DOI 10.1007/s00170-005-2616-y

ORIGINAL ARTICLE

Eyup Bagci Seref Aykut

A study of Taguchi optimization method for identifying optimum surface

roughness in CNC face milling of cobalt-based alloy (stellite 6)

Received: 4 December 2004 / Accepted: 15 February 2005 / Published online: 21 December 2005
Springer-Verlag London Limited 2005
Abstract The aim of this work is to develop a study of Taguchi
optimization method for low surface roughness value in terms of
cutting parameters when face milling of the cobalt-based alloy
(stellite 6) material. The milling parameters evaluated are feed
rate, cutting speed and depth of cut, a series of milling experiments are performed to measure the surface roughness data.
The settings of face milling parameters were determined by
using Taguchi experimental design method. Orthogonal arrays of
Taguchi, the signal-to-noise (S/N) ratio, the analysis of variance
(ANOVA) are employed to find the optimal levels and to analyze
the effect of the milling parameters on surface roughness. Confirmation tests with the optimal levels of cutting parameters are
carried out in order to illustrate the effectiveness of Taguchi optimization method. It is thus shown that the Taguchi method is
very suitable to solve the surface quality problem occurring the
face milling of stellite 6 material.
Keywords Analysis of variance (ANOVA) Face milling
Stellite 6 Surface roughness Taguchi optimization method

1 Introduction
Various kinds of cobalt-based alloys called stellite have been
used in fields requiring high heat and corrosion resistance and
high wear strength, such as the nuclear, aerospace, and gasturbine industries [1, 2]. Because of their good quality, studies
on the production of new kinds of cobalt-based alloys are still
E. Bagci (u)
TUBiTAK-UME,
National Metrology Institute,
P.K. 54, 41470, Gebze-Kocaeli, Turkey
E-mail: eyup@gyte.edu.tr
Tel.: +90 262 679 5000
Fax: +90 262 679 5001
S. Aykut
Institute of Science and Technology,
Marmara University,
Istanbul, Turkey

being carried out extensively. At the same time, some other products such as wires, plates, and welding electrodes made from
these alloys have been used successfully in different fields. Cobase superalloys rely primarily on carbides formed in the Co
matrix and at grain boundaries for their strength and the distribution, size, and shape of carbides depends on processing condition. Solid solution strengthening of Co-base alloy is normally
provided by tantalum, tungsten, molybdenum, chromium, and
columbium [13]. These alloys existing in a variety of more than
20 commercially available today, are being used extensively in
high temperature applications requiring superior wear resistance,
corrosion resistance, and heat resistance [3, 4].
The main usage area of cobalt based superalloys is the place
where corrosion and temperature resistance are needed. Having
more percentage of chrome in alloys gives better magnetic properties, corrosion resistance, and the working ability in higher
temperatures. However, the most certain property is the resistance to temperature [5]. In recent years, cobalt has an important
place especially in medicine applications and manufacturing of
corrosion resistant materials. Most certain properties in the used
area:

High creep resistance,

High structural stability,
Resistance to thermal creep,
Resistance to high thermal corrosion.

The cutting force or the surface roughness models are widely

used for predicting the cutting force [68] and the surface roughness [913], respectively. These models are needed to monitor
the process to obtain machining accuracy and process efficiency.
Until now, most of the developed surface roughness models have
been used for the prediction of surface texture and the quantitative analysis of the machined surface. However, in general,
the insert runout errors in a cutter body cannot be avoided in
a face-milling operation and it quantitatively affects the analysis
of the cutting force and the surface roughness. Consequently, it
is difficult to determine an optimal feed rate based on the surface
roughness model, since it will be affected by the insert run out
errors [14].

941
Fig. 1. Surface roughness profile

2 Surface roughness and measurement

Surface roughness of a machined product could affect several
of the products functional attributes, such as contact causing
surface friction, wearing, light reflection, heat transmission, ability of distributing and holding a lubricant, coating, and resisting
fatigue [15]. There are several ways to describe surface roughness. One of them is average roughness which is often quoted as
Ra symbol. Ra is defined as the arithmetic value of the departure of the profile from the centerline along sampling length as
shown in Fig. 1. It can be expressed by the following mathematical relationships [16].
1
Ra =
L

L
|Y(x)| dx

(1)

where Ra = the arithmetic average deviation from the mean line,

and Y = the ordinate of the profile curve.
There are many methods of measuring surface roughness,
such as using specimen blocks by eye or fingertip, microscopes,
stylus type instruments, profile tracing instruments, etc. A photo
of the used tool while working is shown in Fig. 2. Perthometer M1 model surface roughness tool of Mahr firm was used in
experimental work. The tools measuring surface roughness with

Fig. 2. Surface roughness measurement

probes, measure, and control in appropriate length and circumferences. The probe comes in and out holes while traveling on the
surface. This movement is turned into electrical current by means
of a coil or crystal. After increasing the current by using suitable
units, its value is shown with a pointer or digitally.

3 Taguchi experiment: design and analysis

3.1 Taguchi methods
Essentially, traditional experimental design procedures are too
complicated and not easy to use. A large number of experimental works have to be carried out when the number of the process
parameters increases. To solve this problem, the Taguchi method
uses a special design of orthogonal arrays to study the entire parameter space with only a small number of experiments [17].
Taguchi is the developer of the Taguchi method [18]. Taguchi
methods (orthogonal array) has been widely utilized in engineering analysis and consists of a plan of experiments with the
objective of acquiring data in a controlled way, in order to obtain
information about the behavior of a given process. The greatest
advantage of this method is to save the effort in conducting experiments: to save the experimental time, to reduce the cost, and
to find out significant factors fast.
Taguchi robust design method is a powerful tool for the
design of a high-quality system. He considered three steps in
a processs and products development: system design, parameter
design, and tolerance design. In system design, the engineer uses
scientific and engineering principles to determine the fundamental configuration. In the parameter design step, the specific values
for system parameters are determined. Tolerance design is used
to determine the best tolerances for the parameters [19]. In addition to the S/N ratio, a statistical analysis of variance (ANOVA)
can be employed to indicate the impact of process parameters
on surface roughness. In this way, the optimal levels of process
parameters can be estimated. The analysis results of related subjects discussed above are given in the following sections. The
steps applied for Taguchi optimization in this study are presented
in Fig. 3.

942
Fig. 3. Steps applied in Taguchi optimization method

3.2 Plan of experiments

Taguchi methods which combine the experiment design theory
and the quality loss function concept have been used in developing robust designs of products and processes and in solving
some confusing problems of manufacturing [20]. The orthogonal
array selected was the L 27 (313 ) which has 27 rows corresponding to the number of tests with three columns at three levels, as
shown in Table 2 the factors and the interactions are assigned to
the columns. The outputs studied were surface roughness (Ra ).
For the purpose of observing the effect influence degree of cutting conditions (feed rate, depth of cut, and cutting speed) in face
milling, three factors, each at three levels, are taken into account,
as shown Tables 1 and 2.

4 Experimental setup and cutting conditions

4.1 Cutting conditions and methodology

Table 1. The process parameters and their levels

Sample

Cutting conditions

Level 1

Level 2

Level 3

A
B
C

Depth of cut (mm)

Cutting speed (m/min)
Feed rate(mm/min)

0.25
50
100

0.50
70
140

0.75
90
180

Experimental work is done on a CNC milling machine. Surface roughness is investigated by the effect of cutting rate, feed
rate and cutting depth. Cutting speeds: 50, 70, 90 m/min, feed
rates: 100, 140, 180 mm/min, and cutting depths are selected as
0.25, 0.50, 0.75 mm. Processibility parameter values are selected
as recommended ISO plane milling standard values [21]. Ex-

Table 2. An orthogonal array L 27 (313 ) of Taguchi

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Designation

A
Depth of cut
(mm)

B
Cutting speed
(m/min)

C
Feed rate
(mm/min)

A1 B1 C 1
A1 B1 C 2
A1 B1 C 3
A1 B2 C 1
A1 B2 C 2
A1 B2 C 3
A1 B3 C 1
A1 B3 C 2
A1 B3 C 3
A2 B1 C 1
A2 B1 C 2
A2 B1 C 3
A2 B2 C 1
A2 B2 C 2
A2 B2 C 3
A2 B3 C 1
A2 B3 C 2
A2 B3 C 3
A3 B1 C 1
A3 B1 C 2
A3 B1 C 3
A3 B2 C 1
A3 B2 C 2
A3 B2 C 3
A3 B3 C 1
A3 B3 C 2
A3 B3 C 3

1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3

1
1
1
2
2
2
3
3
3
1
1
1
2
2
2
3
3
3
1
1
1
2
2
2
3
3
3

1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3

Fig. 4. CNC milling machine

943
Table 3. Mechanical and technical specifications of the tool (SECO)
Coating thickness (m)
Hardness (Rockwell C)
Operating temperature ( C)
Thermal expansion coefficient (103 K1 )
Chamfer (mm) ( C)

3-4
78
600
9.4
0.15 20

technique in coating is physical vapor deposition (PVD). PVDTiN coated tools are used. The coating thickness is 34 m and
hardness is 78 HRc. Mechanical and chemical properties of tools
are listed in Tables 3 and 4. Geometry of the cutting tool is shown
in Fig. 6.
4.3 Work-piece materials (stellite 6)

Fig. 5. Symmetric milling

perimental setup and milling methodology are shown in Figs. 4

and 5.
4.2 Cutting tools
Because heat extraction is inevitable in the cutting process, cutting corner of contact edge causes thermal stresses and will become blind in a short time.
This affect could be prevented by coating the surface of the
cutting tool. The heat that comes from tool-chip contact surface
will be reflected by the coated tool to chip. The most preferred
Table 4. Tool holder and inserts standards

Tool holder and insert standard

R220.4306307W OFEN070405-ME15

Fig. 6. Tool holder and cutting tool geometries

Various kinds of cobalt-based alloys called stellite have been

used in fields requiring high heat and corrosion resistance and
high wear strength. The most generally used cobalt alloy, having
excellent resistance to many forms of mechanical and chemical degradation over a wide temperature range. Particular attributes are its outstanding self-mated anti-galling properties,
high temperature hardness, and high resistance to cavitation erosion, which results in its wide use as a valve seat material. This
alloy is ideally suited to a variety of hard facing processes.
Some of applications are in non-ferrous (super)alloys, magnets, high speed tool steels, ultrahigh strength alloy steels,
abrasion-resistant cemented carbides for cutting tools, and stainless steels and they are preferred for stator vanes and diaphragms
in gas turbines because of their excellent thermal shock- and corrosion resistance [5]. Other uses of cobalt include the cemented
carbide cutting materials, where cobalt acts as a binder. Cobalt is

I
(0, 025)

s
(0, 025)

D
(mm)

A
(mm)

H
(mm)

ap
(mm)

Inserts

18,02

4,76

63

75

40

43 C

944
Table 5. Mechanical properties (a) and chemical analysis (b) of cobalt based
superalloy (Stellite 6)

a
Density
Tensile strength (N/mm2 )
Youngs modulus (N/mm2 )
Melting point
Boiling point
Hardness
b
Elements
Silisyum
Mangan
Crom
Nickel
Molibden
Wolfram
Titanium
Fe
Tantal
Carbon
Cobalt

8, 9 g/cm3
183 Mpa
210 Mpa
1493 C
2993 C
43.6 HRc
% wt
1,07
0,485
28,166
1,92
0,96
5,17
0,01
2,88
0,041
1,09
Balans

The smaller is better quality characteristics can be explained

as [23]:
 n

1 2
S/N() = 10 log
(2)
yi
n
i=1

where n = number of measurements in a trial/row, in this case,

n = 3 and yi is the ith measured value in a run/row. S/N ratio
values are calculated by taking into consideration Eq. 2. The surface roughness values measured from experiments and S/N ratio
values are listed in Table 6.
Ra response table for the feed parameter (A) at levels 1, 2,
and 3 was created by using the Ra values between 13, 1012
and 1921 in Table 6. Ra response table for each level of the
process parameters (cutting speed, feed rate, and depth of cut)
was created in the integrated manner and Ra response results are
given in Table 7. On the other hand, the same procedure for S/N
response table including process parameters was applied and the
S/N response results are listed in Table 8. The effects of process
parameters resulting from the optimization process are plotted in
Figs. 8 and 9.
5.2 Analysis of variance (ANOVA)
This method was developed by Sir Ronald Fisher in the 1930s
as a way to interpret the results from agricultural experiments.
ANOVA is a statistically based, objective decision-making tool
for detecting any differences in average performance of groups
of items tested [23].

Fig. 7. View of material stellite microstructure when 100 and 200 times
magnified

also used in hardfacing alloys, where it is most effective above

650 C in retaining the hardness and wear resistance for which
these alloys are known. Minor uses for cobalt-bearing alloys include metal-to-ceramic and metal-to-glass seals, watch springs,
pen nibs, and medical and dental alloys. The chemical composition mechanical properties of workpiece material is given in
Table 5. Figure 7 shows stellite 6 materials microstructure as
100 and 200 times magnified.

5 Data analysis and results

5.1 Analysis of the S/N ratio
In the Taguchi method, the term signal represents the desirable
value (mean) for the output characteristic and the term noise
represents the undesirable value (S.D.) for the output characteristic. Therefore, the S/N ratio is the ratio of the mean to the
S.D. Taguchi uses the S/N ratio to measure the quality characteristic deviating from the desired value. There are several S/N
ratios available depending on type of characteristic; lower is better (LB), nominal is best (NB), or higher is better (HB) [22].

Table 6. The Ra and S/N

ratio values

Experiment
Surface
numbers
roughness value

S/N ratio
(dB)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

6,6509
6,2852
5,8827
13,2309
6,5951
9,9515
13,4733
10,7820
10,2572
6,3391
4,0132
2,6271
6,1079
5,7977
4,8825
8,3815
8,1343
6,2316
9,6561
5,4655
2,9260
7,9588
3,4915
3,2356
13,7649
11,6340
9,7090

0,465
0,485
0,508
0,218
0,468
0,318
0,212
0,289
0,307
0,382
0,630
0,739
0,495
0,513
0,570
0,381
0,392
0,488
0,329
0,533
0,714
0,400
0,669
0,689
0,205
0,262
0,327

945
Table 7. Ra response table for surface roughness
Levels

1
2
3
max min
Rank

A
(mm/tooth)

B
(m/min)

C
(mm)

0.363
0.51
0.458
0.147
3

0.531
0.482
0.318
0.213
1

0.343
0.471
0.517
0.174
2

Table 8. S/N response table for surface roughness

Levels

1
2
3
max min
Rank

A
(mm/tooth)

B
(m/min)

C
(mm)

9, 23
5, 83
7, 53
3,39
2

5, 53
6, 80
10, 26
4,72
1

9, 50
6, 91
6, 18
3,31
3

Fig. 8. Ra response table for surface roughness

ANOVA helps in formally testing the significance of all main

factors and their interactions by comparing the mean square
against an estimate of the experimental errors at specific confidence levels. This is to be accomplished by separating the total
variability of the S/N ratios, which is measured by the sum of
the squared deviations from the total mean S/N ratio, into contributions by each of the design parameters and the error. First,
the total sum of squared deviations SST from the total mean S/N
ratio m can be calculated as [24]:
n

(i m )2
SST =

(3)

i=1

where n is the number of experiments in the orthogonal array and

i is the mean S/N ratio for the ith experiment.
The percentage contribution P can be calculated as below:
P=

SSd
SST

(4)

where SSd is the sum of squared deviations. ANOVA results are

illustrated in Table 7. Statistically, there is a tool called an F
test named after Fisher [19] to see which design parameters have
a significant effect on the quality characteristic. In the analysis,

Table 9. ANOVA results for surface

roughness for steelite 6 material

Fig. 9. The effects of process parameters (S/N response table for surface
roughness)

F- ratio is a ratio of mean square error to residual, and is traditionally used to determine the significance of a factor. F ratio
corresponding 95% confidence level in calculation of process parameters accurately is F0.05,2,26 = 3.37.
P value reports the significance level (suitable and unsuitable) in Table 9. Percent (%) is defined as the significance rate of
process parameters on drill bit temperature. The percent numbers
depicts that depth of cut, feed, and cutting speed have significant
effects on surface roughness. It can observed from Table 9 that
depth of cut (A), cutting speed (B), feed rate (C), affect surface
roughness by 17.88%, 38.27%, 20.14%, the stellite 6 material
surfaces, consecutively. The depth of cut, feed rate, and spindle speed factors present statistical and physical significance on
drill bit temperature, because Test F > F = 5% as shown in
Table 9.

Source of
variation

Degree of
freedom (DOF)

Sum of
squares (S)

MS

F ratio
(F)

P value
(P)

Contribution
P (%)

A
B
C
Error
Total

2
2
2
20
26

0,113645
0,243224
0,128008
0,150596
0,635472

0,056822
0,121612
0,064004
0,007530

7,55
16,15
8,50

0,004
0,000
0,002

17,88%
38,27%
20,14%
23,69%
100%

946
Table 10. L27 (313 ) standard orthogonal array table with factors A, B, and C arranged in columns 2, 5 and 6, respectively. The interactions among factors are
indicated as in columns 1, 7, 8, 9, 11 and 12
Experimental run
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

10

11

12

13

0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
BC

0
0
0
1
1
1
2
2
2
0
0
0
1
1
1
2
2
2
0
0
0
1
1
1
2
2
2
A

0
0
0
1
1
1
2
2
2
1
1
1
2
2
2
0
0
0
2
2
2
0
0
0
1
1
1

0
0
0
1
1
1
2
2
2
2
2
2
0
0
0
1
1
1
0
0
0
1
1
1
2
2
2

0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
B

0
1
2
0
1
2
0
1
2
1
2
0
1
2
0
1
2
0
2
0
1
2
0
1
2
0
1
C

0
1
2
0
1
2
0
1
2
2
0
1
2
0
1
2
0
1
1
2
0
1
2
0
1
2
0
BC

0
1
2
1
2
0
2
0
1
0
1
2
1
2
0
2
0
1
0
1
2
1
2
0
2
0
1
A B

0
1
2
1
2
0
2
0
1
1
2
0
2
0
1
0
1
2
2
0
1
0
1
2
1
2
0
AC

0
1
2
1
2
0
2
0
1
2
1
0
0
1
2
1
2
0
1
2
0
2
0
1
0
1
2

0
1
2
2
0
1
1
2
0
0
1
2
2
0
1
1
2
0
0
1
2
2
0
1
1
2
0
A B

0
1
2
2
0
1
1
2
0
1
2
0
0
1
2
2
0
1
2
0
1
1
2
0
0
1
2
AC

0
1
2
2
0
1
1
2
0
2
0
1
1
2
0
0
1
2
1
2
0
0
1
2
2
0
1

6 Determination of the minimum surface roughness

Using the before mentioned data, one can predict the optimum
surface roughness performance using the cutting parameters as:
Predicted Mean (Minimum roughness)
= A1 + B3 + C1 2x(Y)
= 0.363 + 0.318 + 0.343 2(0.443)
= 0.138 m.

(5)

Similarly, the maximum S/N ratio is calculated to determine

whether or not the minimum surface roughness is acceptable.
Also, the maximum S/N ratio varies from the min = 11 dB to
max = + dB.
The S/N ratio could be predicted as:
Predicted S/N Ratio (Maximum)
= A1 + B3 + C1 x()
= 9.23 10.26 9.50 + 2(7.53)
= 13.93 dB

A confirmation of the experimental design was necessary in

order to verify the optimum cutting conditions.

7 Confirmation tests
The confirmation experiment is very important in parameter design, particularly when screening or small fractional factorial
experiments are utilized. In this study, a confirmation experiment
was conducted by utilizing the level of optimal process parameters (A1 B3 C1 ) in the part surfaces. The purpose of the confirmation experiment in this study was to validate the optimum cutting conditions (A1 B3 C1 ) that were suggested by the experiment
that corresponded with the predicted value. In this research, the
confirmation runs with the optimum cutting condition A1 B3 C1
resulted in response values of 0.147, 0.143 and 0.140 m. Each
Ra measurement was repeated at least three times. Therefore, the
optimum surface roughness (Ra = 0.143 m) can be obtained
under the above-mentioned cutting condition in the Deckel Maho
CNC vertical milling machine.

(6)

where is the average value of surface roughness or S/N ratio.

With this prediction, one could conclude that the machine creates
the best surface roughness (Ra = 0.138 m) within the range of
specified cutting conditions (Table 1). The Ra value of 0.138 m
is the smallest value involving in experimental measurements.

8 Conclusions
This study has discussed an application of the Taguchi method
for investigating the effects of cutting parameters on the surface roughness value in the face milling of stellite 6 material.

947

In the face milling processes, cutting conditions have different

cutting speed, depth of cut, and feed rate values. As shown in
this study, the Taguchi method provides a systematic and efficient methodology for the design optimization of the cutting
parameters with far less effect than would be required for most
optimization techniques.
From the analysis of result in face milling using the conceptual S/N ratio approach and ANOVA, the following can be
concluded from the present study:
1. Statistically designed experiments based on Taguchi methods
were performed using L-27 orthogonal array to analyze surface roughness as response variable.
2. Conceptual S/N ratio and ANOVA approaches for data analysis draw similar conclusion.
3. Statistical results indicate that surface roughness is significantly influenced (at 95% confidence level) by cutting speed,
feed rate, and depth of cut.
4. In this study, the analysis of confirmation experiments has
shown that Taguchi parameter design can successfully verify
the optimum cutting parameters (A1B3C1), which are depth
of cut = 0.25 mm (A1), cutting speed = 90 m/min (B3), and
feed rate = 100 mm/min (C1).
5. The optimum surface roughness (Ra = 0.143 m) can be obtained under the above-mentioned cutting condition in the
Deckel Maho CNC vertical milling machine. Further study
could consider more factors ( different insert geometry, materials, lubricant, cooling strategy etc.) in the research to see
how the factors would affect surface roughness.

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