Int. J. Materials and Product Technology, Vol. 51, No.

1, 2015

Analysis and optimisation of machining parameters

in micro turning using RSM
S. Selvakumar*
Faculty of Mechanical Engineering,
Roever Engineering College,
Elambalur, Perambalur, Tamilnadu, India
Email: sdy.12@rediffmail.com
*Corresponding author

R. Ravi Kumar
Department of Mechanical Engineering,
CMS College of Engineering,
Ernapuram, Namakkal-637 003, Tamilnadu, India
Email: ravikumar_mech@yahoo.com

K. Ganesan
Department of Mechanical Engineering,
PSG College of Technology,
Coimbatore, 641004, Tamilnadu, India
Email: ganesankalliappan@gmail.com
Abstract: Miniaturisation of industrial products has been the trend of
technological development for creating smaller and precision components
which plays an important role in todays need. Titanium alloy Gr.2 is one of
the most extensively used Ti alloys for high temperature application
components, because of its low weight and high strength even at elevated
temperatures for applications like aerospace gas turbine compartments. In this
paper, the performance of micro turning of titanium alloy with cermet insert is
investigated using response surface methodology and Box-Behnken design
(BBD). Two empirical models have been developed for predicting the tool
wear and surface roughness. The analysis reveals that the cutting speed and
feed rate are more influencing parameters on responses. The optimisation
results showed that the combination of medium spindle speed, feed rate,
and high depth of cut are necessary to minimise the tool wear and surface
roughness. A verification experiment is conducted and compared.
Keywords: micro turning; response surface methodology; RSM; titanium
alloy; tool wear; surface roughness.
Reference to this paper should be made as follows: Selvakumar, S. Ravikumar,
R. and Ganesan, K. (2015) Analysis and optimisation of machining parameters
in micro turning using RSM, Int. J. Materials and Product Technology,
Vol. 51, No. 1, pp.7597.

Copyright 2015 Inderscience Enterprises Ltd.

75

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S. Selvakumar et al.
Biographical notes: S. Selvakumar is a Research Scholar of Anna University;
Chennai. He is a faculty in the Department of Mechanical Engineering at
Roever Engineering College, Elambalur, and Perambalur, Tamilnadu, India.
He obtained his Masters in Manufacturing Engineering from Anna University,
Chennai. He is doing his doctoral research on machining optimisation. He has
20 years of teaching experience in the engineering field. He is a member of the
Institution of Engineers (India) and Indian Society of Technical Education.
R. Ravi Kumar is Professor and Principal of the CMS College of Engineering
in Ernapuram, Namakkal, Tamilnadu, India. He completed his Graduate degree
in Mechanical Engineering in 1991 from Madras University in Chennai and
Post Graduate degree in Production Engineering in 2001 from Annamalai
University in Chidambaram. He completed his PhD in National Institute of
Technology in Trichy in April 2008. He has rich academic knowledge and
teaching experience of more than 25 years. He is an approved guide for
research work in mechanical engineering in Anna University in Chennai. He
has published more than six articles in national and international publications.
He has attended more than 20 conferences in international and national level
conferences. He is also a life member of Indian Society for Technical
Education in New Delhi and Indian Institute of Metals, etc.
K. Ganesan is an Associate Professor in Mechanical Engineering, PSG College
of Technology, Coimbatore, India. He completed his Graduate degree in
Mechanical Engineering in 1985 from the Institution of Mechanical Engineers
(India), and Post Graduate degree in Production Engineering in 1989 from
Annamalai University, Chidambaram. He completed his PhD degree at
Bharathiar University in 2009. He has rich academic teaching experience of
more than 26 years. He has published more than 15 papers in international
journals and about 60 papers in the proceedings of national and international
conferences.

Introduction

Nowadays, the miniaturisation of components play an important role in various

application fields such as aerospace, automotive, electronics, communications, etc. The
miniature components are also used in following applications: Biotechnology and
medical engineering: micro size machines are needed to work inside the cells and tissues.
Harsh environments: In vacuum, under high pressure and radiation where the traditional
machines could not be operated. Narrow spaces or narrow channels: In these
applications conventional machines cannot be used as the available spaces are limited.
Micro actuators: micro fittings could be used to assemble the small instruments and soft
machines. Herrero et al. (2006) tried to fix the acceptable size limits for the micro
technologies in the range of 0.5 to 499 m and the components more than 500 m size
are considered as macro size components. The miniature components consume less
power, occupy smaller space and provide high heat transfer, since their surface to-volume
ratio is high. However, miniature components fabrication requires reliable and repeatable
manufacturing methods.

Analysis and optimisation of machining parameters in micro turning

77

Many of the miniature machines are using the components manufactured by

processes like, micro forming, micromachining, etc. The micromachining is one of the
most significant manufacturing processes used for manufacturing precision components
and supports the trend of miniaturisation. For example, the micromachining is mostly
used processing method for semi-conductor manufacturing having large batch
production. Many of the micromachining processes are very similar to the conventional
machining using a solid tool to remove the excess material but the mechanism of material
removal and chip formation are different. The majorities of these methods are very slow
and are limited to a few specific materials. Rahman et al. (2006) had observed that the
precise control of the machine and machining parameters, such as feed rate, depth of cut
and spindle speed were important for the micromachining processes.
Figure 1

Micro turning

The micro turning is grouped under the category of micromachining processes to remove
the material like conventional turning process. Figure 1 shows the concept of micro
turning, where the cutting tool is moved relative to work piece in order to separate the
excess layer of material in the form of chips. The primary motion is accomplished with
certain cutting speed. In addition, the tool must be moved laterally across the work at a
much slower motion, called the feed. The micro turning has the capability to produce
three dimensional features on micro scale and uses a solid cutting tool (Rahman et al.,
2003). The main advantage of the micro turning is its ability to machine any machinable
material, quick process planning but material removal rate is only limited to the type of
machine tool used (Friedrich, 2002). Masuzawa (2000) stated that the major drawback of
micro turning is that the machining force influences machining accuracy and also limit
the size of the component produced. The low aspect ratio work piece would vibrate at
tangential direction, but support of cutting tool reduces the vibration in normal direction
(Lim et al., 2002). The accuracy of the components is improved by controlling the cutting
forces during micro turning (Lu and Yoneyama, 1999).

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S. Selvakumar et al.

Rezaur Rehman et al. (2006) analysed the effect of various micro turning parameters
like spindle speed, feed rate and dwell time on machining performance like tool wear,
cutting force and surface roughness of nickel plated material and concluded that the
cutting force increases with increase in cutting speed and feed but they were not
influencing the surface roughness and tool wear. Patil et al. (2010) concluded that micro
turning is a high precision process and slight deviation in the micro structure like grain
size and other properties of the work material during micro turning would affect the
machinability and induce machining related problems. In general, the performance of the
micro turning can be referred using surface quality (amount of roughness left after
machining) and accuracy of the components produced. The measure of surface roughness
is important, as the good surface finish is useful for assembly purposes and also helps to
reduce the frictional forces developed during roughing of parts like in the linear slides.
The developed surface roughness is mainly a result of the tool geometry such as nose
radius, edge geometry, rake angle, etc., and cutting conditions; cutting speed, feed rate,
depth of cut, etc., used for the machining. Mahajan et al. (2010) investigated the effects
of spindle speed, feed, depth of cut and nose radius of tool on surface roughness during
micro turning of oxygen fuel high conductivity copper (OFHC). The authors concluded
that tool nose radius is the dominating parameter.
Ranjith Kumar and Gowri (2009) studied the parametric influence on surface
roughness by the cutting parameters in machining of copper rods by using cement inserts
under different cutting conditions and observed that the surface finish is increased with
increase in cutting speed and feed. Chan et al. (2001) concluded that surface roughness
and surface integrity can be significantly improved by high spindle speed and fine tool
feed rate during ultra-precision diamond turning of Al6061/SiCp metal matrix composites
and found that the depth of cut had its influence on surface roughness only under low
spindle speed condition. Lanza et al. (2008) analysed the influence of workpiece material,
cutting edge radius, cutting speed and depth of cut on the surface roughness and specific
cutting force and proposed a linear model for the surface roughness and specific cutting
force using experimental data. Rahman et al. (2003) analysed fabrication of micropin
using straight and taper turning processes and found step cutting process helps to
eliminate the deflection of micropin during tuning. The cutting force developed in the
step cutting process is supported by the uncut material. Their strategy helped the
industrial manufacturers for Miniaturising the components with high precision as well as
dimensional integrity. Rahman et al. (2005) assessed the machinability through the
analysis of cutting force, chip produced and tool wear during the fabrication of micro
shafts (< 0.5 mm) of brass, aluminium alloy and stainless steel. They observed that the
depth of cut is the most influential cutting parameter in micro turning. At low depth of
cut conditions, thrust force was the dominating force component due to the plastic
deformation produced by rubbing and burnishing. The value of tangential force was
found dominating when using large depth of cut. Ranjith Kumar et al. (2009) studied the
tool wear and related the wear with acoustic emission signals produced during micro
turning and observed good correlation between AE rms and tool wear. After studied the
scanning electron microscope images of worn out inserts they found that finer feed
facilitates plowing, resulting the higher order wear and with higher feed rate, reduced
order of tool wear. Mostly triangulation mode of wear is observed over the nose region of
cutting tool, with secondary grooving behind the nose. Rahman et al. (2005) investigated
the performance of PCD cutting tools and cermet inserts in micro turning of brass and

Analysis and optimisation of machining parameters in micro turning

79

observed that the abrasive wear on cermet insert flank face and groove wear on the PCD
insert flank face.
Titanium alloy components make up 20-30% of the dry weight in a jet engine (Fang
and Wu, 2009). However, because of their high strength and low thermal conductivity
these alloys often cause numerous problems during machining. The Ti alloys are difficult
to machine as they behave like refractory materials during machining and high amount of
heat is passed on to the tool which makes the tool to wear faster. Ezugwu and Wang
(1997) presented a review about the problems associated with the machining of titanium
alloys and discussed in detail about tool wear and its mechanisms. The effect of tool
geometrical and process parameters on surface roughness produced while machining
Ti-6Al-4V alloy was studied by Satyanarayana and Venu Gopal (2013) and Dillibabu et
al. (2013). The effect of application of coolants on tool wear and surface roughness under
conventional machining conditions were studied extensively by some authors (Hong
et al., 2001, Heretis et al., 2009; Muthukrishnan and Davim, 2011). Satyanarayana and
Venu Gopal (2013) studied the effects of cutting speed, feed, depth of cut and back rake
angle on main cutting force and surface roughness. The experimental results were
analysed using response surface methodology (RSM) face centred, central composite
design (CCD). They found from the experimental results that main cutting force
increased with the increase in depth of cut and feed and decreased with the increase in
cutting speed and rake angle, whereas surface roughness decreased with the increase in
cutting speed and rake angle and increased with depth of cut and cutting speed.
Machining parameters optimisation improves machining economics while providing
required quality for the machined. Modelling and optimisation of the process parameters
to minimise/maximise the output response such as surface roughness, tool wear, etc., are
the two important issues in machining. The surface roughness and tool wear are analysed
to predict machining performance and are optimised machining parameters for process
planning. These output responses tool wear and surface roughness are influenced by
many parameters in various amounts such as process parameters, tool geometry, work
and tool material characteristics, machine condition and cutting environment. In these
certain parameters are constrained and others can be varied to get the required output
responses. It is important to optimise these parameters within their acceptable range for
the suitable performance. Suresh et al. (2002) proposed a model to predict the surface
roughness for machining mild steel, using RSM. The model used to optimise the
machining parameters to minimise surface roughness and was solved using genetic
algorithms (GA). The GA program presented minimum and maximum values of surface
roughness using the optimum machining parameters. Aggarwal and Singh (2005)
presented an extensive review of the literature on optimising the turning parameters and
compiled the traditional and non-traditional optimisation methods proposed by various
authors. Oktem et al. (2005) used RSM to create an efficient analytical model for surface
roughness in terms of cutting parameters: feed, cutting speed, axial depth of cut, radial
depth of cut and machining tolerance. The model used to optimise the cutting parameters
for the minimum surface roughness in milling of mold surfaces. Farhad and Abachizadeh
(2008) used simulated annealing (SA) algorithm to optimise machining parameters in
turning operation of cylindrical work pieces to minimise the overall machining cost.
Their optimisation approach showed reduction in total operation cost by optimally
determining machining parameters. Saha and Mandalb (2013) conducted experiments to
get the optimum combination of turning parameters for the optimum multi performance
characteristics of turning process. Their confirmation test proved that the determined

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optimum turning parameters satisfy the performance requirements. Nithin and

Kanthababu (2013) carried out multi-objective optimisation using particle swarm
optimisation (PSO) to maximise the material removal rate (MRR) and minimising surface
roughness (Ra) and tool wear (TW) simultaneously in micro turning operation.

1.1 Step micro turning

A micro shaft with a high aspect ratio and a micron-range diameter cannot be machined
by a cut parallel to the axis of the job like in conventional turning, as shown in Figure 2.
The major drawback of micro turning process is that high machining force affects
machining accuracy and the limit of machinable size. During machining, reduced
diameter and increase in unsupported work piece length make the shaft to deflect.
Therefore, the control of the reacting force during micro turning is one of the important
factors for improving the machining accuracy. The value of the cutting force must be
kept low by increasing the cutting speed, and this causes lesser plastic deformation to the
work piece. This is an effective method to overcome work piece deflection in micro
turning process, and also high cutting speed aids the continuous chip formation leads to
higher tool life (Rahman, 2005).
Figure 2

Turning by parallel cut to workpiece axis

Figure 3

Turning by step cutting

Analysis and optimisation of machining parameters in micro turning

81

Figure 3 describes a possible way of the fabrication of miniature shafts by step cutting
process proposed by Rahman et al. (2003). Unlike the conventional parallel cut turning,
in step cutting tool is moved towards the work piece rotational axis and the cutting force
developed is supported by the uncut material. In this research work, turning is carried out
in a step-wise manner. In order to increase the productivity with good surface quality in
shorter machining time, it is required to use the best machining method and best
combination of input parameters and their precise control to increase the output quality,
based on specified criteria and economical aspects. The tool wear and surface roughness
play an important role in many areas and is a factor of great importance in the evaluation
of the machining accuracy.

Motivation and problem statement

The modern industries are trying to achieve high machining performance in terms of
work piece dimensional accuracy, surface finish, economy of machining and try to reduce
the environmental impact during and after manufacturing. The machining accuracy, tool
wear and the surface roughness are the key parameters used for evaluating the machining
performance. The most important performance measures in micro turning are tool life,
cutting force generated, surface roughness and energy consumption. The survey results in
USA showed that the correct cutting tool selected was less than 50% of times, the tool
was used at the rated cutting speed only about 58% of the time and only 38% of the tools
were used up to their full tool life capacity (Astakhov, 1999). The same result was also
reported by US aircraft industry that selected cutting speed was far below the optimal
economic speeds. Hence, to get high machining performance the machining has to be
done with optimum cutting parameters and suitable cutting conditions. It has been
recognised that the reliable quantitative predictions of the various technological
performance measures of micro turning, preferably in the form of empirical equations
(process models) are essential. The model helps to develop the strategies for finding the
optimum cutting parameters and cutting conditions which are useful for process planning.
The progress in the development of predictive models, based on micro turning theory has
not established much when concerned with the individual machines used for specific
work piece materials. From the literature survey, it was observed that very few authors
investigated the effect of micro turning parameters during machining of titanium alloy.
But micro turned titanium alloy components found many applications.
The existing solution in machining area are either try to analysis the significance of
input parameters or development of process models and optimisation of the input
parameters or analyses the interaction effect of input parameters on output responses.
Developing an approach which simultaneously analysis the significance of input
parameters, developing the process models, optimisation of the input parameters and able
to analysis the interaction effect of the input parameters on output responses is more
useful for the machining industries. Hence in this work, RSM-BBD based approach is
used to study the effect of cutting speed, feed and depth cut on the tool wear produced in

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the cermet insert and surface roughness produced while micro turning of Ti alloy Gr.2
and the machining performance is analysed.

Material and tool selection

In this paper, an attempt is made to analyse the performance of micro turning of

Ti alloy Gr. 2 with cermet insert. The cermet is a composite material designed to
have high temperature resistance and hardness, and able to plastically deform to get a
shape. The composition of cermet insert is 85% TiC2 and binder is Ni. The cermet
material has small, well controlled grain structures, hence, they show higher wear
resistance. In addition, cermet insert maintain a sharp edge longer than carbide and
has superior resistance to built-up edge during machining. The SUMITOMO cermet
insert with 0.4 mm nose radius, 7 front clearance angle and 10 rake angle is used
with SUMITOMO STGCR 10-10-09 mini tool holder for machining the Ti alloy
work pieces.
Titanium alloy Gr. 2 is one of the most commonly used titanium alloys and its
usability makes best alloy for airframe components, cryogenic vessels, heat exchangers,
communications and power industries equipment, condenser tubing, pickling baskets,
etc., (ASM data sheet, 2012). The titanium alloy may be heat treated to increase its
strength and can be used in welded construction at service temperature of up to 315C
(600F). This alloy offers its high strength with less weight, and has useful formability
and high corrosion resistance. The composition of Ti alloy Gr. 2 is given in Table 1. The
work pieces of cylindrical rod 5 mm diameter and 150 mm length is used for conducting
the experiments.
Table 1
Element
Weight %

Chemical composition (%) of titanium alloy Gr. 2

C

Fe

Ti

Max 0.1

Max 0.3

Max 0.015

Max 0.03

Max 0.25

Bal

Experimental process

The micro turning experiments are performed using a micro machining centre
(micro tools DT 110) shown in Figure 4. The cylindrical rod is turned by cermet
insert type tool under dry operating conditions. Different sets of machining parameter
sets are used in the experiments in order to analyse the effect of cutting speed, feed
and depth of cut on tool wear and surface roughness. The work material is fixed to the
chuck. The cermet insert is clamped to the tool holder and the necessary settings
are made. The process parameters selected for the experiments are feed into the part
program and experiments are conducted with combinations of cutting speed, feed and
depth of cut as per the experimental design. The amount of wear on insert and the surface
roughness (Ra) are measured using a non contact video measuring system and a surface
tester (surfcorder SE3500, Figure 4) respectively. The measured experimental results are
given in Table 2.

Analysis and optimisation of machining parameters in micro turning

Figure 4

Table 2

83

Experimental setup with measuring device (see online version for colours)

RSM design matrix-input data

Exp run Cutting speed (rpm) Feed (m/rev) DOC (m) Tool wear (mm) Surface roughness (m)

3000

10

0.187

0.612

2500

12

10

0.231

1.12

3000

15

0.181

0.809

3000

12

15

0.197

0.875

2500

15

0.221

0.896

2500

10

0.309

0.712

3500

0.261

0.997

2500

0.282

0.623

3500

10

0.254

1.093

10

3500

12

10

0.189

1.132

11

3000

12

0.203

0.879

12

3500

15

0.133

0.987

13

3000

0.367

0.662

14

3000

10

0.185

0.636

15

3000

10

0.186

0.639

Mathematical modelling

The mathematical process models represent relationship between the input process
parameter with output response(s). The process models helps to predict the output
responses based on the input parameters. The process models are able to predict the
output without conducting experiments and reduce the time for choosing the right
combinations of parameters. The process models are also useful for optimising the
parameters for the maximum/minimum output response(s) under the set constraints. In
this paper, for developing mathematical models, RSM is used for the experimental
design. The RSM is a collection of mathematical and statistical techniques which are

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S. Selvakumar et al.

useful for the modeling, analysis of problems in which a response of interest is influenced
by several variables and the objective is to optimise the response (Montgomery, 2001).
The general form of the second order RSM model is given below is able to improve the
optimisation accuracy:
k

Y = bo +

b X
i

i =1

i , j =1, i j

bij X i X j +

b X
ii

(1)

i =1

y = 0 + 1 x1 + 2 x 2 + 3 x3 + 11 x12 + 22 x 22 + 33 x32 + 12 x1x 2 + 13 x1x3 + 23 x 2 x3

(2)

where, y is the predicted response, 0 is the model constant; x1, x2 and x3 are independent
variables; 1, 2, and 3 are linear coefficients; 12, 13, and 23 are cross product
coefficients and 11, 22, and 33 are the quadratic coefficients. All the coefficients
mentioned above are estimated. The choice of the design of experiments in RSM decides
the accuracy of the approximation and the cost involved in conducting the experiments.
To construct the models and to understand the interaction effects of the input parameters,
full factorial design can be used in RSM approach. The BBD in RSM is an alternate to
full factorial design and efficiently reduce the number of experiments. In this paper, for
three factors (parameters) RSM by BBD used which uses fewer experiments compared to
other designs are employed for designing the experiments, analysing the results and
optimising the parameters.

Results and discussion

In a machining process, minimising the tool wear and surface roughness are the important
criterion. The BBD in RSM approach is used to design of experiments and is analysed
using analysis of variance (ANOVA) for the identification of the best levels of cutting
parameters, level of their significance, and optimisation of the parameters. By
considering the cutting speed, feed rate, depth of cut, and their interactions, the minimum
number of experiments required is calculated as fifteen, and the micro turning
experiments are conducted with cermet insert based on the design matrix level shown in
Table 2. The following discussion focuses on the effects of process parameters on the
observed values (tool wear and surface roughness) based on the RSM.

6.1 Mathematical models

In this research work, the experimental design is developed using commercial RSM
software, which supports the ANOVA. The mathematical modeling of micro turning
operation is performed by using all the 15 trials data and the effect of each factor of the
turning parameters on surface roughness and tool wear are analysed. The mathematical
models are obtained in coded form from the software and are converted to actual form
(incorporating the parameters) for the analysis. The mathematical model in actual form is
given as equations (3) and (4) for the responses namely the tool wear and the surface
roughness. To predict the responses (VB and Ra), the input process parameters (cutting
speed, feed rate and depth of cut) are to be substituted in the corresponding equations
(model). The mathematical models for forecasting tool wear and surface roughness are
given in equations (3) and (4) respectively.

Analysis and optimisation of machining parameters in micro turning

85

Tool wear, VB = +1.57650 0.0005615* CS 0.072719 * Feed

0.019225* DOC + 0.000001625* CS* Feed
0.0000067 * CS* DOC + 0.00225* Feed * DOC

(3)

+ 0.000000094 * CS 2 + 0.00226563* Feed 2

+ 0.00059 * DOC 2

Surface roughness, Ra = + 6.48900 0.0045905*CS + 0.022187 * Feed

+ 0.09465* DOC 0.000046125*CS* Feed
0.0000283*CS* DOC
0.0018875* Feed * DOC

(4)

+ 0.0000009095*CS

+ 0.00986719* Feed 2
+ 0.000775* DOC 2

6.2 Analysis of variance

The ANOVA test is performed for identifying the significance of the regression models,
individual model coefficients and the lack of fit. Table 3 summarises ANOVA result of
the quadratic model, and other model terms for tool wear. The same table shows the other
adequacy measures R2, Adjusted R2, and Predicted R2. The larger values of R2 are being
more desirable. The entire adequacy measures are closer to 1, which indicates the
adequacy of the models. Lee and Um (2000) reported that model terms are significant, if
the probability value (p-value) is less than 0.05. Here the model terms are significant as
the p-value is less than 0.05. The output showed that the model is significant with
probability value (p-value) 0.0001. The p-value for no lack of fit is 0.1211, which is
larger than the reference limit of p-value, 0.05. The model F-value of 1149.02 implies
that the model is significant and the adequate precision measures of signal to noise ratio.
The adequate precision ratio greater than 4 is desirable. The adequate precision ratio of
128.952 indicates an adequate signal. It is observed that the effect of the cutting speed
and the factor associated with the cutting speed are having the least significance on the
responses while compared to other input parameters (feed rate and depth of cut).
Table 4 summarises the ANOVA of quadratic model and other model terms for the
surface roughness. The output shows that the model is significant with the probability
value (p-value) 0.0001 and no lack of fit with p = 0.1033, which is larger than the
reference limit of p of 0.05. The model F-value of 44.76 implies that the model is
significant. As stated earlier if the precision ratio is greater than 4 then it is desirable.
Here the precision ratio is 17.185 which indicates the adequacy of the signal to noise
ratio. The normal probability plot of the residuals (i.e. error = predicted value from
modelactual value) for the tool wear and the surface roughness are shown in Figure 5
and Figure 6, respectively. These figures reveal that the residuals lie reasonably closer to
the straight line, giving support to the model which is significant (Montgomery, 2001).

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S. Selvakumar et al.

Table 3

ANOVA Table for tool wear

ANOVA for response surface quadratic model tool wear
ANOVA table (partial sum of squares type III)

Source
Model

Sum of squares

df

Mean square

F value

p-value
prob > F

Remarks
significant

0.050

5.573E-003

1149.02

< 0.0001

5.305E-003

5.305E-003

1093.71

< 0.0001

B-feed rate

0.011

0.011

2182.50

< 0.0001

C-DOC

0.018

0.018

3741.26

< 0.0001

AB

4.225E-005

4.225E-005

8.71

0.0318

AC

1.122E-003

1.122E-003

231.39

< 0.0001

A-cutting speed

BC

8.100E-003

8.100E-003

1670.10

< 0.0001

A2

2.039E-003

2.039E-003

420.43

< 0.0001

4.852E-003

4.852E-003

1000.40

< 0.0001

C2

8.033E-004

8.033E-004

165.63

< 0.0001

7.42

0.1211

Residual

2.425E-005

4.850E-006

Lack of fit

2.225E-005

7.417E-006

Pure error

2.000E-006

1.000E-006

Cor total

0.050

14

not significant

Note: R2 = 0.9995; adj. R2 = 0.9986; pred. R2 = 0.9928; adeq precision = 128.952

Table 4

ANOVA table for surface roughness

ANOVA for response surface quadratic model surface roughness
ANOVA table (partial sum of squares type III)

Source

Sum of squares

df

Mean square

F value

p-value
prob > F

Remarks
significant

Model

0.50

0.056

44.76

0.0003

A-cutting speed

0.092

0.092

73.64

0.0004

B-feed rate

0.067

0.067

53.31

0.0008

C-DOC

0.021

0.021

16.49

0.0097

AB

0.034

0.034

27.24

0.0034

AC

0.020

0.020

16.02

0.0103

BC

5.700E-003

5.700E-003

4.56

0.0858

A2

0.19

0.19

152.76

< 0.0001

B2

0.092

0.092

73.65

0.0004

C2

1.386E-003

1.386E-003

1.11

0.3405

8.84

0.1033

Residual

6.248E-003

1.250E-003

Lack of fit

5.810E-003

1.937E-003

Pure error

4.380E-004

2.190E-004

Cor total

0.51

14

Note: R2 = 0.9877; adj. R2 = 0.9657; pred. R2 = 0.8156; adeq precision = 17.185

not significant

Analysis and optimisation of machining parameters in micro turning

Figure 5

87

Normal probability plot of residuals for tool wear (VB) data

(see online version for colours)

Design-Expert Software
Tool wear

Normal Plot of Residuals

Color points by value of

Tool wear:
0.367

99

0.133

Normal % Probability

95
90
80
70
50
30
20
10
5
1

-2.00

-1.00

0.00

1.00

2.00

Internally Studentized Residuals

Figure 6

Normal probability plot of residuals for surface roughness (Ra) data (see online version
for colours)

Design-Expert Software
Surface roughness

Normal Plot of Residuals

Color points by value of

Surface roughness:
1.132

99

0.612

Normal % Probability

95
90
80
70
50
30
20
10
5
1

-3.00

-2.00

-1.00

0.00

1.00

2.00

3.00

Internally Studentized Residuals

6.3 Interaction plot

The interaction plots are used to observe the influence of variation of a parameter along
with other while third parameter is kept constant on tool wear and surface roughness.

6.3.1 Observations on tool wear

Figure 7 shows the interaction effect of the cutting speed and the feed rate on the tool
wear, the depth of cut is kept constant. The analysis shows that the cutting speed
increases from 2500 rpm to 3500 rpm at 4 m/rev feed rate with constant depth of cut

88

S. Selvakumar et al.

15 m, the tool wear decreases from 0.259 mm to 0.162 mm (as per equation (3)) which
amounts to 37.4% decrease in tool wear. The analysis shows that the cutting speed
increases from 2500 rpm to 3500 rpm at 8 m/rev feed rate with constant depth of cut
15 m, the tool wear decreases from 0.221 mm to 0.133 mm (as per equation (3)) which
amounts to 39.8% decrease in tool wear. It is found that the cutting speed increases from
2500 rpm to 3500 rpm at 12 m/rev feed rate with constant depth of cut 15m, the tool
wear decreases from 0.265 mm to 0.183 mm (equation (3)) which amounts to 30.9%
decrease in tool wear. With this effect, it is observed that the cutting speed plays primary
role and feed rate attributes secondary effect in the reduction of tool wear. With this high
reduction in tool wear at medium feed rate along with higher depth of cut, the nature of
curve shows that the effect of increase in speed towards higher position is having a
parabolic in shape will give better performance.
Figure 7

Contour plot showing the effect of cutting speed and feed rate on tool wear (see online
version for colours)

Design-Expert Software
Factor Coding: Actual
Tool wear
Design Points
0.367

Tool wear

12

0.240

0.133

0.220
10

X1 = A: Cutting Speed
X2 = B: Feed rate

0.180

B: Feed rate

Actual Factor
C: DOC = 15

0.200

Prediction
X1
X2

0.182
3497
12

Prediction
Observed
X1
X2

0.134
0.133
3500
8

0.160

0.140

0.220

Prediction
X1
X2

0.240

0.158
3500
4

4
2500

2700

2900

3100

3300

3500

A: Cutting Speed

Note: DOC = 15 m

The interaction effect of feed and depth of cut on tool wear with constant cutting speed is
shown in Figure 8. With constant higher cutting speed and feed rate at 8 m/rev, the
depth of cut is increased from 5 m to 15 m the predicted tool wear is decreased from
0.261 mm to 0.133 mm (equation (3)) which amounts to 49% reduction in tool wear. The
tool wear is determined at constant higher cutting speed and feed rate at
12 m/rev when the depth of cut is increased from 5 m to 15 m and it is observed that
the predicted tool wear is decreased from 0.230 mm to 0.181 mm (equation (3)) which
amounts to 21.3% reduction in tool wear. At higher depth of cut with higher cutting
speed, the tool wear reduction rate is doubled between 12 m/rev to 8 m/rev feed rate.
This indicates that the contribution of interactive effect between feed rate and depth of
cut is very essential, which shows the medium feed rate will give better performance than

Analysis and optimisation of machining parameters in micro turning

89

other conditions, i.e., whenever decreases in feed rate from 12 m/rev to 8 m/rev the
reduction of the tool wear is doubled. The role of depth of cut is in primary contribution
and feed rate gives secondary contribution on the tool wear. From the interaction curve, it
is inferred that the minimum tool wear is obtained at maximum depth of cut with medium
range of feed rate. Hence, the contribution of cutting speed is essential for the reduction
of the tool wear. The higher cutting speed and lower feed rate produced better surface
quality. In such a way by increasing the cutting speed with medium feed rate the tool
wear is reduced.
Figure 8

Contour plot showing the effect of feed rate and depth of cut on tool wear (see online
version for colours)

Design-Expert Software
Factor Coding: Actual
Tool wear
Design Points
0.367

Tool wear

15

Prediction
X1
X2

0.133

0.134
8
15 0.150

Prediction
X1
X2

0.182
12
15

13

X1 = B: Feed rate
X2 = C: DOC

C: DOC

Actual Factor
A: Cutting Speed = 3500
10

0.200

0.250

0.300
Prediction
0.350

0.263
8
5

X1
X2

5
4

10

12

B: Feed rate

Note: Cutting speed = 3500 rpm

6.3.2 Surface roughness

The interaction effect of the feed rate and the depth of cut, the cutting speed is kept
constant on surface roughness are shown in Figure 9. As per the inference from the curve,
whenever increases in feed rate as well as depth of cut the surface roughness increases.
But increase in feed rate definitely affects the surface quality and the depth of cut is not
influencing surface integrity, it only increases the temperature of the cutting zone. But in
machining, the contact length (depth of cut) increases between the tool and the
workpiece. The condition of heat flow improves from the cutting zone and successively
reduced tool wear and improves the surface quality and continuous chips are produced.
Hence, formation of continuous chip is a prime condition of higher tool life (Trent and
Wright, 2000). Based on the interaction effect of feed rate and depth of cut, it is observed
that the cutting speed and feed rate play a major role than depth of cut on surface quality.
With this effect, it can be inferred that the depth of cut is not influencing both the tool
wear and surface roughness.

90

S. Selvakumar et al.

Figure 9

Contour plot showing the effect of feed rate and depth of cut on surface roughness
(see online version for colours)

Design-Expert Software
Factor Coding: Actual
Surface roughness
Design Points
1.132

Surface roughness

15

0.612

1.100
13

X1 = B: Feed rate
X2 = C: DOC

Prediction
Observed
X1
X2

C: DOC

Actual Factor
A: Cutting Speed = 2500

0.724
0.712
4
10

0.800
0.900

1.000

10

0.700

Prediction
Prediction
Observed0.6000.584
0.583
X1
4
X1
X2
5
X2

0.647
0.623
8
5

5
4

10

12

B: Feed rate

Note: Cutting speed = 2500 rpm

Figure 10 Contour plot showing the effect of cutting speed and feed rate on surface roughness
(see online version for colours)
Design-Expert Software
Factor Coding: Actual
Surface roughness
1.132

Surface roughness

12

1.100

0.900

1.000

0.612

1.000

0.800

X1 = A: Cutting Speed
X2 = B: Feed rate

10

B : F eed rate

Actual Factor
C: DOC = 15

Prediction
X1
X2

0.697
3021
8

0.700

1.000

1.100
4
2500

2750

3000

3250

3500

A: Cutting Speed

Note: DOC = 15 m

The interaction effect of the cutting speed and the feed rate on surface roughness while
the depth of cut is kept constant is shown in Figure 10. The analysis shows that the
cutting speed increases between 2500 rpm to 3000 rpm and 3000 rpm to 3500 rpm at
8 m/rev feed rate with constant depth of cut 15 m, the surface roughness decreases

Analysis and optimisation of machining parameters in micro turning

91

from 0.896 m to 0.698 m which amounts to 22% decrease in surface roughness and
another side surface roughness increases from 0.698 m to 0.987 m (equation (4) which
amounts to 29.2% increases of the surface roughness value. It is attributed to the
secondary effect of interaction between cutting speed and feed rate will influence more
than primary effect. The curve in the shape of elliptical section infers that the surface
roughness value, at high cutting speed and low feed rate is 1.157 m, then the high
cutting speed and high feed rate the surface roughness is 1.091 m, it almost identical.
Hence, the contribution of feed rate and cutting speed is very essential for the reduction
on surface roughness. This clearly indicates that the medium speed with feed rate and
higher depth of cut gives better performance than others. This result has been indicated
on the Figure 10 with flag display.
This is because of increase in cutting speed leads to the machining time reduction,
increase of tool life and the production rate increases. The better surface quality is
obtained with the decreased tool wear at medium cutting speed and feed rate. In this
effect the feed rate is the most significant factor associated with the surface roughness.
This anticipation is based on the given tool nose radius, the theoretical surface roughness
(Ra = f2/(32 re) is mainly a function of the feed rate (Shaw, 1984). Based on the effect,
the cutting speed increases in higher side will contribute to better surface quality. This
indicates that the cutting speed and feed rate play a significant role in tool wear and
surface roughness. In order to obtain the minimum surface roughness, the operation has
to be performed at the medium feed rate (Figure 10).
Based on the direct and interaction effects, it is identified that the cutting speed is the
major parameter influencing the tool wear and surface roughness followed by the feed
rate and the depth of cut has the least effect on the responses.

Optimisation of micro turning operation

Optimisation of cutting parameters is one of the most important elements in any process
planning of metal parts. In view of achieving the best quality product with higher rate of
productivity, tooling cost, surface roughness, and tool wear are to be minimised. The
micro turning process parameters can be optimised for the above requirements. In
traditional optimisation problem, there are many drawbacks and it does not fare well in
solving problems in over a broad spectrum of domains. The non-traditional optimisation
methods such as GA, SA algorithm, PSO, ant colony (AC) algorithm, etc., perform well
and produce nearly global optimum solutions. Many engineering optimisation problems
have multiple optimum solutions, among which one or more be the absolute minimum or
maximum solutions. For obtaining the best quality surface, higher rate of productivity
with low cost of production, it is required to minimise the surface roughness and the tool
wear. In order to obtain the best quality machining operation, the mathematical models
are developed for the turning parameter profile which is very useful to identify the correct
and optimal combination of the machining input variables. In this paper, the RSM-BBD
approach is used to formulate the experimental layout, to analyse the effect of each
parameter on the machining characteristics, and to predict the optimal choice for each
machining parameter such as cutting speed, feed rate and depth of cut.
The optimisation module in design-expert software searches for a combination of
factor levels of speed, feed and depth of cut that simultaneously satisfy the minimum tool
wear and minimum surface roughness. The numerical and graphical optimisation

92

S. Selvakumar et al.

methods are used by choosing the desired goals for each factor (input) and response
(output). The objective function may be stated as maximum cutting speed, maximum
depth of cut and the feed rate to be within the range of 4 m/rev to 12 m/rev. The
numerical optimisation finds a point or more that minimises both the tool wear and the
surface roughness. In the graphical optimisation with multiple responses it is required to
define regions where the requirements simultaneously meet the proposed criteria by
superimposing or overlaying critical response contours on a contour plot. Then visual
search for the best compromise becomes possible. As suggested by Benyounis et al.
(2005) for multiple responses, it is recommended to do numerical optimisation first;
otherwise it may be impossible to uncover a feasible region. Hence, the numerical
optimisation is carried out first and then the graphical optimisation is done. Table 5
illustrates the goal, lower and upper limits of independent variables and the importance of
each factor on the responses.
Table 5

Criteria for numerical optimisation

Variable name
Cutting speed

Units

Goal

Lower limit

Upper limit

Importance

rpm

Maximise

2500

3500

m/rev

Is in range

12

Depth of cut

Maximise

15

Tool wear

mm

Minimise

0.133

0.367

Surface roughness

Minimise

0.612

1.132

Feed rate

The Table 6 shows the comparative analysis of actual and predicted values of the
responses with optimal turning conditions, which lead to minimum level of tool wear and
surface roughness. It is evident, the minimum tool wear of 0.140 mm and minimum
surface roughness of 0.741 m are achieved by using cutting speed 3180 rpm, feed rate
8 m/rev and depth of cut 15 m. If the cutting speed increases slightly, the tool wear
maintains the same position but the surface roughness increases. With this effect, it is
observed that the cutting speed plays a dominant role in the tool wear and feed rate
significantly influences the tool wear and surface roughness. The percentage error range
between the actual and predicted value for tool wear and surface roughness was as
follows: tool wear 1.45 to +3.45% and surface roughness 3.33 to +1.60%. From the
above statement, it can be said that the empirical models developed are reasonably
accurate. It is observed that all the experimental values of the confirmation run are within
the 95% prediction interval.
The graphical optimisation results allow the visual inspection to choose the optimum
micro turning parametric conditions. Figure 11 shows the overlay plot drawn between the
cutting speed and the feed rate. The shaded areas on the overlay plots are the regions that
to do meet the proposed criteria. The various locations in contour flag represent the input
variables and the corresponding responses. The yellow colour shaded area is the
optimised region to obtain the desired machining qualities. It is noted that as the cutting
speed is increased result in improved productivity of the machine and the machining cost
will be reduced. The validation trials are conducted to compare the results of the
optimisation and the mathematical models with the experimental results. The results of
the validation trial match with the mathematical model developed and amount of
variation between them is within the acceptable range.

3180

3181

3173

3182

3189

Cutting speed (rpm)

Feed rate (m/rev)

15

15

15

15

15

Depth of cut (m)

0.145

0.139

0.139

0.144

0.138

Actual

0.140

0.140

0.141

0.140

0.140

0.005

0.001

0.002

0.004

0.002

Residual

Tool wear (mm)

Predicted

3.45

0.72

1.44

2.78

1.45

Error (%)

0.721

0.754

0.742

0.739

0.745

Actual

0.741

0.745

0.742

0.738

0.742

0.024

0.012

0.004

0.003

0.004

Residual

Surface roughness (m)

Predicted

3.33

1.60

0.54

0.41

0.54

Error (%)

Table 6

S. no

Analysis and optimisation of machining parameters in micro turning

RSM optimisation of responses in titanium alloy with comparative analysis

93

94

S. Selvakumar et al.

Figure 11 Overlay plot shows the region of the optimal working condition on the criteria
(see online version for colours)
Design-Expert Software
Factor Coding: Actual
Overlay Plot
Tool wear
Surface roughness
Design Points

Surface roughness: 1.132

14

X1 = A: Cutting Speed
X2 = B: Feed rate

Tool wear: 0.367

12

B: Feed rate

Actual Factor
C: DOC = 15

Overlay Plot

16

Tool wear:
Surface
Tool wear: roughne
0.367
X1
X2

10

0.140
0.741
3180
8

Tool wear:
Surface roughne
X1
X2

0.163
1.007
3339
4

2
1000

1444

1889

2333

2778

3222

3667

4111

4556

5000

A: Cutting Speed

Conclusions

In this paper micro turning of Ti alloy Gr.2 with cermet insert type tool is analysed using
RSM-BBD approach. The micro turning experiments are conducted on work pieces using
various combinations of cutting speed, feed rate and depth of cut as per the experimental
plan and tool wear and surface roughness are measured. The design-expert software is
used to develop the design matrix, analyse the significance of the parameters, develop the
process models and optimise the process parameters for minimum tool wear and surface
roughness. This paper presents the findings of the analysis and optimisation of micro
turning parameters of Ti alloy and the following conclusions are drawn from the analysis
and optimisation.

It is observed that the effect of the cutting speed and the factor associated with the
cutting speed are having the least significance on the responses while compared to
other input parameters (feed rate and depth of cut).

The analysis shows that the cutting speed increases from 2500 rpm to 3500 rpm at 8
m/rev feed rate with constant depth of cut 15 m, the tool wear decreases as 39.8%,
which is larger than the other feed rates.

It is identified that the cutting speed is the major parameter influencing the tool wear
and surface roughness followed by the feed rate and the depth of cut has the least
effect on the responses.

The contribution of feed rate and cutting speed is very essential for the reduction on
surface roughness. This clearly indicates that the medium speed with feed rate and
higher depth of cut gives better performance than others.

In the case of 2500 rpm cutting speed, 4 m/rev feed position developed the stress
and cutting wedge action taking place against tool to workpiece. The wedge action
develops a pit and it occurs on the rake face of the tool.

Analysis and optimisation of machining parameters in micro turning

95

While machining, the contact length increases between the tool and work piece, the
condition of heat flow improves from the cutting zone and improves the surface
quality and produced continuous chips with reduced tool wear.

The percentage error range between the actual and predicted values for tool wear and
surface roughness was as follows: tool wear 1.45 to +3.45% and surface roughness
3.33 to +1.60%.

The minimum tool wear and surface roughness is obtained from experimental studies
were 0.140 mm and 0.741 m, when the process parameters such as cutting speed,
feed rate and depth of cut were maintained at 3180 rpm, 8 m/rev, and 15 m.

The results of the validation trial match with the mathematical model developed and
amount of variation between them is within the acceptable range.

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