B.TECH.

OPTIMISATION OF PROCESS
PARAMETERS ON CNC LATHE MACHINE
A Project Report Submitted
In Partial Fulfillment of the Requirements
For the award of the Degree of
OPTIMISATION OF PROCESS PARAMETERS ON CNC LATHE MACHINE

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING

by
DIVYANSHU SRIVASTAVA (1413240067)
KUNAL SINGH (1413240091)
ROHIT PANDEY (1413240173)
CHETAN ANAND (1413240053)
ASHISH KUMAR GUPTA (1413240042)

Under the supervision of

MR. ANUJ DIXIT

DEPARTMENT OF MECHANICAL ENGINEERING

GREATER NOIDA INSTITUTE OF TECHNOLOGY
Plot no. 7, Knowledge Park – II, Greater Noida, U.P(201310)
MAY 2018

Affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow,

(Formerly Uttar Pradesh Technical University, Lucknow, U.P.)
MAY, 2018
OPTIMISATION OF PROCESS PARAMETERS ON
CNC LATHE MACHINE
A Project Report Submitted
In Partial Fulfillment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING

by
DIVYANSHU SRIVASTAVA (1413240067)
KUNAL SINGH (1413240091)
ROHIT PANDEY (1413240173)
CHETAN ANAND (1413240053)
ASHISH KUMAR GUPTA (1413240042)

Under the supervision of

MR. ANUJ DIXIT

DEPARTMENT OF MECHANICAL ENGINEERING

GREATER NOIDA INSTITUTE OF TECHNOLOGY, GREATER NOIDA
Affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow
(Formerly Uttar Pradesh Technical University, Lucknow, U.P.)
MAY, 2018
 GREATER NOIDA INSTITUTE OF TECHNOLOGY
PLOT NO. 7, K.P. II, GREATER NOIDA, UP-201310
Affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow, UP
(Formerly known as Uttar Pradesh Technical University, Lucknow)

CERTIFICATE

This is to certify that project report entitled “OPTIMISATION OF PROCESS

PARAMETERS ON CNC LATHE MACHINE” which is submitted by Divyanshu
Srivastava, Kunal Singh, Chetan Anand, Rohit Pandey and Ashish Kumar Gupta in
partial fulfillment of the requirements for the award of degree Bachelor of Technology in
Department of Mechanical Engineering from Greater Noida Institute of Technology,
affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow is a record of the
candidates own work carried out by them under my supervision. The matter embodied in
this project report is original and has not been submitted for the award of any other degree.

(Mr. ANUJ DIXIT)

Supervisor &
Project Co-ordinator, ME Deptt.

(Dr. SUDHIR KUMAR)

Prof. & HOD ME Deptt.

ii
 DECLARATION

We hereby declare that this submission is our own work and that, to the best of our
knowledge and belief. It contains no material previously published or written by another
person nor material which to a substantial extent has been accepted for the award of any
other degree or diploma of the university or other institute of higher learning, except where
due acknowledgment has been made in the text.

Signature: Signature:
Name: Divyanshu Srivastava Name: Kunal Singh
Roll no: 1413240067 Roll no: 1413240091
Date: /05/2018 Date: /05/2018

Signature: Signature:
Name: Rohit Pandey Name: Chetan Anand
Roll no: 1413240173 Roll no: 1413240053
Date: /05/2018 Date: /05/2018

Signature:
Name: Ashish Kumar Gupta
Roll no: 1413240042
Date: /05/2018

iii
 ACKNOWLEDGEMENT
It gives us a great sense of pleasure to present the report of B.Tech project undertaken
during B.Tech. Final Year. We express our sincere gratitude to our respected supervisor,
Mr. Anuj Dixit, (Assistant Professor, Department of Mechanical Engineering, Greater
Noida Institute of Technology, Greater Noida) for his invaluable inspiring guidance and
constant encouragement during the period of project work.

His sincerity, thoroughness and perseverance have been a constant source of inspiration
for us. It is only his cognizant efforts that our endeavors have seen light of the day.

We also take the opportunity to acknowledge the contribution of Professor Sudhir Kumar,
(Head, Department of Mechanical Engineering, Greater Noida Institute of Technology,
Greater Noida) for his full support and assistance during the development of the project.

We also like to acknowledge the contribution of all faculty members of the department for
their kind assistance during the development of our project. Last but not the least, we
acknowledge our friends for their contribution in the completion of this project.

Signature: Signature:
Name: Divyanshu Srivastava Name: Kunal Singh
Roll no: 1413240067 Roll no: 1413240091
Date: /05/2018 Date: /05/2018

Signature: Signature:
Name: Rohit Pandey Name: Chetan Anand
Roll no: 1413240173 Roll no: 1413240053
Date: /05/2018 Date: /05/2018

Signature:
Name: Ashish Kumar Gupta
Roll no: 1413240042
Date: /05/2018

iv
 ABSTRACT
Advanced makers, looking to stay focused in the business sector, depend on their
assembling architects and creation work force to rapidly and adequately set up assembling
procedures for new items. Taguchi Parameter Design is an intense and effective technique
for enhancing quality and execution yield of assembling procedures, along these lines a
capable apparatus for meeting this test. concerned with optimizing the process or say input
parameters of a CNC machine which in turn helps us to get a better and optimised output.
Optimised in terms of technology, economics and knowledge.
Into this project we have went through a number of research work done by various
researchers over a variety of materials on CNC machine through various machining
operations. In our project our material under operation turning is an Aluminium 6063 T6
alloy which we have selected due to its various applications in the various different
industries and also due to cost effectiveness and availability. The machine over which we
have performed our turning operation is 3 axis CUB/XXZ semi-automatic CNC turret lathe
having 8 tool inserting positions. We have also worked upon Minitab 2015 software for the
statistical analysis of our project by calculating the means, clamor proportions and signal-
to-noise ratios for each turning operation we have performed. Also a L9 orthogonal array
was used to decide the combination of values for each turning operation on Aluminium
6063 T6. The process parameters we have considered under our project for an optimised
output are feed rate (in mm per spindle revolution), depth of cut (in mm) and spindle speed
(in rpm). With the help of an L9 orthogonal array we have decided a set of combination of
values for our considered process parameters for an optimised surface roughness and
material removal rate.

v
 CONTENTS

CERTIFICATE ii
DECLARATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
CONTENTS vi
LIST OF FIGURES viii
LIST OF TABLES ix
CHAPTER: 1 INTRODUCTION 1-7
1.1 Background of CNC 1-2
1.2 Introduction of CNC 2-3
1.3 Basic Principle of CNC 3
1.4 Classification of CNC 3-4
1.4.1 Point-to-point system 3-4
1.4.2 Contouring system 4
1.5 Parameters of CNC 5-6
1.5.1 Cutting parameters for CNC turning 5-6
1.5.1.1 Cutting speed 5
1.5.1.2 Cutting feed 5
1.5.1.3 Spindle speed 5
1.5.1.4 Feed rate 5
1.5.1.5 Axial Depth of Cut 6
1.5.1.6 Radial Depth of Cut 6
1.6 Advantages of CNC 6
1.7 Limitations of CNC 6-7
1.8 Applications of CNC
CHAPTER: 2 LITERATURE REVIEW 8-14
2.1 Review of literature 8-13
2.2 Gaps in literature review 14
2.3 Objective 14
CHAPTER: 3 EXPERIMENTAL SET-UP 15-22

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 3.1 Investigational set-up 15
3.1.1 Machine Specifications 15
3.1.2 Workpiece specifications 16-17
3.1.2.1 Material Name 16
3.1.2.2 Physical Properties 16-17
3.1.2.3 Temper sorts 17
3.1.3 Tool Specifications 17-18
3.2 Selection of process parameters 18-20
3.3 Measurement of surface roughness 20-22
3.3.1 Amplitude parameters 20
3.3.2 Measurements 21-22

CHAPTER: 4 METHODOLOGY 23-32

4.1 Taguchi Method 23-24
4.2 Taguchi design methodology 24-27
4.2.1 Static problems 24-26
4.2.1.1 Smaller the better 25
4.2.1.2 Larger the better 25
4.2.1.3 Nominal the best 26
4.2.2 Dynamic problems 26-27
4.2.2.1 Sensitivity 27
4.2.2.2 Linearity 27
4.3 Steps of Taguchi methodology 27-28
4.4 Data Analysis 28-31
4.4.1 Minitab software 28-31
4.5 Advantages of Taguchi design 31-32
4.6 Disadvantages of Taguchi design 32
CHAPTER: 5 EXPERIMENTATION & ANALYSIS 33-44
5.1 Orthogonal array and L-9 matrix 33
5.2 Levels of control factors 33-36
5.3 Analysis 37-44
5.3.1 Interpretation 38-43
5.3.2 Conformation Experiments 43
CHAPTER: 6 RESULTS AND CONCLUSION 45-46
REFERENCES 47

vii
 LIST OF FIGURES

Fig. No. Figure Description Page No.

Figure 1.1 Schematic diagram of CNC 2

Figure 1.2 Point-to-point system 4

Figure 1.3 Contouring system 4

Figure 1.4 Contouring systems 4

Figure 3.1 Surface roughness tester 22

Figure 4.1 P-diagram for static problems 25

Figure 4.2 P-diagram for dynamic problems 26

Figure 5.1 Minitab Window 33

Figure 5.2 Turning Procedure 34

Figure 5.3 CNC CUB/XXZ servo controlled turret lathe 35

Figure 5.4 Plot for means 37

Figure 5.5 Plot for S/N proportion 40

Figure 5.6 Plot for means for MRR 41

Figure 5.7 Plot for S/N proportion for MRR 42

Figure 5.8 Turned workpieces(s) 44

viii
 LIST OF TABLES

Table No. Table Description Page No.

Table 3.1 Machine specifications 15

Table 3.2 Workpiece specifications 16

Table 3.3 Physical properties of workpiece 16-17

Table 3.4 Tool specification 17-18

Table 3.5 Insert specification 18

Table 5.1 Levels of control components 34

Table 5.2 Levels of control elements 34

Table 5.3 L9 orthogonal exhibit framework 35

Table 5.4 Result framework for surface roughness 36

Table 5.5 Result framework for Material Removal Rate 36

Table 5.6 Response table for means 39

Table 5.7 Response table for signal-to-noise ratio 40

Table 5.8 Response table for means 41

Table 5.9 Response table for signal-to-noise ratio 42

Table 5.10 Optimum table for surface roughness 43

Table 5.11 Optimum table for Material Removal Rate 43

Table 6.1 Analysis of Variance for Ra (µm), using adjusted SS 46

Table 6.2 Analysis of Variance for MRR (cc/min), using adjusted SS 46

ix
 CHAPTER 1

INTRODUCTION

1.1 Background of CNC

Today, Computer Numerical Control is an extension of what was once Numerical
Control. It refers essentially to the concept of controlling automated machine tools via
programmable computers. Clearly, with the older system of Numerical Control, a
computer wasn’t involved, but today the technology has advanced in leaps and bounds
(and continues to advance every year). CNC has set the stage for a tremendous upsurge in
productivity – it’s an environment where machine tools can operate automatically, and
without the attention and oversight of an operator.

Historically, the first commercial Numerical Control machines were used in the early
1950’s, and operated with “punch tape”. And although a proven method, the so-called
“new” technology was not readily accepted by manufacturers. In the late 1950’s,
Numerical Control began to capture the interest of more and more manufacturers, but still
with some problems and issues that required attention. Things became more manageable
when industry groups standardized the operational aspects of NC, bringing some order
and commonality to the manufacturing sector.

Over the years, as CNC technology gained acceptance (with proven results),
manufacturers began to replace older technologies and manual machining methods with
Computer Numerical Control. And while the United States launched the CNC technology
revolution, Germany and Japan became more successful in enhancing the technologies
and bringing down unit costs. In more recent years, microprocessors have brought down
unit costs even more, and have made CNC technology much more accessible to smaller
manufacturing companies, as well as individuals. Whether it’s metal cutting machines, or
woodworking machines, the technology is being used universally, and with advanced
applications emerging every year. As for the CNC machinist, CAD programs, CAM
programs, and other computer software are the basis for designing and fabricating almost

1
every product that consumers use on a daily basis. Indeed, like the 1950’s and 1960’s,
advances and innovations in technology will continue to revolutionize throughout the
2000’s.

1.2 Introduction of CNC

The term “CNC” is a generic term which can be used to describe many types of device,
this would include plotters, vinyl cutters, 3D printers, milling machines and others. CNC
stands for Computer Numerically Controlled and basically means that the physical
movements of the machine are controlled by instructions, such as co-ordinate positions
that are generated using a computer.

The term “CNC Machine” is typically used to refer to a device which uses a rotating
cutting tool which moves in 3 or more axes (X, Y and Z) to cut-out or carve parts in
different types of materials. The information on these pages will focus on what are
typically referred to as “CNC Routers” although it would be applicable to most CNC
milling and engraving machines too.

Fig 1.1 Schematic diagram of CNC [1]

2
CNC’s are incredibly versatile and allow you to cut a variety of different types of product
and materials. The exact abilities of a machine will vary with size, rigidity and power.
Typically most CNC Routers can cut soft and hard wood, plastics, other composites and
non-ferrous metals. Signage, custom furniture, plaques, trophies, chocolate & cookie
molds, awards, folk-art, toys, wall-hangings, plates & bowls, lithophanes, memorials,
cabinets, doors, boxes, clocks, religious carvings, panel goods, architectural millwork &
moldings, picture frames, mantels, archways, prototypes, remote control vehicle parts,
face plates, heirloom gifts, military awards, education projects, movie & theatre props,
coasters, chests, bottle totes, pool cues, rustic carvings and many other applications.

1.3 Basic Principle of CNC

 Movements of X, Y, Z axis are controlled by motor which supplies either AC/DC.
 Movement of machine is done by giving commands.
 All the operations are carried out by codes like speed, feed, depth of cut, etc.
 For each operation separate code is available.
 Warning system is available to save guard the various operations and components.

1.4 Classification of CNC

There are two main types of machine tools and the control systems required for use with
them differ because of the basic differences in the functions of the machines to be
controlled. They are known as point-to-point and contouring controls.

1.4.1 Point-to-point systems: Some machine tools for example drilling, boring and
tapping machines etc., require the cutter and the work piece to be placed at a certain fixed
relative positions at which they must remain while the cutter does its work. These
machines are known as point-to-point machines and the control equipment for use with
them are known as point-to-point control equipment. Feed rates need not to be
programmed. In these machine tools, each axis is driven separately. In a point-to-point
control system, the dimensional information that must be given to the machine tool will
be a series of required position of the two slides. Servo systems can be used to move the
slides and no attempt is made to move the slide until the cutter has been retracted.

3
1.4.2 Contouring systems (Continuous path systems): Other type of machine tools
involves motion of work piece with respect to the cutter while cutting operation is taking
place. These machine tools include milling, routing machines etc. and are known as
contouring machines and the controls required for their control are known as contouring
control.
Contouring machines can also be used as point-to-point machines, but it will be
uneconomical to use them unless the work piece also requires having a contouring
operation to be performed on it. These machines require simultaneous control of axes. In
contouring machines, relative positions of the work piece and the tool should be
continuously controlled. The control system must be able to accept information regarding
velocities and positions of the machines slides. Feed rates should be programmed.

Fig 1.2 Point-to-point system [2] Fig 1.3 Contouring system [2]

Fig 1.4 Contouring Systems [2]

4
1.5 Parameters of CNC
There are various kinds of CNC machines used today. One of them is CNC turning
machines, which are used to produce cylindrical parts. In these machines, a work piece
keeps on rotating, and the cutting tool moves in a linear fashion.

1.5.1 Cutting Parameters for CNC Turning Machines:

Right cutting parameters produce a precise output, which helps in reducing cycle times,
and machine costs. The speed and motion of the cutting tool are specified through several
parameters that can be modified for different operations based upon the workpiece
material and tool size.

1.5.1.1 Cutting speed: This criterion measures the number of feet the tool passes over the
surface of the work piece per minute in Surface Feet per Minute (SFM). The material and
the process often decide the cutting speed. For example, grooving requires slower cutting
speed for accurate results.

1.5.1.2 Cutting Feed: this parameter measure the distance undertaken by the cutting tool
for every single revolution. It is measured in Inches per Revolution (IPR). Depending
upon the mode of operation, the tool is either fed into the workpiece or the workpiece is
fed into the tool.

1.5.1.3 Spindle Speed: The spindle speed is obtained when the cutting speed is divided by
the circumference of the work piece in Revolutions per Minute (R.P.M). The speed varies
depending upon several factors like the diameter of the cut or the surface area.

1.5.1.4 Feed Rate: It is defined as the speed of the cutting tool when it cuts through the
material. It is the product of the cutting and spindle speed measured in Inches per Minute
(IPM).

1.5.1.5 Axial Depth of Cut: This parameter measures the depth of a tool as it cuts towards
the axis of the material. A large axial depth of cut is needed to overcome the high load on
the tool.

5
1.5.1.6 Radial Depth of the Cut: This parameter measures the depth of the tool as it cuts
along the radius of the material. To enhance the quality of the cutting tool, a lower feed
rate is needed.

1.6 Advantages of CNC

2 CNC machines can be used continuously 24×7 throughout the year and only need
to be switched off for occasional maintenance.
3 CNC machines are programmed with a design which can then be manufactured
hundreds or even thousands of times. Each manufactured product will be exactly
the same.
4 Less skilled/trained people can operate CNC machines unlike manual lathes
milling machines etc. which need skilled engineers.
5 CNC machines can be updated by improving the software used to drive the
machines
6 Training for correct use of CNC machines is available through the use of ‘virtual
software’. This software is like a computer game that allows the operator to
practice using the CNC machine on the screen of a computer.
7 Modern design software allows the designer to simulate the manufacture of
his/her idea. There is no need to make a prototype or a model. This saves time and
money.
8 One person can supervise many CNC machines as once they are programmed
they can usually be left to work by themselves. Only the cutting tools need
replacement occasionally.

1.7 Limitations of CNC

 CNC machines are more expensive than manually operated machines, although
costs are slowly coming down.
 The CNC machine operator only needs basic training and skills, enough to
supervise several machines. In years gone by, engineers needed years of training
to operate center lathes, milling machines and other manually operated machines.
This means many of the old skills are being lost.

6
 Fewer workers are required to operate CNC machines compared to manually
operated machines. Investment in CNC machines can lead to unemployment.
 Many countries no longer teach pupils / students how to use manually operated
lathes / milling machines etc… Pupils / students no longer develop the detailed
skills required by engineers of the past. These include mathematical and
engineering skills.

1.8 Applications of CNC

 Metal Fabrication
 Wood Manufacturing
 Computer Parts and Components Manufacturing
 Electrical Industry
 Plastics Manufacturing
 Precise Component Machining
 Range of Materials
 Repeatability
 Higher flexibility
 Increased productivity
 Consistent quantity
 Reduced scrap rate
 Reliable operation
 Reduced nonproductive time
 Reduced manpower
 Shorter cycle time
 Higher accuracy
 Reduced lead time
 Just In time (JIT) manufacture
 Automatic material handling
 Lesser floor space
 Increased operational safety

7
 CHAPTER 2

LITERATURE REVIEW

2.1 Review of Literature

Over the years a lot of research work has been done over the working of a Computer
Numeric Control machine and optimization of its process parameters in order to have a
controlled and feasible output. Here is some of the research works done under explained
as the literature review.

Prajapati, K. et al [1] have optimized the machining parameters for SR and MRR in
CNC turning. SS 316 (austenite steel) work material of Ø 45 mm and length 35 mm was
used in turning in dry environment conditions. In this study, the effect and optimization
of machining parameters (cutting speed, feed rate and depth of cut) on SR and MRR is
investigated. An L27 Orthogonal array, analysis of variance (ANOVA) and grey relation
analysis is used. The percentage contribution of cutting speed is 5.29 %, feed of 86.13 %
and depth of cut of 3.27 % on surface roughness. From the ANOVA it is conclude that
the feed rate is most significant parameter which contributes more to surface roughness.
In multi response optimization the optimum parameter combination is meeting at
experiment 3 and its parameter value is 1.4 mm depth of cut, 125 m/min cutting speed
and 0.1 mm/rev feed rate. From the ANOVA it is conclude that the depth of cut is most
significant parameter which contributes more to material removal rate.

Zhang, Julie, Z. et al [2] investigated the Taguchi design application to optimize surface
quality in a CNC face milling operation. An orthogonal array of L9 was used and
ANOVA analyses were carried out to identify the significant factors affecting surface
roughness. CNC Mill: Fadal VMC-40 vertical machining center was used for this
experiment and 19.1×38.1×76.2 mm aluminum blocks as a work piece. The experimental
results indicate that in this study the effects of spindle speed and feed rate on surface
were larger than depth of cut for milling operation. In this study the optimal cutting
condition for face milling was selected by varying cutting parameters through the

8
Taguchi parameter design method. With the L9(34) orthogonal array, a total of 36
experimental runs, covering three main factors each at three levels and two noise factors
each at two levels, indicated that the Taguchi parameter design was an efficient way of
determining the optimal cutting parameters for surface finish. The experimental results
indicate that in this study the effects of spindle speed and feed rate on surface were larger
than depth of cut for milling operation. In addition, one of the noise factors, tool wear,
was found to be statistically significant. The surface finish achievement of the
confirmation runs under the optimal cutting parameters indicated that of the parameter
settings used in this study, those identified as optimal through Taguchi parameter design
were able to produce the best surface roughness in this milling operation. This was
accomplished with a relatively small number of experimental runs, given the number of
control and noise factors, suggesting that Taguchi parameter design is an efficient and
effective method for optimizing surface roughness in a milling operation.

Joshi, A. et al [3] investigated the SR response on CNC milling by Taguchi technique.

Analysis of variance (ANOVA) was used in this investigation. The material used for the
experiment is (100 x 34 x 20 mm) 5 blocks of aluminum cast heat-treatable alloy. The
output characteristic, surface finish is analysed by software Minitab 15 and ANOVA is
formed, which shows the percentage contribution of each influencing factor on surface
roughness. CNC End milling is a unique adaption of the conventional milling process
which uses an end mill tool for the machining process. CNC Vertical End Milling
Machining is a widely accepted material removal process used to manufacture
components with complicated shapes and profiles. During the End milling process, the
material is removed by the end mill cutter. The effects of various parameters of end
milling process like spindle speed, depth of cut, feed rate have been investigated to reveal
their Impact on surface finish using Taguchi Methodology. Experimental plan is
performed by a Standard Orthogonal Array. The results of analysis of variance
(ANOVA) indicate that the feed Rate is most influencing factor for modeling surface
finish. The graph of S-N Ratio indicates the optimal setting of the machining parameter
which gives the optimum value of surface finish. The optimal set of process parameters
has also been predicted to maximize the surface finish.

9
Reddy, B. et al [4] Pre-hardened steel (P20) is a widely used material in the production
of molds/dies due to less wear resistance and used for large components. In this study,
minimization of surface roughness has been investigated by integrating design of
experiment method, Response surface methodology (RSM) and genetic algorithm. To
achieve the minimum surface roughness optimal conditions are determined. The
experiments were conducted using Taguchi’s L50 orthogonal array in the design of
experiments (DOE) by considering the machining parameters such as Nose radius (R),
Cutting speed (V), feed (f), axial depth of cut (d) and radial depth of cut(rd). A predictive
response surface model for surface roughness is developed using RSM. The response
surface (RS) model is interfaced with the genetic algorithm (GA) to find the optimum
machining parameter values. In this study, an efficient optimization methodology using
RSM and GA is introduced in minimizing surface roughness of P20 mold steel in CNC
end milling process. To achieve the minimum surface roughness, the appropriate process
parameters are determined. Nose radius, cutting speed, feed rate, axial depth of cut and
radial depth of cut are considered as process parameters. A predictive model for surface
roughness is created in terms of the process parameters using RSM to increase the quality
of the surface finish. The RSM model is interfaced with an effective GA to find the
optimum process parameter values. GA has reduced the surface roughness of the initial
model significantly. Surface roughness is improved by about 44.22%.

Kromanis, A. et al [5] studied to develop a technique to predict a surface roughness of

part to be machined. 3D surface parameters give more precise picture of the surface;
therefore it is possible more precisely to evaluate the surface parameters according to
technological parameters. In result of the study, the mathematical model of end-milling is
achieved and qualitative analysis is maintained. Achieved model could help technologists
to understand more completely the process of forming surface roughness. Pre-hardened
steel (P20) is a widely used material in the production of molds/dies due to less wear
resistance and used for large components. In this study, minimization of surface
roughness has been investigated by integrating design of experiment method, Response
surface methodology (RSM) and genetic algorithm. To achieve the minimum surface
roughness optimal conditions are determined. The experiments were conducted using
Taguchi’s L50 orthogonal array in the design of experiments (DOE) by considering the

10
machining parameters such as Nose radius (R), Cutting speed (V), feed (f), axial depth of
cut (d) and radial depth of cut (rd). A predictive response surface model for surface
roughness is developed using RSM. The response surface (RS) model is interfaced with
the genetic algorithm (GA) to find the optimum machining parameter values.

Bajic, D. et al [6] this paper focuses on surface morphology of machined brass reinforced
epoxy composite with different particle sizes in computer numerical control (CNC)
milling process. Morphological studies in this research contain composite’s surface
roughness and dispersion of brass particles. Surface roughness is a proper criterion for
predicting the performance of machining parameters and the quality of products. In this
experiment, cutting parameters evaluated are feed rate, spindle speed, and depth of cut.
Scanning electron microscope (SEM) and surface roughness measurement are carried out
to study the major changes in texture of the machined surface and determine the optimal
mixed-level array of cutting parameters. The results indicate that these parameters have
significant effects on surface roughness. In the other word, a better surface quality can be
obtained by varying the level of cutting parameters. In addition, it is concluded that a
better surface roughness would be achieved by using the smallest size of brass particles.

Chockalingam, P. et al [7] studied the effect of different coolant conditions on milling of

AISI 304 stainless steel. Cooling methods used in this investigation were flooding of
synthetic oil, water-based emulsion, and compressed cold air. Cutting forces and the
surface roughness were studied and tool flank wears observed. In this study, the
comparison between different coolants effect to the milling of AISI 304 stainless steel is
done. This research deals with the effect of different coolant conditions on milling of
AISI 304 stainless steel. Cooling methods used in this investigation were flooding of
synthetic oil, water-based emulsion, and compressed cold air. Cutting forces and the
surface roughness were studied and tool flank wears observed. In this study, the
comparison between different coolants’ effect to the milling of AISI 304 stainless steel is
done and the results from the study can provide very useful information in manufacturing
field. The experiment results showed that water-based emulsion gave better surface finish
and lower cutting force followed by synthetic oil and compressed cold air. Different
cooling condition required different parameters in order to obtain lower surface

11
roughness and cutting force. Chipping was the initial wear mode in the milling of AISI
304 stainless steel.

Rajput, R. et al [8] studies that the quality of finished work piece depends on the relative
positions between the work pieces, cutting tool, machining process parameters. It can be
achieved if a CNC machine tool possesses sufficient strength to withstand the cutting
forces, stiffness against deformation and capability of CNC controller. CNC controller is
the heart of the CNC machine which controls most of the functions of CNC machine.
Accurate and Perfect machining in minimum time is the requirement of manufacturing
industries and along with other hardware and machining process parameters, CNC
control system also playing vital and an important role. Hence, in this work an attempt is
being made to investigate and analyze the comparison of the CNC milling controllers
with same set of parameters. This project gives the detailed comparison of the three
major CNC controllers used by industries on the basis of important parameter. Overall
the research study reveals that the different–different CNC controllers have the different
features. This research study conclude that for the given geometry, the result are better
for the HEIDENHAIN 426 TNC and SINUMERIK 840D milling controller as compare
to the FANUC21M for the given geometry or job some more important result are
concluded during this work .Different Controllers are having different capabilities, so we
need to identify the right controller for right job that can minimize the machining time
and ultimately optimize the associated parameters. Average processing time for the
HEIDENHAIN TNC 426 is minimum as compared to other two controllers. In some
observations, the results of SINUMERIK 840D are very near to the HEIDENHAIN TNC
426. MRR is found dependent on the controller features. During this work MRR is found
high for the H TNC 426, than compared low for the S 840D and lowest for the F 21 M.

Sureshkannan, G. et al [9] analyzes the effects of material properties on surface

roughness, material removal rate, and tool wear on high speed CNC end milling process
with various ferrous and nonferrous materials. The challenge of material specific decision
on the process parameters of spindle speed, feed rate, depth of cut, coolant flow rate,
cutting tool material, and type of coating

12
for the cutting tool for required quality and quantity of production is addressed.
Generally, decision made by the operator on floor is based on suggested values of the tool
manufacturer or by trial and error method. This paper describes effect of various
parameters on the surface roughness characteristics of the precision machining part. The
prediction method suggested is based on various experimental analyses of parameters in
different compositions of input conditions which would benefit the industry on
standardization of high speed CNC end milling processes. The high speed CNC
machining is a vital and costly machining process and a less harder material in ductile
class would yield good surface finish whereas the closer variation in brittle class, but less
porous brittle material, has good surface finish with higher depth of cut and feed rate and
spindle speed more than the mid value, which improves productivity.

Makwana, R., D. et al [10], a fixture is designed and built to hold, support and locate
every component to ensure that each is drilled or machined with accuracy and
manufactured individually. The fixture designing and manufacturing is considered as
complex process that requires the knowledge of different areas, such as geometry,
dimensions, tolerances, procedures and manufacturing processes. This paper will give
brief overview about the 3-2-1 locating principle to design the fixture for complex parts
and other clamping principles. This paper also gives the idea and procedure for fixture
design. This paper gives the idea about the modular fixture and dedicated fixture. From
the study they concluded that for designing the fixture the geometry method (3-2-1
principle) is very useful for the complex component having various machining processes
though it is the basic principle of the fixture design.

13
2.2 Gaps in Literature Review
After a comprehensive study of the existing literature review, a number of gaps have
been observed in machining of CNC-
 Most of the researchers have investigated influence of a limited number of
process parameters on the performance measures of CNC parts.
 Literature review reveals that the researchers have carried out most of the work on
CNC developments, monitoring and control but very limited work has been
reported on optimization of process variables.
 The effect of machining parameters on Aluminium alloy has not been fully
explored using CNC.
 Multi-response optimization of CNC process is another thrust area which has
been given less attention in past studies.

2.3 Objective
 The main objective of this project is the development of the data model for the
interface of the interface of CNC for turning. The technology grinding was
excluded because a first study showed that a lot of manual interactions hamper the
automatic flow and that the process dependency of data is very high.
 The developed interface for the other technologies should be tested by prototype
implementation at the CAM and the CNC level.
 The prototypes should be tested and validated at real machines with suitable
workpiece(s). After the validation the data model should be fixed in an
international standard.

14
 CHAPTER 3

EXPERIMENTAL SET-UP

3.1 Investigational Set-up

Numerical control (NC) is a system for naturally working an assembling machine in view
of a code letters, numbers and exceptional characters. The numerical information needed
to create a section is given to a machine as system, called part program or CNC (PC
numerical control). The system is interpreted into the proper electrical signs for info to
engines that run the machine. A CNC machine is a numerical control machine with the
included component of a board PC. The PC is alluded to as the machine control unit
(MCU).

3.1.1 Machine Specifications:

A servo controlled CNC 3-axes XXZ Turret lathe is used for turning operation, operating
on a DC power source and having 8 tool inserting positions as a part of the turret.

Table 3.1 Machine Specifications

Machine type CUB/XXZ

Machine number 708
Year 2007
Supply voltage 380V/415V
Control voltage 24V D.C.
Back up fuse 32 AMPS
Rated current 21/20 AMPS
KVA rating 14 KVA
Size of wire 6 SQ mm
Turret Profile SERVO TURRET

15
3.1.2 Workpiece Specifications:
An Aluminium alloy has been selected as the workpiece of choice to perform turning
operation with the aimed objective of the project. It is Aluminium 6063-T6 alloy have
Aluminum, Magnesium and silicon as it major constituent.

3.1.2.1 Material name- Aluminium 6063-T6/UNS A96063/ISO AlMg0.5Si

Table 3.2 Workpiece specifications

Components Wt.%
Al Max 97.5
Cr Max 0.1
Cu Max 0.1
Fe Max 0.35
Mg 0.45-0.9
Mn Max 0.1
Si 0.2-0.6
Ti Max 0.1
Zn Max 0.1
Other, each Max 0.05
Other, total Max 0.15

3.1.2.2 Physical properties

Apart from its metallurgical characteristics, the physical properties of Aluminium 6063
T6 alloy is also having a major role in calculating the values of various responses one can
obtain from a machining operation using a CNC turret lathe.

Table 3.3 Physical Properties of workpiece

Hardness, Brinell 79
Hardness, Knoop 96
Hardness, Vickers 83
Ultimate tensile strength 241 MPa

16
Tensile yield strength 214 MPa
Elongation at break 12%
Modulus of elasticity 68.9 GPa
Ultimate bearing strength 434 MPa
Bearing yield strength 276 MPa
Poisson’s ratio 0.33
Fatigue strength 68.9 MPa
Machinability 70%
Shear modulus 25.8 GPA
Shear strength 152 MPa

3.1.2.3 Temper sorts: The most well-known tempers for 6082 aluminum are:

• T6 - Solution warmth treated and misleadingly matured

• 0-Soft

• T4 - Solution warmth treated and normally matured to a considerably stable condition

• T651 - Solution warmth treated, anxiety assuaged by extending then falsely matured

3.1.3 Tool Specifications

Tool material- Tool Steel

Tool holder specification- DVJNR 2020k 16

Table 3.4 Tool Holder Specifications

Tool cutting edge angle 93 deg

Tool lead angle -3 deg
Maximum ramping angle 44 deg
Machine side body angle 0 deg

17
Workpiece side body angle 0 deg
Orthogonal rake angle -4 deg
Inclination angle -13 deg
Shank height 20 mm
Shank width 20 mm
Functional length 125 mm
Functional width 25 mm
Functional height 20 mm
Maximum overhang 46.6 mm
Torque 3 Nm
Weight 0.426 kg
Body material code Steel

Tool Insert- VNMG 160408

Table 3.5 Insert Specifications

Grade 4325
Coating CVD Ti(C,N) + Al2O3 +TiN
Clearance angle 0 deg
Weight 0.01 kg

3.2 Selection of Process Parameter

The three key mechanical inputs in metal evacuation operations are bolster, rate, and
profundity of cut. Controlling the food, rate and profundity of cut can amplify the
advantages of a specific cutting liquid and can expand efficiency. Be that as it may, as
most choices, the decision of food, pace and profundity of cut must be in light of the
client's targets. What is their objective in this application? Would they like to make parts
quicker or augment instrument life? How critical is the surface completion and
dimensional exactness of the part? Answers to these inquiries will drive their choices on
bolsters, velocities and profundity of cut.

18
Some of the process parameters are

 Speed: Speed is the rate of turn of the axle where the device is held. It is measured
in cycles every moment (RPMs).
 Feed: Feed is the rate at which the instrument is moved into the part or the part
into the device. Food is measured in feet, inches or millimeters per time period.
 Depth of Cut (DOC): The estimation typically in inches or millimeters) of how
wide and profound the apparatus cuts into the work piece. Speed, food and DOC
 Tool life
 Surface wrap up
 Dimensional precision of the produced part
 Power needed by the machine instrument

In turning, the rate and movement of the slicing device is determined through a few
parameters. These parameters are chosen for every operation based upon the work piece
material, instrument material, device size, and that's just the beginning. Turning
parameter that can influence the procedure is:

 Spindle speed - The rotational velocity of the shaft and the work piece in cycles
every moment (RPM). The axle pace is equivalent to the cutting rate partitioned
by the perimeter of the work piece where the cut is being made. With a specific
end goal to keep up a steady cutting speed, the shaft speed must shift taking into
account the breadth of the cut. In the event that the shaft pace is held consistent,
then the cutting rate will change.
 Feed rate - The rate of the slicing apparatus' development in respect to the work
piece as the instrument makes a cut. The food rate is measured in millimeter per
unrest (RPM).
 Tool life: For the most part, expanding the food rate lessens apparatus life.
Uprooting more material makes more warmth. Warmth debases the work piece
and the tooling. On the off chance that you lessen your food rate, the instrument
life enhances on the grounds that it is not functioning as hard.

19
 Surface finish: It might be justified, despite all the trouble to the client to build the
expense of the coolant (with a somewhat higher fixation or higher lubricate
liquid) to enhance the surface completion at higher paces. Obviously, this implies
that surface completion must be worth something to yours client. Expanding the
DOC can advance prattle as a result of higher strengths. The machine device must
be sufficiently inflexible to withstand these powers. Vibrations in the machine
apparatus can have an expansive impact on surface completion. Machine
apparatuses composed and built for rapid machining have enhanced solidness to
minimize the vibration that effects surface completion.
 Material Removal Rate: It can be defined as the amount of material removed per
unit machining time. For a turning operation it can also be mathematically
depicted as the product of feed rate, depth of cut and cutting speed. That is,
MRR = Feed x Depth of Cut x Cutting Speed……………………………….(F1)

3.3 Measurement Of Surface Roughness

Surface unpleasantness, regularly abbreviated to harshness, is a measure of the
composition of a surface. It is evaluated by the vertical deviations of a genuine surface
from its optimal structure. On the off chance that these deviations are expansive, the
surface is harsh; in the event that they are little the surface is smooth. Harshness is
ordinarily thought to be the high recurrence, short wavelength part of a deliberate surface.

3.3.1 Amplitude parameters- Sufficiency parameters portray the surface in light of

the vertical deviations of the harshness profile from the mean line. A considerable lot of
them are firmly identified with the parameters found in insights for describing populace
tests. For instance, Ra is the number juggling normal of the outright values and Rt is the
scope of the gathered harshness information focuses. The normal harshness, Ra, is
communicated in units of tallness. In the Imperial (English) framework, 1 Ra is normally
communicated in "millionths" of an inch. This is additionally alluded to as "small scale
crawls" or once in a while generally as "miniaturized scale". The plentifulness parameters
are by a long shot the most well-known surface unpleasantness parameters found in the
United States on mechanical designing drawings and in specialized writing.

20
3.3.2 Measurement- The accompanying instruments are mechanically utilized for
measuring surface unpleasantness. There are numerous makers executing these
innovations into items,

 Profilometer, customarily called a stylus and works like a phonograph

 Atomic power magnifying instrument.
 Surface Roughness Tester

Roughness is an important parameter when trying to find out whether a surface is suitable
for a certain purpose. Rough surfaces often wear out more quickly than smoother surfaces
Rougher surfaces are normally more vulnerable to corrosion and cracks, but they can also
aid in adhesion. A roughness tester is used to quickly and accurately determine the
surface texture or surface roughness of a material. A roughness tester shows the measured
roughness depth (Rz) as well as the mean roughness value (Ra) in micrometers or
microns (µm). Measuring the roughness of a surface involves applying a roughness filter.
Different international standards and surface texture or surface finish specifications
recommend the use of different roughness filters. For example, a Gaussian filter often is
recommended in ISO standards. Roughness tester is an ideal instrument for fast and
simple checking of the surface roughness in shop floor, metalworking, manufacturing,
quality control, inspection, automotive and aerospace engineering. It is a portable and
pocket-sized instrument, which provides you with highly accurate measurements of
surface finish.

This instrument is compatible with four standards of site to measure surface roughness of
various machinery-processed parts, calculate corresponding and clearly display all
measurement parameters. When measuring the roughness of a surface, the sensor is
placed on the surface and then uniformly slides along the surface by driving the
mechanism by the sharp built-in probe. This roughness causes displacement of the probe
which results in change of inductive amount of induction coils so as to generate analogue
signal, which is in proportion to the surface roughness at output end of phase-sensitive
rectifier.

21
 The exclusive DSP processes and calculates and then outputs the measurement
results on LCD.
 Multiple parameter measurement: Ra, Rz, Rq, Rt
 Highly sophisticated inductance sensor
 Four wave filtering methods : RC, PC-RC, GAUSS and D-P
 Built-in lithium ion rechargeable battery and control circuit with high capacity
 Can communicate with PC computer for statistics, printing and analysing by the
optional cable and the software for RS232C interface.
 Manual or automatic shutdown. The tester can be switched off by pressing the
Power key at any time.
 On the other hand, the tester will power itself off about 5 minutes after the last
key operation.

Fig 3.1 Surface Roughness Tester [3]

22
 CHAPTER 4

METHODOLOGY
4.1 Taguchi Method-
Dr. Taguchi of Nippon Telephones and Telegraph Company, Japan has developed a
method based on “ORTHOGONAL ARRAY” experiments which gives much reduced
“variance” for the experiment with “optimum settings” of control parameters.

Thus the marriage of Design of Experiments with optimization of control parameters to

obtain BEST results is achieved in the Taguchi Method. "Orthogonal Arrays" (OA)
provide a set of well balanced (minimum) experiments and Dr. Taguchi's Signal-to-Noise
ratios (S/N), which are log functions of desired output, serve as objective functions for
optimization, help in data analysis and prediction of optimum results. Numerous Japanese
firms made awesome progress by applying his routines. Taguchi has gotten a percentage
of the Japan's most prestigious honors for quality accomplishment, including the Deming
Prize.

Pignatiello has recognized two unique parts of Taguchi method.

 The method of Taguchi

 Strategies of Taguchi procedure is the theoretical casing work for arranging a
procedure or item outline test. Taguchi strategies allude to the gathering of particular
systems utilized by Taguchi. Taguchi has tended to Design, Engineering
(disconnected from the net) and also Manufacturing (online) quality. This idea
separates Taguchi strategy from Statistical Process Control (SPC) which is absolutely
an online quality control method.

Taguchi thoughts can be lessened into two major ideas.

 Quality misfortunes ought to be characterized as deviation from target, not

conformance to self-assertive details.

23
 To accomplish high framework quality levels financially obliges quality to be
outlined into item. Quality is outlined, not fabricated, into the item. Taguchi strategies
speak to rationality. Quality is measured by the deviation of a useful trademark from
its objective worth. Clamors (wild components) will bring about such deviations
which bring about loss of Quality. Taguchi procedures try to evacuate the impact of
Noises. The most essential piece of the Taguchi strategy is quality misfortune
capacity. Taguchi has observed that a quadratic capacity (parabola) approximates the
conduct of misfortune by and large. When the quality normal for hobby is to be
expanded or minimized, the misfortune capacity will turn into a half parabola. Loss
happens not just when the item is outside its determination additionally when item
falls inside of its detail. Taguchi has prescribed sign to commotion proportion (S/N
proportion) as execution insights. Sign alludes to the adjustment in quality attributes
of an item under scrutiny in light of an element presented in the trial configuration.
Clamor alludes to the impact of outside variables (wild parameters) on the result of
the quality attributes.

4.2 Taguchi Design Methodology-

Taguchi Method treats optimization problems in two categories,

4.2.1 Static Problems- Generally, a process to be optimized has several control

factors which directly decide the target or desired value of the output. The optimization
then involves determining the best control factor levels so that the output is at the the
target value. Such a problem is called as a "STATIC PROBLEM".

This is best explained using a P-Diagram which is shown below ("P" stands for Process
or Product). Noise is shown to be present in the process but should have no effect on the
output! This is the primary aim of the Taguchi experiments - to minimize variations in
output even though noise is present in the process. The process is then said to have
become ROBUST.

24
 Fig 4.1 P-diagram for static problems [4]

There are 3 Signal-to-Noise ratios of common interest for optimization of Static

Problems;

4.2.1.1 Smaller The Better-

n = -10 Log10 [mean of sum of squares of measured data]………… ……………(F2)

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

n = -10 Log10 [mean of sum of squares of {measured - ideal}]……………………….(F3)

4.2.1.2 Larger The Better-

n = -10 Log10 [mean of sum squares of reciprocal of measured data]…………………(F4)

This case has been converted to SMALLER-THE-BETTER by taking the reciprocals of

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

25
4.2.1.3 Nominal The Best-

n = 10 Log10 (square of mean/variance)………………………………………………(F5)

This case arises when a specified value is MOST desired, meaning that neither a smaller
nor a larger value is desirable.

4.2.2 Dynamic Problems- If the product to be optimized has a signal input that
directly decides the output, the optimization involves determining the best control factor
levels so that the "input signal / output" ratio is closest to the desired relationship. Such a
problem is called as a "DYNAMIC PROBLEM".
This is best explained by a P-Diagram which is shown below. Again, the primary aim of
the Taguchi experiments - to minimize variations in output even though noise is present
in the process- is achieved by getting improved linearity in the input/output relationship.

Fig 4.2 P-diagram for dynamic problems [4]

In dynamic problems, we come across many applications where the output is supposed to
follow input signal in a predetermined manner. Generally, a linear relationship between
"input" "output" is desirable. There are 2 characteristics of common interest in "follow-
the-leader" or "Transformations" type of applications,

26
(i) Slope of the I/O characteristics
(ii) Linearity of the I/O characteristics (minimum deviation from the best-fit straight
line)

The Signal-to-Noise ratios for these 2 characteristics have been defined as,

4.2.2.1 Sensitivity- The slope of I/O characteristics should be at the specified

value (usually 1). It is often treated as Larger-The-Better when the output
is a desirable characteristics (as in the case of Sensors, where the slope
indicates the sensitivity).

n = 10 Log10 [square of slope or beta of the I/O characteristics]………(F6)

On the other hand, when the output is an undesired characteristic, it can be treated as
Smaller-the-Better. n = -10 Log10 [square of slope or beta of the I/O characteristics]

4.2.2.2 Linearity- Most dynamic characteristics are required to have direct

proportionality between the input and output. These applications are
therefore called as "TRANSFORMATIONS". The straight line
relationship between I/O must be truly linear i.e. with as little deviations
from the straight line as possible.

n= 10Log10 (Square of slope or beta/variance)…………..(F7)

Variance in this case is the mean of the sum of squares of deviations of measured data
points from the best-fit straight line (linear regression).

4.3 Steps in Taguchi Methodology-

Taguchi method is a scientifically disciplined mechanism for evaluating and
implementing improvements in products, processes, materials, equipment, and facilities.
These improvements are aimed at improving the desired characteristics and
simultaneously reducing the number of defects by studying the key variables controlling
the process and optimizing the procedures or design to yield the best results. The method

27
is applicable over a wide range of engineering fields that include processes that
manufacture raw materials, sub systems, products for professional and consumer markets.

Taguchi proposed a standard 8-step procedure for applying his method for optimizing any
process,

1. IDENTIFY THE MAIN FUNCTION,SIDE EFFECTS, AND FAILURE MODE

2. IDENTIFY THE NOISE FACTORS,TESTING CONDITIONS, AND QUALITY
CHARACTERISTICS
3. IDENTIFY THE OBJECTIVE FUNCTION TO BE OPTIMIZED
4. IDENTIFY THE CONTROL FACTORS AND THEIR LEVELS
5. SELECT THE ORTHOGONAL ARRAY MATRIX EXPERIMENT
6. CONDUCT THE MATRIX EXPERIMENT
7. ANALYZE THE DATA,PREDICT THE OPTIMUM LEVELS AND PERFO
RMANCE
8. PERFORM THE VERIFICATION EXPERIMENT & PLAN THE FUTURE
ACTION

4.4 Data Analysis-

4.4.1 Minitab Software- Minitab is a measurable Analysis programming that permits

to effortlessly lead examinations of information. This is one of the proposed
programming for the class. This aide is expected to guide you through the essentials of
Minitab and help you begin with it.

Utilizing Minitab as a part of Harper and Gleacher Centre.

Minitab can be found in the PC lab PCs. With a specific end goal to stack the product go
to: Begin - > PROGRAMS - > MATH and STATS - > MINITAB 15 - > MINITAB 15
STATISTICAL SOFTWARE ENGLISH

Minitab has two fundamental sorts of records, undertakings and worksheets. Worksheets
are documents that are comprised of information; think about a spread sheet containing

28
variables of information. Undertakings are comprised of the summons, charts and
worksheets. Each time you spare a Minitab venture you will be sparing charts,
worksheets and orders. However every one of the components can be spared separately
for utilization in different records or Minitab ventures. Similarly you can print ventures
and its components.

Minitab records are sorted out as "undertakings". Every venture will contain all the
information you utilize and the charges and examination you perform on the information.
You can open another, unfilled worksheet whenever. In this unfilled worksheet you can
duplicate, glue and sort the information you require by just chipping away at the
worksheet as you would on any spread sheet.

Approaches To Analyze Data- Examination in Minitab should be possible in two ways:

utilizing the Built-As a part of schedules or utilizing charge dialect as a part of the
Session window. These two can be utilized conversely. Most of the capacities required is
essential and more progressed measurable investigation are found as Minitab Built-in
schedules. These schedules are gotten to through the menu bar. To utilize the menu
orders, click on a thing in the menu bar to open a menu, click on a menu thing to execute
a charge or open a submenu or dialog box. Charge Language: To have the capacity to sort
summons in the Session window, you must acquire the "MTB>" brief. All orders are then
entered after the FALL 2009 BUSINESS STATISTICS 41000 GUIDE TO MINITAB 15
9 "MTB>" brief. All order lines are free arrangement, at the end of the day, all content
may entered in upper or lowercase letters anyplace in the line. Descriptively,

To acquire spellbinding insights of a variable or set of variables, go to

• Details - > DISPLAY DESCRIPTIVE STATISTICS

• Furthermore, a brief window ought to show up. In the window select the
variable(s) you need to investigate and click alright.

• Results will be displayed in the Session window as takes after.

29
Chart attracting assembled schedules in Minitab can be found under the GRAPH menu in
the menu bar. On the Graph Menu you have a few sorts of plots that you can look over,
and that you can use to deliver your coveted plot. The following is a clarification of how
to utilize the most well-known chart schedules. Minitab charts will show up as particular
windows that are considered piece of the venture, on the other hand they can be spared
and replicated for utilization in reports. Plots can be altered by adjusting the plot choices.

With a specific end goal to figure essential insights for sets of variables, similar to
covariance and connection, go to STAT - > BASIC STATISTICS In this record cases of
measurements are computed accepting just two variables are being examined, however
combine savvy measurements for more than two variables can be ascertained by basically
adding all the craved variables to the "VARIABLES" enclose the dialog windows.

• Pick COVARIANCE to acquire the accompanying dialog box. Pick the pair of
variables you wish to examine and click OK.

• The outcome will be exhibited in the Session window as introduced beneath.

• Pick CORRELATION and acquire the accompanying dialog box. Pick the pair of
variables to be investigated.

• Results are shown in the Session window as displayed beneath. Adding variables

• To include variables name the variable where you need to store the outcomes.

• Select the first variable, press the "+" sign and select the second variable (thus on
for more than two variables). You ought to acquire something like the window in
the privilege

• The outcome will then be indicated in the worksheet window Taking logarithms
another helpful capacity in factual investigation is to take logs of variables.

30
• Search for the "Characteristic LOG" or "LOG BASE 10" (contingent upon the
one you require) in the capacity list. An alternate way to discovering the
capacities is to pick "LOGARITHM" from the capacity drop down menu.

• Inside the bracket, change number for the variable name. Highlighting
"NUMBER" and after that selecting the variable you need to change does this.

• Verify that you have characterized a variable where you need to store results, by
putting the name in the "STORE RESULT IN VARIABLE" box.

• The outcome will show up in the worksheet window. Logical capacities Some
measurable investigation should separate by gatherings as indicated by qualities
that are contained in the information. Consistent capacities are especially helpful
in these cases. A straightforward case on the best way to utilize them is portrayed
underneath.

• Pick the variable you need to do the sensible test to. Here we are taking a gander
at the variable.

• Pick the sensible test you need to utilize. Here we need to see which perceptions
have the variable equivalent.

• Verify that you have shown a variable in which to store your outcomes, by
writing the name of your outcome variable in the "STORE RESULT IN
VARIABLE" box.

• The outcome variable will be a double (variable of 1s and 0s)

4.5 Advantages of Taguchi Design-

1. It emphasizes a mean performance characteristic value close to the target value

rather than a value within certain specification limits, thus improving the product
quality.

31
2. Additionally, Taguchi's method for experimental design is straightforward and
easy to apply to many engineering situations, making it a powerful yet simple
tool.
3. It can be used to quickly narrow down the scope of a research project or to
identify problems in a manufacturing process from data already in existence.
4. Also, the Taguchi method allows for the analysis of many different parameters
without a prohibitively high amount of experimentation. For example, a process
with 8 variables, each with 3 states, would require 6561 (38) experiments to test
all variables.
5. However using Taguchi's orthogonal arrays, only 18 experiments are necessary,
or less than .3% of the original number of experiments. In this way, it allows for
the identification of key parameters that have the most effect on the performance
characteristic value so that further experimentation on these parameters can be
performed and the parameters that have little effect can be ignored.

4.6 Disadvantages Of Taguchi Design-

1. The main disadvantage of the Taguchi method is that the results obtained are only
relative and do not exactly indicate what parameter has the highest effect on the
performance characteristic value. Also, since orthogonal arrays do not test all
variable combinations, this method should not be used with all relationships
between all variables are needed.
2. The Taguchi method has been criticized in the literature for difficulty in
accounting for interactions between parameters.
3. Another limitation is that the Taguchi methods are offline, and therefore
inappropriate for a dynamically changing process such as a simulation study.
Furthermore, since Taguchi methods deal with designing quality in rather than
correcting for poor quality, they are applied most effectively at early stages of
process development. After design variables are specified, use of experimental
design may be less cost effective.

32
 CHAPTER 5

EXPERIMENTATION AND ANALYSIS

5.1 Orthogonal Array And L-9 Matrix-

To choose a suitable orthogonal exhibit for analyses, the aggregate degrees of
opportunity should be processed. The degrees of opportunity are characterized as the
quantity of examinations between procedure parameters that should be made to figure out
which level is better and particularly how much better it is. For instance, a Three-level
procedure parameter means four degrees of flexibility. The degrees of opportunity
connected with collaboration between two procedure parameters are given by the result
of the degrees of flexibility for the two procedure parameters.

5.2 Levels Of Control Factors-

Fig 5.1 Minitab window [5]

33
 Table 5.1 Levels of control component

Level Feed (mm/rev) Depth (mm) Speed (RPM)

1 0.1 0.1 2000
2 0.15 0.2 2500
3 0.20 0.25 3000

Table 5.2 Levels of control elements

Run Columns
1 2 3
1 1 1 1
2 1 2 2
3 1 3 3
4 2 1 3
5 2 2 1
6 2 3 2
7 3 1 2
8 3 2 3
9 3 3 1

Fig 5.2 Turning Procedure [6]

34
 Fig 5.3 CNC CUB/XXZ servo controlled turret lathe

Table 5.3 L9 orthogonal exhibit framework

Cutting speed
Run Feed (mm/rev) Depth (mm) Speed (RPM)
(m/min)
1 0.1 0.1 2000 188.32
2 0.1 0.2 2500 235.40
3 0.1 0.25 3000 282.48
4 0.15 0.1 3000 282.48
5 0.15 0.2 2000 188.32
6 0.15 0.25 2500 235.40
7 0.2 0.1 2500 235.40
8 0.2 0.2 3000 282.48
9 0.2 0.25 2000 188.32

35
 Table 5.4 Result framework for surface roughness

Cutting
Feed Depth Speed Ra
Run speed SNRA1 MEAN1
(mm/rev) (mm) (RPM) (µm)
(m/min)
1 0.1 0.1 2000 188.32 0.409 -7.7655 0.409
2 0.1 0.2 2500 235.40 0.997 -0.0261 0.997
3 0.1 0.25 3000 282.48 0.959 -0.3636 0.959
4 0.15 0.1 3000 282.48 1.700 4.6090 1.700
5 0.15 0.2 2000 188.32 1.688 4.5474 1.688
6 0.15 0.25 2500 235.40 3.425 10.6932 3.425
7 0.2 0.1 2500 235.40 3.422 10.6856 3.422
8 0.2 0.2 3000 282.48 3.002 9.5482 3.002
9 0.2 0.25 2000 188.32 1.736 4.7910 1.736

Table 5.5 Result framework for Material Removal Rate

Cutting MRR
Feed Depth Speed
Run speed (cc/min) SNRA2 MEAN2
(mm/rev) (mm) (RPM)
(m/min)
1 0.1 0.1 2000 188.32 1.8832 5.4979 1.8832
2 0.1 0.2 2500 235.40 4.708 13.4567 4.7080
3 0.1 0.25 3000 282.48 7.062 16.9786 7.0620
4 0.15 0.1 3000 282.48 4.2372 12.5416 4.2372
5 0.15 0.2 2000 188.32 5.6496 15.0404 5.6496
6 0.15 0.25 2500 235.40 8.8275 18.9168 8.8275
7 0.2 0.1 2500 235.40 4.708 13.4567 4.7080
8 0.2 0.2 3000 282.48 11.2992 21.0610 11.2992
9 0.2 0.25 2000 188.32 9.416 19.4773 9.4160

36
5.3 Analysis-
At first the analysis is done for surface roughness and thereafter moving towards material
removal rate. When you add a signal factor to an existing static design, Minitab adds a
new signal factor column after the factor columns and appends new rows (replicates) to
the end of the existing worksheet. For example, if you add a signal factor with 2 levels to
an existing L4 (23) array, 4 rows (1 replicate of 4 runs) are added to the worksheet. If you
add a signal factor with 3 levels, 8 rows (2 replicates of 4 runs) are added to the
worksheet. A replicate is the entire set of runs from the static design. In a usual Taguchi
robust parameter design experiment, you would subject each control factor combination
to each of the noise conditions and measure the response variable. If you are doing a
dynamic experiment, the response is measured at each level of the signal factor. Record
the results for each noise condition in a separate response column in the worksheet.

Main Effects Plot for Means

Data Means

A B
3.0
2.5
2.0

1.5
Mean of Means

1.0

1 2 3 1 2 3
C
3.0

2.5
2.0
1.5
1.0

1 2 3

Fig 5.4 Plot for means

37
Use the response tables to select the best level for each factor. Usually you have the
following objectives with a Taguchi design:

 Minimize the standard deviation

 Maximize the S/N ratio
 Meet a target with the mean (static design)
 Meet a target with the slope (dynamic design)

Use the delta and rank values to identify the factors that have the largest effect on each
response characteristic. Then, determine which levels of these factors meet your
objectives. Sometimes, the best level of a factor for one response characteristic is
different from the best level for a different response characteristic. To resolve this issue,
it may help to predict the results for several combinations of factors levels to see which
one produces the best result.

5.3.1 Interpretation

 Average response characteristics- For each factor, Minitab calculate the average
of the response characteristic at each level of the factor. For example, the design
includes factor A at 2 levels (1 and 2) and 4 measurements at each level. Minitab
calculates the mean of the 4 S/N ratios at level 1 and the mean of the other 4 S/N
ratios at level 2.
 Signal-to-Noise Ratio- Minitab calculates a separate signal-to-noise ratio (S/N)
for each combination of control factor levels in the design. You can choose from
different S/N ratios, depending on the goal of your experiment. In all cases, you
want to maximize the S/N ratio.
 Means (for static designs)- Minitab calculates a separate mean for each
combination of control factor levels in the design.
 Slopes (for dynamic designs)- Minitab calculates a separate slope for each
combination of control factor levels in the design.
 Standard deviations- Minitab calculates a separate standard deviation for each
combination of control factor levels in the design.

38
  Delta- Measures the size of the effect by taking the difference between the
highest and lowest characteristic average for a factor.
 Rank- The ranks in a response table help you quickly identify which factors have
the largest effect. The factor with the largest delta value is given rank 1, the factor
with the second largest delta is given rank 2, and so on.

In these results, the response tables show the following:

 For the Signal to Noise Ratios, A is ranked 1, followed by B and C.

 For the Means, A is ranked 1, followed by C and B

Here feed, depth and speed are our factor A, B and C respectively.

Table 5.6 Response table for means

Level Feed Depth Speed

1 0.7883 1.8437 2.2787
2 2.2710 1.8957 1.4777
3 2.7200 2.0400 2.0230
Delta 1.9317 0.1963 0.8010
Rank 1 3 2

We want to maximize the S/N ratio and the mean. For example, for factor B, the average
S/N ratio for all runs with level 1 is 2.510, the average for runs with level 2 is 4.690 and
the average for runs with level 3 is 5.040. This indicates that level 3 maximizes the
signal-to-noise ratio.

Here from the response table for the means we can conclude that the level 3, level 3 and
level 1 maximizes the mean values for factors A, B and C respectively. The above
combination of level is also the part of our L9 orthogonal array generated using Minitab,
run 9. This will help us further in concluding about the requirement of confirmation test
for our experiment. A similar type of conclusion can also be made for signal-to-noise
ratio further.

39
 Main Effects Plot for SN ratios
Data Means

A B
10

5
Mean of SN ratios

1 2 3 1 2 3
C
10

1 2 3
Signal-to-noise: Larger is better

Fig 5.5 Plot for S/N proportion

Table 5.7 Response Table for signal to noise ratio

Level Feed Depth Speed

1 -2.718 2.510 4.956
2 6.617 4.690 3.125
3 8.342 5.040 4.159
Delta 11.060 2.531 1.832
Rank 1 2 3

Here from the response we have concluded that the level 3, level 3 and level 1 maximizes
our signal-to-noise ratio for our factors A, B & C respectively, namely Feed (mm/rev),
depth of cut (mm) and spindle speed (RPM) respectively. This combination of levels
maximizing the signal-to-noise ratio for our experiment is also the part of our L9
orthogonal array, run 9.

40
Now moving towards our material removal rate. From result framework for material
removal rate we plot two graphs for means and signal to noise ratios respectively.

Main Effects Plot for Means

Data Means
A B

8
7
6
5
Mean of Means

1 2 3 1 2 3
C

8
7
6
5
4

1 2 3

Fig 5.6 Plot for Means for MRR

Table 5.8 Response table for means

Level Feed Depth Speed

1 4.551 3.609 7.337
2 6.238 7.219 6.120
3 8.474 8.435 5.807
Delta 3.923 4.826 1.530
Rank 2 1 3

Here from the response table for the means we can conclude that the level 3, level 3 and
level 1 maximizes the mean values for factors A, B and C respectively. The above
combination of level is also the part of our L9 orthogonal array generated using Minitab,

41
run 9. This will help us further in concluding about the requirement of confirmation test
for our experiment on calculation of Material Removal Rate.

Main Effects Plot for SN ratios

Data Means
A B
18

16
14
Mean of SN ratios

12

10
1 2 3 1 2 3
C
18

16

14
12

10
1 2 3
Signal-to-noise: Larger is better

Fig 5.7 Plot for S/N ratio for MRR

Table 5.9 Response table for signal-to-noise ratio

Level Feed Depth Speed

1 11.98 10.50 15.16
2 15.50 16.52 15.16
3 18.00 18.46 15.16
Delta 6.02 7.96 0.00
Rank 2 1 3

Here from the response table for the means we can conclude that the level 3, level 3 and
level 1 maximizes the mean values for factors A, B and C respectively. The above
combination of level is also the part of our L9 orthogonal array generated using Minitab,
run 9.

42
5.3.2 Conformation Experiments
We can conclude that for our surface roughness the required combination to maximize
the means and signal-to-noise ratios is of the order 3, 3, and 1is the part of our L9
orthogonal exhibit framework. Therefore we do not require any confirmation test for our
surface roughness measurement.

We can conclude that for our Material Required Rate, the required combination to
maximize the means and signal-to-noise ratios is of the order 3, 3, and 1is the part of our
L9 orthogonal exhibit framework. Therefore we do not require any confirmation test for
our Material Removal Rate.

Table 5.10 Optimum table for Surface roughness

Exp. No. Optimum Combination Feed (mm/rev) Depth (mm) Speed (RPM)

1 A3B3C1 0.2 0.25 2000

Table 5.11 Optimum table for Material Removal Rate

Exp. No. Optimum Combination Feed (mm/rev) Depth (mm) Speed (RPM)

1 A3B3C1 0.2 0.25 2000

43
Fig 5.8 Turned workpiece(s)

44
 CHAPTER 6
RESULTS AND CONCLUSION

In the investigation, the aggregate of squares and fluctuation are ascertained. F-test
quality at 95% certainty level is utilized to choose the critical elements influencing the
procedure and rate commitment is as certained.

 DF- The total degrees of freedom (DF) are the amount of information in your
data. The analysis uses that information to estimate the values of unknown
population parameters. The total DF is determined by the number of observations
in your experiment. The DF for a term show how much information that term
uses. Increasing your sample size provides more information about the
population, which increases the total DF. Increasing the number of terms in your
model uses more information, which decreases the DF available to estimate the
variability of the parameter estimates.
 Seq SS- Sequential sums of squares are measures of variation for different
components of the model. Unlike the adjusted sums of squares, the sequential
sums of squares depend on the order the terms are entered into the model. In the
Analysis of Variance table, Minitab lists the sequential sums of squares for the
main effects, interactions, and error term.
 Adj SS- Adjusted sums of squares are measures of variation for different
components of the model. The order of the predictors in the model does not affect
the calculation of the adjusted sum of squares. In the Analysis of Variance table,
Minitab separates the sums of squares into different components that describe the
variation due to different sources.
 Adj MS- Adjusted mean squares measure how much variation a term or a model
explains, assuming that all other terms are in the model, regardless of the order
they were entered. Unlike the adjusted sums of squares, the adjusted mean squares
consider the degrees of freedom. The adjusted mean square of the error (also
called MSE or s2) is the variance around the fitted values.

45
  F-value- The Analysis of Variance table lists an F-value for each term. The F-
value is the test statistic used to determine whether the term is associated with the
response.
 P-Value- The p-value is a probability that measures the evidence against the null
hypothesis. Lower probabilities provide stronger evidence against the null
hypothesis.

The ANOVA investigation for rate adjustment is demonstrated in the table

Table 6.1 Analysis of Variance for Ra (µm), using Adjusted SS for Tests
Source DF Seq SS Adj SS Adj MS F P
Feed 2 6.131 6.131 3.066 2.28 0.305
Depth 2 0.062 0.062 0.031 0.02 0.977
Speed 2 1.004 1.004 0.502 0.37 0.728
Error 2 2.688 2.688 1.344
Total 8 9.886

S = 1.15939 R-Sq = 72.81% R-Sq(adj) = 0.00%

Table 6.2 Analysis of Variance for MRR (cc/min), using Adjusted SS for Tests
Source DF Seq SS Adj SS Adj MS F P
Feed 2 23.240 23.240 11.620 3.98 0.201
Depth 2 37.795 37.795 18.897 6.47 0.134
Speed 2 3.919 3.919 1.959 0.67 0.598
Error 2 5.840 5.840 2.920
Total 8 70.793

S = 1.70879 R-Sq = 91.75% R-Sq(adj) = 67.00%

From the experiment we can conclude that with increased feed and reduced spindle speed
we can get a better surface finish. Meanwhile with increased depth of cut and reduced
spindle speed, we can get a better material removal rate. Percentage combination of
which can be observed from the Analysis of Variance done above.

46
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[9] Sureshkannan, G., Dhandapani, N., V., Thangarasu, V., S., “Investigation on Effect of
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