International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 1, January 2017, pp. 213234, Article ID: IJMET_08_01_024

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=1
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication

PROCESS OPTIMIZATION IN DRY TURNING OF

STEEL, CAST IRON AND BAKELITE USING LOW
COST TOOL MATERIAL
Tapas Banerjee
Mechanical Engineering Department, Jadavpur University,
Kolkata, West Bengal, India

Asish Bandyopadhyay
Mechanical Engineering Department, Jadavpur University,
Kolkata, West Bengal, India

Pradip Kumar Pal

Mechanical Engineering Department, Jadavpur University,
Kolkata, West Bengal, India

ABSTRACT
The present work includes a methodical study of the effects of input parameters viz. spindle
speed, longitudinal feed and depth of cut on surface roughness (Ra) of machined components and
vibration generated during machining. Vibration is an output response produced in metal cutting
operation. This vibration acts directly as a response which takes part in roughness formation on
work materials. There is an impact on both surface finish and productivity. The design of
experiment plan is based on L16 orthogonal array with three factors and four levels for each
variable as per Taguchi method. The experiments are conducted on Low Carbon steel, Grey Cast
Iron and Bakelite on Centre Lathe using HSS single point turning tool under dry cutting condition.
Response variables viz. surface roughness (Ra) and cutting vibration (dB) in the three directions
are recorded by using accelerometer placing on the periphery of work holding chuck end bearing
housing. An attempt is made to optimize the cutting parameters in respect of multi-response
variables viz. surface roughness (Ra) and cutting vibration (dB) in three directions to achieve a
breakeven level of both the quality and yield by using low cost tool material. CQL perception in
WPCA based Taguchi technique is used to evaluate optimal input parameters.
Key words: Surface Finish; Cutting Vibration; Multi-objective optimization; WPCA; CQL.
Cite this Article: Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal. Process
Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material.
International Journal of Mechanical Engineering and Technology, 8(1), 2017, pp. 213234.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=1

http://www.iaeme.com/IJMET/index.asp 213 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

1. INTRODUCTION
The lathe is a flexible machine tool. In lathe, most common process of material removal is turning. Surface
roughness is one of the most important output parameters in metal cutting processes. Shape, waviness and
roughness or irregularities are the three basic criterion of a surface. Straightness error is the result of
changing shape of a cylindrical work piece during turning. Vibration develops waviness. The combined
result of feed, tool nomenclature, tool material, work piece material and temperature of tool work piece
interface generates roughness or irregularities. Moreover by achieving good surface finish in turning, time
is substantially reduced for finishing operations like grinding, polishing, electro polishing etc. It also saves
assembly time in precision fits. The interaction of vibrations and surface roughness are studied in turning
operation on different materials (Low Carbon Steel, Grey Cast Iron, Bakelite etc.). It is observed in cutting
operation that apart from chatter (indicates severe vibration) self excited vibration (oscillations present
when no periodic forces are available in the system) also developed. These vibrations normally affect both
surface roughness and dimensional accuracy. One parameter is dependent on other parameters. If one
change others are affected.
Major influential factors which affect surface roughness has been outlined by the following block
diagram (Figure 1)

Figure 1 Major influential factors which affect surface roughness

Both shop floor engineers and operators apply their individual experience and skill to select effective
parameters for obtaining desired surface finish by minimizing the effect of vibration generated during
machining processes. Moreover, nowadays, various data ranges on cutting parameters are available from
different experimentations on different metals with turning operation in centre lathe. But still those data are
not sufficient enough to cover the entire spectrum of metal cutting application for obtaining desired surface
finish. So more and more experimentation are being designed and machining operation performed with
different metals and non metals with or without coolant by changing various input parameters to optimize
the outputs. So that all the assimilated data are accessible as well as acceptable during operation in
manufacturing industries without any hesitation.
AISI 1020 steel is utilized for uncomplicated structural application like cold headed bolts and also for
manufacturing of axles, general engineering components and spares for machinery, shafts, camshafts,
gudgeon pins, ratchets, light duty gears, worm gears, spindles etc. Case harden, more than HRC 65, is
possible for tiny section as well as for bulky section without influencing the core strength. Carbonitriding
can be performed for attaining certain benefits over normal carburizing.
IS210 FG200 grey cast iron is used for outstanding resistance to sliding friction and wear in cylinder
bores, piston rings and sideways on machine tools. Percentage of graphite flakes presence in cast iron
increases the capacity of damping vibration.

http://www.iaeme.com/IJMET/index.asp 214 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

DIN7735 Type-Hgw2008 bakelite is preferred for a wide variety of components where finest quality is
required. It is used for intricate appearance as well as for superior finish and accuracy of machined
components. Typical components contain fine jagged gears & pinions, geneva wheels, cams, seal retaining
rings, insulating sleeves and bushes, actuating arms, spares related to cryogenic temperatures, medium and
low voltage insulations, a broad range of other precision machined parts etc.
Choudhury et al.[8] achieved vibration control by relative vibration sensation between the tool and the
work piece by producing a force which leans to counterbalance the excitation. Choudhury et
al.[9]developed a system for on-line vibration control on a turning lathe by introducing a closed loop
feedback circuit and suitable varying its phase difference and gain. Su et al.[41] proposed an effective
procedure based on principle component analysis (PCA) to optimize the Taguchi methods multi-response
problems. Abouelatta et al.[1] observed the possibility of predicting roughness parameters on the basis of
tool vibrations and cutting parameters in turning operation. Four models were used to predict the roughness
parameters (Ra , Rt , Rsk) as functions of the cutting parameters and tool vibrations. The predicted models
were depend on both cutting parameters and tool vibrations. Risbood et al.[30] predicted dimensional
deviation and surface roughness by measuring vibrations and cutting forces in turning process by using
neural net work to locate effective approximates on surface finish and dimensional deviation. Benardos et
al.[6] reviewed different approaches for predicting surface roughness with RSM, Taguchi techniques,
analyzing experimental results by using ANOVA, Artificial neural networks (AAN), Neuro-fuzzy systems,
Genetic Algorithms etc. Noordin et al.[23] performed cutting tests of AISI 1045 Steel with constant depth
of cut under dry cutting conditions using multilayer tungsten carbide tool. Also investigated the most
significant factor, feed which influenced the response variables viz. tangential force and surface roughness.
Luo et al.[18] found that the feed rate and depth of cut played significant role on machined surfaces. Hung-
Chang L [13] proposed weighted principal components (WPC) method to overcome the shortcomings in
principal component analysis (PCA). Mahapatra et al.[19] conducted study of hard turning operation on an
engine lathe using P-10 grade tungsten carbide for machining of S45C steel. Taguchi methodology had
been used to find out the effective performance output and machining conditions. Stoic et al.[40] studied
on surface quality which was affected by cutting unsteadiness during hard turning. Antic et al.[4]
developed an appropriate model with Neural-Networks for monitoring tool-wear during hard turning.
Pusavec et al.[25] conducted study on high speed cutting of soft grey cast iron with advanced tool material
such as CBN. Mazid A.M. [20] developed a methodology to correlate between accuracy of MFTW
(machine tools, jig-fixture, cutting tool and workpiece) elastic system and the dimensional output of the
machined product. Thamizhmanii et al.[42] analyzed surface roughness on dry turning of SCM440 alloy
steel with Al2O3 + TiC golden coated cutting tool using Taguchi method. Taguchi method had shown that
the depth of cut played a significant role in producing lower surface roughness followed by feed. Bajic et
al.[5] investigated the effect of turning on both the surface roughness and cutting force. They also studied
the sway of cutting parameters viz. feed, cutting speed and depth of cut. Both regression analysis and
neural network methodology were used and compared for better prediction. Lu. Chen [17] investigated on
prediction of surface quality in machining process on a CNC turning lathe with stainless steel 304L as
workpiece (diameter 95.5 mm) and carbide coated inserts as tool. The developed RBF neural network
model supported on cutting speed, feed & depth of cut. It was reflected the prediction of surface contour
with low cost, high accuracy and high speed. Sahoo et al.[32] investigated optimal parametric combination
for minimum cutting force in turning of low carbon steel with HSS cutting tool by using RSM. It was
observed that the feed force and cutting force were high at low cutting speed and moderately low at high
cutting speed due to thinner chips and higher trim angle. Velchev et al.[44] investigated the cutting speed
on the specific cutting force during turning of steel (40CrMnMo7), bronze & aluminium alloy with P30
brazed carbide inserts. They developed new mathematical models which deal with the approximation in a
broad range of the dependence of the specific cutting force on the cutting speed in turning of different
materials. Gokkaya Hasan[11] used CNC turning machine and uncoated carbide tools for orthogonal
cutting of aluminium alloy (T4) using fixed depth of cut to study the properties of machining parameters
on surface roughness, cutting forces, built-up layer (BUL) and built-up edge (BUE). It was also observed

http://www.iaeme.com/IJMET/index.asp 215 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

that average surface roughness was increasing for increasing feed rate. Selvaraj et al.[34] investigated the
sway of cutting parameters (cutting speed, feed, and depth of cut) on the surface roughness of austenitic
stainless steel during dry turning with TiC and TiCN coated tungsten carbide cutting tool. They had
applied Taguchi optimization method to find out the optimal process parameters to improve surface
roughness in dry turning of Austenitic Stainless Steel (AISI 304).
Ramesh et al.[27] investigated the cutting conditions in turning of Duplex Stainless Steel 2205 using
CVD triangular carbide insert. They also established correlation between cutting speed, feed rate, depth of
cut etc. and optimized the turning conditions based on surface roughness by regression analysis.
Abuthakeer et al.[3] investigated the spindle vibrations effect on surface roughness of workpiece in dry
turning using Artificial Neural Networks (ANN). They conducted the experiments on CNC lathe with
carbide turning insert. They attempted to estimate the surface finish value and vibration level using Multi-
layer perceptions (MPL) architecture. Neseli et al.[22] investigated the tool geometrys influence on
surface finish. It was obtained in turning of AISI 1040 steel with Al2O3 coated insert tools. They found that
nose radius was the most significant factor for obtaining better surface roughness than other tool geometry
like approach angle, rake angle etc. Sharma et al.[35] investigated, analyzed and optimized cutting
parameters specifically, depth of cut, insert radius, feed & cutting speed with consideration of surface
roughness by turning of AISI 410 grade steel on a CNC lathe with P-20 and P-30 TiN coated inserts. They
found that feed rate had effected on Ra. Krishankant et al.[15] optimized turning process by the effect of
machining parameters using Taguchi methods to develop the value of manufactured goods. Kumar et
al.[16] investigated the effect of process parameters in turning of carbon alloy steel (SAE 8620, EN8,
EN19, EN24 and EN47 ) in a CNC lathe using carbide tip tool in wet condition. Finer surface finish
attained in turning of alloy carbon steel with higher spindle speeds at low feed rate.
Eze et al.[10] investigated experimentally the correlation of induced vibration with surface roughness
in turning of 41Cr4 alloy steel with F30 type carbide cutting tool by using response surface methodology
RSM. Wang et al.[47] investigated the sway of tool-tip vibration on surface irregularity. Rogov et al.[31]
used two cutting tools made of AISI 5140 and Tic coated carbide insert for turning of alluminium alloy
(AA2024) in lathe to ascertain the effect of cutting parameters on both surface irregularity and free
vibration. They also determined the percentage contribution of various parameters influencing natural
frequency and surface roughness using Taguchi Technique. Hessainia et al.[12] investigated the combined
effects of cutting parameters (speed, feed, depth of cut etc.) and tool vibration on surface roughness by
employing the analysis of variance (ANOVA) in hard turning of 56HRC hardened 42CrMo4 steel (74 mm
dia. 380 mm long) with Al2O3 / TiC mixed ceramic tool, type SNGN 120408 T01020. They also
developed completed and reduced experimental model to show a relationship between the parameters of
surface roughness with machining ones and tool vibrations. Rajasekaran et al.[26] investigated diverse
process parameters such as feed, cutting speed, depth of cut etc. and their importance in deciding the
surface roughness during machining of carbon fiber reinforced polymer material with cubic boron nitride
(CBN) tool. They found that response surface methodology (RSM) was well matched for predicting the
surface roughness of carbon fiber reinforced polymer composites. Rao et al.[28] investigated the influence
of feed, speed, and depth of cut on surface roughness and cutting force, on industrial CNC lathe, during
turning of AISI 1050 steel having hardness of 484 HV by using ceramic cutting tool [Al2O3 + TiC matrix
(KY1615)]. They also determined a combination of feed rate and depth of cut for achieving best possible
surface finish. Kayastha et al.[14] optimized process parameters for turning operation by using both
Taguchi and Principal Component Analysis method. Saraswat et al.[33] studied the performance
characteristics in turning of unalloyed medium carbon steel (EN9) by using Analysis of Variance
(ANOVA) and Signal to Noise ratio. Cutting parameters optimized to obtain better surface finish in turning
of medium carbon steel. Singarvel et al.[37] analyzed the optimum machining parameters on turning of
EN25 steel for minimizing of cutting force, surface irregularity, and rate of material removal by using
Taguchi based utility concept coupled with Principal Component Analysis (PCA). CVD and PVD coated
carbide tools were used during the experimental work. Nayak et al.[21] investigated the sway of machining
parameters (speed, depth of cut, and feed) on diverse performance measured in dry turning of AISI 304

http://www.iaeme.com/IJMET/index.asp 216 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

austenitic stainless steel with ISO P30 grade uncoated cemented carbide inserts. They optimized the
machining parameters for three important characteristics like material removal rate, cutting force, surface
roughness etc. using grey relational analysis. Vinayagamoorthy et al.[46] analyzed the performance of
precision turning by using conventional lathe on Ti-6Al-4V under dry working condition. They used
Analysis of Variance (ANOVA) to understand the influence of various cutting parameters on surface
roughness, tool ware, cutting force and cutting tool temperatures while precision turning of titanium alloy.
They also identified optimal levels of parameters using grey relational analysis. Abhang et al.[2]
investigated the effect of machining parameters such as feed rate, cutting speed, tool nose radius, depth of
cut, and lubricant (boric acid mixed with base oil SAE-40) on surface roughness during turning of EN31
steel on heavy duty lathe machine with diamond shape carbide tool (CNMA 120404, CNMA 120408,
CNMA 120412). They found that the surface roughness had been increased due to enhanced feed rate,
subsequently depth of cut, but surface roughness had been decreased with enhanced cutting speed and tool
nose radius respectively. Venkataramaiah et al.[45] investigated the sway of feed rate and tool
nomenclature on feed force, cutting force and radial force. during turning of aluminium workpiece with
HSS cutting tool using Taguchi Method and Fuzzy Logic. They examined the test result with ANOVA and
found that influencing factor on all the cutting forces were rake angle, feed rate and approach angle.
Valera et al.[43] investigated on power consumption and roughness attributes of surface generated in
operation of turning of EN31 alloy steel on general purpose lathe machine with TiN+Al2O3+TiCN coated
tungsten carbide under different cutting parameters. They concluded that spindle speed, feed and depth of
cut significantly affected the surface roughness and power consumption. They also suggested for further
work to find out most significant cutting parameter for EN31 ally steel work material. Sharma et al.[36]
investigated the optimization of cutting parameters (cutting speed, depth of cut and feed rate) for metal
removal rate and surface roughness in CNC turning operation of AISI 8620 steel using coated carbide
insert using Taguchi and Grey Taguchi analysis. Feed rate was found the most considerable factor for both
the material removing rate and surface roughness. Ojha et al.[24] optimized the input parameters in dry
turning and studied the effects of foremost input factors on the output using Taguchi technique and
response surface methodology. Srithar et. al.[39] analyzed the surface roughness parameters in machining
of AISI D2 steel (having 66 HRC hardness) by coated carbide insert. They found that feed rate influenced
the surface roughness parameters in machining of AISI D2 steel. Silberschmidt et. al.[38] investigated on
surface roughness and compared response of various alloys and metals from ones with well known good
machinability to hard-to-machine ones having ultrasonic assisted turning. They noticed the remarkable
improvement of surface roughness of all the studied alloys (Inconel 718, Ti 15 3 3 3, X2CrNi18-9, ASTM
A 48 class 20, AlMg1SiCu, CuZn37Pb2, CuSn11P, X2CrNi18-9 etc.) with hybrid turning technique UAT
(ultrasonic assisted turning). Bhuiyan et. al.[7] investigated tool wear, chip formation and surface
roughness of workpiece under various cutting conditions in machining utilizing acoustic emission (AE) for
vibration signature and tool condition monitoring(TCM) in turning. They found that amplitude of vibration
components had been increased due to increase of feed rate, depth of cut and cutting speed respectively.
Reddy et al.[29] conducted experiments on CNC lathe with tungsten carbide tool and EN16 steel as work
material to optimized the turning parameters such as cutting speed, feed rate and depth of cut for best
output responses such as surface finish and material removing rate. They used Taguchis L27 orthogonal
array for experimental investigation. Experiments were analyzed using analysis of variance to find
significance of each input parameter on the evaluation of process performances, surface roughness and
material removal rate.
Within the scope of literature survey for the present work, it has been observed that most of the
investigators had worked with advanced productive machine tools with latest developed tool materials.
They had also experimented with special materials for special applications purpose. Very few had worked
with widely used common materials (ferrous, non-ferrous, non-metal etc.) as well as commonly low cost
available tools materials to bring down the cost of production. Moreover they had not attempted any
redesign work on cutting tool angles on which both surface quality and tool life depends. They had
followed either tool manufactures or handbooks guide line only.

http://www.iaeme.com/IJMET/index.asp 217 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

The present studys focus is to uncover a correlation between cutting vibrations and surface roughness
in turning machines by collecting and analyzing data generated during turning of low carbon steel, grey
cast iron and bakelite samples. Input parameters have been optimized using WPCA coupled Taguchi
method for multi-objective optimization to improve surface quality and reduce cutting vibration.
In the present study optimization has been done by using combined quality loss (CQL). This CQL is
finally optimized by Taguchi method.

2. MATERIAL AND METHODS

All the AISI 1020 Low Carbon steel, IS210-FG200 Grey Cast Iron, and DIN 7735 Type-Hgw 2008
bakelite have been selected for present study for its wider application in both the Industries and general
engineering.
Chemical compositions, Physical properties and Mechanical properties of the test pieces are listed
below in Table 1,2,3, & 4.

Table 1 Chemical Composition

Content %
Materials C Fe Si Mn P S
AISI1020, Low carbon steel 0.17 0.23 99.08 99.53 - 0.30 0.60 0.04 0.05
FG200, Grey cast iron 3.0 3.3 - 1.6 2.0 0.8 1.0 0.15 0.12

Table 2 Physical & mechanical properties

Properties
Materials Density Tensile strength Yield strength Modulus of elasticity Hardness
g/cc Mpa Mpa Gpa RC
AISI1020, Low carbon 7.87 395 295 200 64
steel

Table 3 Physical & mechanical properties

Properties
Materials Density Tensile strength Comp. strength Modulus of elasticity Hardness
g/cc Mpa Mpa Gpa HBW
FG200, Grey cast iron 7.10 200 720 114 160-220

Table 4 Physical properties of Bakelite round bar

Properties Metric
Tensile strength 60 MPa
Compressive strength 200 MPa
Flexural Strength 170 MPa
Water assimilation 2.5 mg/cm2
Insulation Resistance after dipping in water 5 X 108 Ohms
Relative Density 1.35
In turning operation, some parameters involved in the metal cutting process are strongly related with
other parameters. It is not possible to consider all the parameters. Important machining parameters
optimized for turning operation is speed (N), longitudinal feed (f) and Depth of cut(d). Parameters have
been optimized for output responses like surface roughness (Ra) and vibrations in X, Y and Z axis.
Machining data are constantly reliant on the cutting data, the actual operation, and the machine tool. The

http://www.iaeme.com/IJMET/index.asp 218 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

machining parameter may have to be adjusted the actual conditions of a specific machining operation.
Process parameters and selected process variables are listed in Table 5. Input parameters viz, spindle speed
(N), longitudinal feed (f), depth of cut (d) etc. have been selected on the basis of available machine power,
trial and error approach based on shop floor experience and reference data available from both the
machinery handbook and past work of researchers. Moreover selection of the values of variables is limited
by the capacity of machine used for experimentation. Four levels in the operating range have been selected
for each of the factor. L16 orthogonal array (OA) design has been considered in present work.
a) Checking of spindle speed and longitudinal feed range of the lathe by using Prestige Counter
Instruments Pvt. Ltd. make calibrated hand held Tachometer and Mitutoyo make analog precision
Dial Gauge. Figure 2 shown the recorded feed curve.
b) Turning of all the AISI 1020 low carbon steel , IS210-FG200 grey cast iron & DIN7735 Type Hgw
2088 bakelite rounds to size 30 mm 30 mm long in lathe for proper clamping of samples rigidly on
dead end supported threaded mandrel for mounting on three jaw self centering chuck as well as to maintain
constant cutting speed for performing turning operation. Figure 3 & Figure 4 shown the experimental
arrangement.
c) Measuring vibration along X(longitudinal), Y (cross) and Z(vertical) axis of general purpose lathe
machine with the help of Accelerometer of Kistler-USA make and data logging at 60MHz, Tektronik make
two channel digital Oscilloscope.
d) Measuring surface roughness Ra with the help of stylus type profilometer of Taylor Hobson UK make,
Surtronic 3+.

Figure 2 Calibration curve of feed (mm/rev)

http://www.iaeme.com/IJMET/index.asp 219 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

Present work includes a methodical study and optimization of input parameters viz. spindle/chuck
speed, longitudinal feed and depth of cut to achieve good surface finish of machined samples. Table 5
represents process variables and their levels. Mitutoyo make analog precision Dial Gauge has been used
to measure depth of cut during experiments.

Table 5 Process variables and their levels

Factor Levels
Parameter unit Symbol 1 2 3 4
Spindle Speed rpm N 120 280 460 800
Feed mm/rev f 0.05 0.07 0.10 0.12
Depth of cut mm d 0.05 0.10 0.15 0.20
Centre Lathe of Parmar Mechanic Works, Surendranagar make, Type MKP3, has been used for turning
of work pieces. Moreover acceptability for experimentation of the machine tool has been based on the
study of the prevailing condition of machine tool as shown in feed curve in Figure 2. Commonly used High
Speed Steel (HSS) square tool bit, manufactured by Miranda Tools as per ISO5421, has been selected for
turning work of test pieces. A common tool nomenclature (shown in Table 6) has been designed for
turning of work pieces.

Table 6 Designed angles for high speed cutting tools

Front Side Side Side End Nose
Front/Back
Materials Clearance Rake Clearance Cutting Cutting Radius
Rake Angle
Angle Angle Angle Angle Angle (mm)
Low Carbon Steel
Grey Cast Iron 7 9 10 10 15 8 1.2
Bakelite

http://www.iaeme.com/IJMET/index.asp 220 editor@iaeme.com

Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

Table 7 DOE and corresponding experimental data of AISI 1020 Low Carbon Steel

Parameters Measured Responses

RMS
Run Avg.
f Vibration
No. N d Ra
(mm/rev) (dB)
(rpm) (mm) m
X Y Z
1 1 1 1 1.38 90.67 88.22 90.12
2 1 2 2 1.97 90.88 89.56 90.77
3 1 3 3 2.92 89.64 89.76 91.63
4 1 4 4 3.07 86.08 90.71 89.77
5 2 1 2 1.75 84.16 82.03 85.02
6 2 2 1 1.56 85.02 83.25 84.56
7 2 3 4 2.50 82.89 82.64 85.04
8 2 4 3 3.60 84.11 82.54 84.70
9 3 1 3 1.33 82.14 81.36 82.23
10 3 2 4 2.76 81.89 80.80 82.81
11 3 3 1 2.40 81.43 80.86 82.83
12 3 4 2 2.79 81.78 81.25 82.83
13 4 1 4 1.41 78.38 78.48 79.31
14 4 2 3 1.42 78.36 77.74 78.49
15 4 3 2 1.76 78.00 77.89 78.40
16 4 4 1 1.80 78.51 79.59 79.59

Table 8 DOE and corresponding experimental data Of IS210-FG200 Grey cast iron

Parameters Measured Responses

RMS
Run Avg.
f Vibration
No. N d Ra
(mm/rev) (dB)
(rpm) (mm) m
X Y Z
1 1 1 1 2.04 81.39 83.58 84.39
2 1 2 2 1.87 84.14 84.47 85.02
3 1 3 3 1.98 82.77 83.31 84.39
4 1 4 4 2.07 84.37 83.77 84.59
5 2 1 2 1.78 82.72 80.03 84.23
6 2 2 1 1.54 84.70 82.15 82.09
7 2 3 4 1.95 84.66 84.52 83.03
8 2 4 3 2.26 84.76 84.40 84.54
9 3 1 3 1.78 82.84 82.19 80.92
10 3 2 4 1.41 82.62 81.80 80.90
11 3 3 1 1.70 82.68 81.73 81.38
12 3 4 2 2.42 83.09 81.90 81.40
13 4 1 4 1.91 80.04 79.80 77.77
14 4 2 3 2.41 79.21 78.68 77.82
15 4 3 2 1.88 80.22 78.92 79.60
16 4 4 1 2.15 79.32 77.85 78.27

http://www.iaeme.com/IJMET/index.asp 221 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

Table 9 DOE and corresponding experimental data of DIN7735 Type-Hgw2008 Bakelite

Parameters Measured Responses

Run
Avg. RMS
No. f
N d Ra Vibration
(mm/min)
(rpm) (mm) m (dB)
X Y Z
1 1 1 1 1.39 84.68 85.30 84.37
2 1 2 2 1.24 84.26 83.75 84.36
3 1 3 3 1.51 84.93 85.50 83.63
4 1 4 4 2.46 84.83 84.59 83.17
5 2 1 2 2.70 85.19 84.59 83.08
6 2 2 1 1.39 84.75 81.19 83.39
7 2 3 4 2.21 84.95 85.03 83.10
8 2 4 3 1.30 83.96 82.57 82.37
9 3 1 3 1.68 82.68 80.36 80.85
10 3 2 4 1.96 82.84 82.09 81.14
11 3 3 1 1.30 82.59 81.77 83.22
12 3 4 2 1.59 82.72 81.84 81.24
13 4 1 4 1.85 82.15 79.64 80.11
14 4 2 3 2.04 83.46 80.61 81.94
15 4 3 2 1.27 78.98 78.46 78.14
16 4 4 1 1.56 78.94 77.01 80.39

DOE and corresponding experimental data shown in Table 7, 8 & 9.

3. RESULTS
Normalization is a part of optimization processes, (Su and Tong, 1997). It is the process to fit data within
1. Data values are to be in between 0.1 to 1. Since at zero, model perhaps crumple. The original
experimental data must be normalized to eliminate such an effect. The three types of normalization are
represented by the following equations.

a) LB (Lower-the-Best), = (1)

HB (Higher-the-Better), = (2)

,
c) NB (Nominal-the-Best), = (3)
,

= 1, 2, . ,
Here
= 1, 2, ,
*
Where Xi (k) is the normalized data of the k th factor in the i th series.

http://www.iaeme.com/IJMET/index.asp 222 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

and X0b(k) is the desired value of the k th quality attribute. The value of Xi*(k) will be between 0 and 1
after data normalization. The series Xi*, i = 1,2,3..m can be viewed as the proportional series used in the
present case.
All the response data have been normalized using the equation no.(1) i.e. Lower-the-Best. Normalized
response data are shown in Table 10, 11 & 12 for low carbon steel, grey cast iron and bakelite respectively.

Table 12 Normalized experimental data of DIN7735 Type-Hgw2008 Bakelite

Sl. Normalized Data of Responses
No. Ra X Y Z
Ideal 1.0000 1.0000 1.0000 1.0000
1 0.8921 0.9322 0.9028 0.9262
2 1.0000 0.9369 0.9195 0.9263
3 0.8212 0.9294 0.9007 0.9343
4 0.5041 0.9306 0.9104 0.9395
5 0.4593 0.9266 0.9104 0.9405
6 0.8921 0.9314 0.9485 0.9370
7 0.5611 0.9293 0.9057 0.9403
8 0.9538 0.9402 0.9327 0.9486
9 0.7381 0.9548 0.9583 0.9664
10 0.6326 0.9529 0.9381 0.9630
11 0.9538 0.9558 0.9419 0.9389
12 0.7798 0.9543 0.9409 0.9618
13 0.6703 0.9609 0.9669 0.9754
14 0.6078 0.9458 0.9553 0.9536
15 0.9764 0.9995 0.9815 1.0000
16 0.7949 1.0000 1.0000 0.9720

http://www.iaeme.com/IJMET/index.asp 223 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

A check has to be made for correlation of the responses, (Su and Tong, [41])

!, " = # , $ , % , . (4)
& ( , = 1, 2, ,
It is the normalized sequence of the ith quality attribute. The correlation of constant quantity (coefficient)
between two quality attribute is calculated by the following equation:
+,-./0 ,/1 2
)* = (5)
340 341
5 = 1, 2, 3, ,
here = 1, 2, 3, ,
5
Here, jk is the correlation coefficient between quality attribute j and quality attribute k ;
Cov(Qj ,Qk) is the positive covariance of quality attribute j and quality attribute k ;
Qj and Qk are the standard deviation of quality characteristic j and quality characteristic k
correspondingly ;
The correlation is checked by examining the following proposition:
H0 : jk = 0 (There is no correlation)
(6)
H1 : jk 0 (There is correlation)
Table 13,14 & 15 Shown the Pearsons correlation coefficient. Non-zero value in all the cases of
correlation coefficient shows that all the response features are correlated to each other.
Table 13 Table 14
Check for correlation between responses Check for correlation between responses
of AISI 1020 Low carbon steel of IS 210-FG200 Grey Cast Iron
Correlatio Pearson Correlation Pearson
Sl. n between correlation Observation Sl. between correlation Observation
no. responses coefficient no. responses coefficient
1 Ra and X 0.302 Both are correlated 1 Ra and X 0.001 Both are correlated
2 Ra and Y 0.396 Both are correlated 2 Ra and Y 0.160 Both are correlated
3 Ra and Z 0.436 Both are correlated 3 Ra and Z 0.152 Both are orrelated
4 X and Y 0.942 Both are correlated 4 X and Y 0.877 Both are correlated
5 X and Z 0.975 Both are correlated 5 X and Z 0.824 Both are correlated
6 Y and Z 0.977 Both are correlated 6 Y and Z 0.858 Both are correlated

Table 15 Check for correlation between responses of DIN 7735 Type-Hgw2008 Bakelite
Correlatio Pearson
Sl. n between correlation Observation
no. responses coefficient
1 Ra and X 0.402 Both are correlated
2 Ra and Y 0.336 Both are correlated
3 Ra and Z 0.169 Both are correlated
4 X and Y 0.914 Both are correlated
5 X and Z 0.887 Both are correlated
6 Y and Z 0.856 Both are correlated

http://www.iaeme.com/IJMET/index.asp 224 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

Now Principal Component Analysis (PCA) has been applied to eliminate response correlation. PCA
results viz. Eigenvalue, Eigenvector, accountability proportion (AP) and cumulative accountability
proportion (CAP) have been shown in Table 16, 17 & 18. PCA done with MINITB 16 software.
Table 16 Table 17
Computation of Principal Component Computation of Principal Component
Analysis (PCA) Analysis (PCA)
or AISI 1020 Low carbon steel for IS 210-FG200 Grey cast iron
PCA Results 1 2 3 4 PCA Results 1 2 3 4
Eigenvalue, Eigenvalue,
3.1311 0.8093 0.0532 0.0064 2.7251 0.9998 0.1690 0.1061
K K

0.294 -0.949 -0.074 0.086 0.104 -0.984 -0.097 0.110

Eigenvector, 0.542 0.261 -0.652 0.461 Eigenvector, 0.569 0.180 -0.527 0.650
K 0.552 0.142 0.751 0.334 K 0.583 0.001 -0.256 -0.771
0.561 0.105 -0.069 -0.818 0.571 -0.000 0.805 0.164

AP 0.783 0.202 0.013 0.002 AP 0.681 0.250 0.042 0.027

CAP 0.783 0.985 0.998 1.000 CAP 0.681 0.931 0.973 1.000

Table 18 Computation of Principal Component Analysis (PCA) for DIN 7735 Type-Hgw 2008 Bakelite

PCA Results 1 2 3 4
Eigenvalue, K 2.9164 0.8891 0.1271 0.0674

0.266 -0.943 -0.143 0.142

0.572 0.040 -0.017 -0.819
Eigenvector, K
0.560 0.104 0.729 0.380
0.538 0.314 -0.669 0.405

AP 0.729 0.222 0.032 0.017

CAP 0.729 0.951 0983 1.000
From the result of Table 16 (low carbon steel), it has been found that the four principal components i.e.
1 , 2 , 3 & 4 can take care of 78.3%, 20.2% , 1.3% and 0.2% variability in data respectively. The
cumulative accountability proportion (CAP) for the four principal components (1 , 2 , 3 & 4) has
been found 100%.
Similarly, from the result of Table 17 (grey cast iron), it has also been found that the four principal
components i.e. 1 , 2 , 3 & 4 can take care of 68.1%, 25.0%, 4.2% and 2.7% variability in data
respectively. The cumulative accountability proportion (CAP) for the four principal components (1 , 2 ,
3 & 4) has been found 100%.
Frther, from the result of Table 18 (Bakelite), it has been found that the four principal components i.e.
1 , 2 , 3 & 4 can take care of 72.9%, 22.2%, 3.2% and 1.7% variability in data respectively. The
cumulative accountability proportion (CAP) for the four principal components (1 , 2 , 3 & 4) has
been found 100%.

http://www.iaeme.com/IJMET/index.asp 225 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

Next step is to calculate the principal component scores of the normalized comparative sequence and
reference sequences using the equation shown below, (Su and Tong, 1997):

8 = 9 5 : * , = 0, 1, 2, , , = 1, 2, , 7
<=$

Where, Yi (k) is the principal component score of the kth element in the ith series. Xi*(j) is the normalized
value of the jth element in the ith sequence, and kj is the jth element of eigenvector k..
Now, all the correlated responses have been converted into independent (uncorrelated) quality indices
i.e. individual principal components using equation no. (7) and have been shown in Table 19, 20 & 21 for
low carbon steel, grey cast iron and bakelite respectively.
Table 19 Table 20
Independent Principal Component Independent Principal Component
for AISI 1020 Low carbon steel for IS210-FG200 Grey cast iron

Sl. Independent Principal Component Independent Principal Component

Sl.
No. 1 2 3 4 No. 1 2 3 4
Ideal 1.9490 -0.4410 -0.0440 0.0630 Ideal 1.8270 -0.8030 -0.0750 0.1530
1 1.7241 -0.4736 -0.0305 0.0622 1 1.6949 -0.5040 -0.0765 0.1416
2 1.6274 -0.2027 -0.0173 0.0371 2 1.6737 -0.5716 -0.0688 0.1343
3 1.5636 0.0077 -0.0096 0.0297 3 1.6896 -0.5275 -0.0708 0.1310
4 1.5815 0.0388 -0.0395 0.0268 4 1.6718 -0.5003 -0.0586 0.1194
5 1.7662 -0.2479 -0.0124 0.0548 5 1.7216 -0.6061 -0.0872 0.1109
6 1.7835 -0.3397 -0.0239 0.0497 6 1.7208 -0.7316 -0.0616 0.1333
7 1.7029 -0.0289 -0.0100 0.0396 7 1.6787 -0.5422 -0.0459 0.1309
8 1.6504 0.1224 0.0115 0.0167 8 1.6596 -0.4448 -0.0486 0.1158
9 1.8709 -0.4654 -0.0413 0.0630
9 1.7274 -0.6064 -0.0496 0.1359
10 1.7201 0.0273 0.0005 0.0275
10 1.7533 -0.8105 -0.0720 0.1571
11 1.7438 -0.0400 -0.0088 0.0361
11 1.7324 -0.6427 -0.0599 0.1363
12 1.7163 0.0318 -0.0039 0.0260
12 1.7027 -0.4008 -0.0331 0.1075
13 1.9181 -0.3910 -0.0429 0.0621
13 1.7796 -0.5473 -0.0379 0.1363
14 1.9272 -0.3822 -0.0362 0.0564
14 1.7773 -0.3947 -0.0326 0.1154
15 1.8761 -0.2094 -0.0274 0.0413
15 1.7728 -0.5593 -0.0591 0.1240
16 1.8475 -0.1998 -0.0369 0.0420
16 1.7868 -0.4646 -0.0460 0.1132

http://www.iaeme.com/IJMET/index.asp 226 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

Table 21 Independent Principal Component for DIN 7735 Type-Hgw 2008 Bakelite
Independent Principal Component
Sl.No.
1 2 3 4
Ideal 1.9360 -0.4850 -0.1000 0.1080
1 1.7744 -0.4192 -0.1049 0.0813
2 1.8151 -0.5190 -0.1083 0.0993
3 1.7571 -0.3501 -0.1017 0.0761
4 1.6816 -0.0484 -0.0528 0.0359
5 1.6680 -0.0060 -0.0469 0.0332
6 1.8054 -0.4111 -0.0788 0.1038
7 1.6938 -0.1025 -0.0649 0.0436
8 1.8242 -0.4670 -0.1071 0.1040
9 1.7991 -0.2547 -0.0697 0.0784
10 1.7568 -0.1585 -0.0671 0.0559
11 1.8330 -0.4685 -0.0943 0.0908
12 1.7977 -0.2974 -0.0852 0.0763
13 1.7942 -0.1868 -0.0598 0.0707
14 1.7507 -0.1366 -0.0445 0.0609
15 1.9191 -0.4647 -0.1101 0.0980
16 1.8663 -0.3004 -0.0519 0.0675

Accountability proportion of individual principal component has been treated as individual priority
weight, Hung-Chang L (2006). Multi-response performance index (MPI) has been computed using the
following equations and shown in Table 22, 23 & 24 for low carbon steel , grey cast iron and bakelite
respectively.

?@A = 9 B< C<

<=$
Where WJ is the weight of the j principal components and J principal components of jth no.
th

MPILCS = 1 X 0.783 + 2 X 0.202 + 3 X 0.013 + 4 X 0.002 (8)

MPICI = 1 X 0.681 + 2 X 0.250 + 3 X 0.042 + 4 X 0.027 (9)

MPIBk = 1 X 0.729 + 2 X 0.222 + 3 X 0.032 + 4 X 0.017 (10)

N.B. : LCS stands for low carbon steel, CI stands for cast iron and BK stands for bakelite
The larger the MPI is the higher the quality.
Combined Quality Loss (CQL) is defined as the deviation of individual/independent principal
component from its ideal value. Now, CQL has been treated as single objective function for optimization
in order to minimize it. These calculated CQL on the basis of MPI are the optimal parametric combination
to obtain quality surface. Lastly, Taguchi method has been used with Smaller-the-Best, S/N criteria for
final optimization. The calculated values of MPI and CQL are laid down in the Table 22, 23 & 24 for low
carbon steel , grey cast iron and bakelite respectively.

http://www.iaeme.com/IJMET/index.asp 227 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

Table 22 Table 23
Calculated MPI and CQL Calculated MPI and CQL
for AISI 1020 Low carbon steel for IS210-FG200 Grey cast iron

Sl. Sl.
MPI CQL S/N Ratio MPI CQL S/N Ratio
No. No.
of CQL of CQL
Ideal 1.4365 0.0000 - Ideal 1.0444 0.0000 -
Ideal
1 1.2540 0.1825 14.7735 Ideal
1 1.0288 0.0156 36.1394
2 1.2331 0.2034 13.8324 2 0.9976 0.0468 26.5971
3 1.2258 0.2107 13.5248 3 1.0193 0.0251 31.9968
4 1.2457 0.1908 14.3864 4 1.0142 0.0302 30.3875
5 1.3328 0.1037 19.6822 5 1.0202 0.0242 32.3123
6 1.3277 0.1089 19.2605 6 0.9899 0.0545 25.2764
7 1.3275 0.1091 19.2472 7 1.0093 0.0351 29.0869
8 1.3172 0.1194 18.4627 8 1.0201 0.0243 32.2874
9 1.3706 0.0659 23.6135 9 1.0264 0.0180 34.8732
10 1.3525 0.0841 21.5059 10 0.9926 0.0518 25.7059
11 1.3573 0.0793 22.0177 11 1.0202 0.0242 32.3257
12 1.3502 0.0863 21.2805 12 1.0609 0.0165 35.6714
13 1.4224 0.0141 37.0064 13 1.0772 0.0328 29.6905
14 1.4315 0.0051 45.8953 14 1.1134 0.0690 23.2217
15 1.4264 0.0101 39.8948 15 1.0683 0.0239 32.4284
16 1.4058 0.0307 30.2571 16 1.1018 0.0573 24.8293

Table 24 Calculated MPI and CQL for DIN7735 Type-Hgw2008 Bakelite

Sl.
MPI CQL S/N Ratio
No.
of CQL
Ideal 1.3023 0.0000 -
Ideal
1 1.1985 0.1038 19.6729
2 1.2062 0.0961 20.3481
3 1.2013 0.1010 19.9113
4 1.2141 0.0882 21.0890
5 1.2137 0.0886 21.0522
6 1.2241 0.0782 22.1346
7 1.2107 0.0916 20.7641
8 1.2245 0.0778 22.1792
9 1.2541 0.0482 26.3354
10 1.2443 0.0579 24.7342
11 1.2308 0.0715 22.9112
12 1.2431 0.0592 24.5518
13 1.2658 0.0365 28.7533
14 1.2456 0.0567 24.9250
15 1.2939 0.0083 41.6033
16 1.2934 0.0089 40.9998

http://www.iaeme.com/IJMET/index.asp 228 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

S/N ratio plots of CQL have been shown in Fig. 5, 6 & 7 considering SB (Smaller-the-Better) criterion.
Analysis of means are also laid down in Table 25, 26 & 27 for low carbon steel ,grey cast iron and bakelite
respectively.

Figure 5 Level of factors

Figure 6 Level of factors

Figure 7 Level of factors

http://www.iaeme.com/IJMET/index.asp 229 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

Table 28 Results of conformity experiments Table 29 Results of conformity experiments

AISI 1020 Low carbon steel IS210-FG200 Grey cast iron

Optimal Setting (Low Optimal Setting (Grey

Description Description
Prediction Experiment Prediction Experiment
Level of N4f2d3 N4f2d3 Level of N3f1d2 N3f1d2
SN ratio for 41.9309 45.8953 SN ratio for 36.7964 37.8525

Table 30 Results of conformity experiments DIN7735 Type-Hgw2008 Bakelite

Optimal Setting (Bakelite)

Description
Prediction Experiment
Level of factors N4f4d2 N4f4d2
SN ratio for 37.9185 42.2721

4. DISCUSSION
The following discussion has been highlighted to analyze the above results:

4.1. Low Carbon Steel

Optimal setting has been appraised from the main effects plot for S/N ratio and response table for signal to
noise ratio (Fig. 5 & Table 25). Optimal combination has been studied as N4f2d3 i.e. N=800 RPM, f = 0.07
mm/rev and d = 0.15 mm. This result has been verified in the course of conformity test. Taguchi predicted
value of S/N ratio for combined quality loss (CQL) which has been computed as 41.9309, where as in
verification of experimental test it has been observed as 45.8953 (Table 28) at optimal setting (N4f2d3).
Responses viz. average surface roughness Ra and RMS vibration in X , Yand Z axis have been
recorded as 1.42 m, 78.36 dB, 77.74 dB and 78.49 dB respectively against the optimal parameters which
are the same as experiment run no.14 (Table 22). Further it has been observed that S/N ratio is 45.8953
against experiment run no. 14 in Table 22 corresponding to parameters viz. N=800 RPM, f =0.07 mm/rev,
and d = 0.15 mm. Hence , run no. 14 as per Table 22 is the optimal parameter offered, better S/N ratio and
surface finish with a reduction of machine vibration has been achieved.

4.2. Grey Cast Iron

Optimal setting has been assessed from the main effects plot for S/N ratio and response table for signal to
noise ratio (Fig. 6 & Table 26). Optimal combination has been studied as N3f1d2 i.e. N = 460 RPM, f =
0.05 mm/rev, and d = 0.10 mm. This result has been verified through conformity test. Taguchi predicted
value of S/N ratio for combined quality loss (CQL) which has been computed as 36.7964, where as in
verification of experimental test it has been observed as 37.8525 (Table 29) at optimal setting (N3f1d2).
Responses viz. average surface roughness Ra and RMS vibration in X, Y and Z axis have been
recorded as 1.38 m, X = 81.95 dB, Y= 81.56 dB and Z = 81.60 dB respectively against the optimal
parameters which are better than experiment run no. 01 (Table 23) corresponding parameters viz. N = 120
RPM, f = 0.050 mm/rev, d = 0.05 mm. Responses obtained at this parameters are Ra = 2.04m, X = 81.39
dB, Y = 83.58 dB and Z = 84.39 dB. Here, S/N ratio obtained (37.8525) in practical verification is higher
than predicted value (36.7964) and quality of surface finish has been improved with a reduction of
machine vibration. Moreover S/N ratio (37.8525) observed in confirmation test, has been improved than
experiment run no.01 as per Table 23 (36.1394).

http://www.iaeme.com/IJMET/index.asp 230 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

4.3. Bakelite
Optimal setting has been assessed from the main effects plot for S/N ratio and response table for signal to
noise ratio (Fig. 7 & Table 27). Optimal combination has been studied as N4f4d2 i.e. N = 800 RPM, f =
0.12 mm/rev, and d = 0.10 mm. This result has been verified through conformity test. Taguchi predicted
value of S/N ratio for combined quality loss (CQL) which has been computed as 37.9185, where as in
verification of experimental test it has been observed as 42.2721 (Table 30) at optimal setting (N4f4d2).
Responses viz. average surface roughness Ra and RMS vibration in X, Y and Z axis have been
recorded as 1.19 m, X = 77.96 dB, Y= 77.72 dB and Z = 77.22 dB respectively against the optimal
parameter which are better than experiment run no. 15 (Table 24) corresponding parameters viz. N = 800
RPM, f = 0.10 mm/rev, d = 0.10 mm. Responses obtained at this parameters are Ra = 1.27 m, X = 78.98
dB, Y= 78.46 dB and Z = 78.14 dB. Here, S/N ratio obtained (42.2721) in practical verification is higher
than predicted value (37.9185) and quality of surface finish has been improved with a reduction of
machine vibration. Moreover S/N ratio (42.2721) observed in confirmation test, has been improved than
experiment run no.15 as per Table 22 (41.6033).
In the above confirmative study, it has been observed that material removing rate (MRR) has been
substantially improved by reducing time and keeping the quality of the test surface better by reducing the
machine vibration.

5. CONCLUSIONS
The foregoing study deals with optimization of surface roughness by reducing machine vibration of AISI
1020 low carbon steel, DIN 7735 Type-Hgw 2008 Bakelite and IS210-FG200 grey cast iron in turning
operations for the expedition of optimal parameters. The study recommends an integrated optimization
approach utilizing combined quality loss (CQL) perception in WPCA based Taguchi technique. Some
conclusions can be drawn up based on the experiments themselves and the analysis of the experimental
data.
PCA application is recommended to eradicate response correlation by altering correlated responses into
uncorrelated quality indices known as principal components that are treated as independent response
variables for optimization.
Accountability proportion (AP) is taken as weight of individual response. Weighted Principal Component
analysis (WPCA) combines individual principal constituents into a single multi-response performance index
(MPI). It is utilized for optimization. Application of this can optimize simultaneously a large number of
responses.
CQL concept involves considerable physical analysis to the objective function. CQL always has a positive
value. Thus, SN ratio that is in Taguchi technique can be calculated easily.
For unhindered quality as well as productivity improvement in small variable batch production, and even the
off-line quality control of a product or a process, the technique of multi-objective optimization is suggested.

6. ACKNOWLEDGEMENTS
The work illustrated in this paper was entirely supported by the Mechanical Engineering Department,
Jadavpur University, Kolkata.

REFERENCES
[1] Abouelatta, O. B., Madl, J., Surface roughness prediction based on cutting parameters and tool
vibrations in turning operations. Journel of Materials Processing Technology, 118, 2001, pp. 269-277.
[2] Abhang, L. B., & Hameedullah, M., Parametric investigation of turning process on en-31 Steel. Procedia
Material Science, 6, 2014, pp.1516-1523.

http://www.iaeme.com/IJMET/index.asp 231 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

[3] Abuthakeer, S. S., Mohanram, P.V., & Mohankumar, G.,The Effect of Spindle Vibration on Surface
Roughness of Workpiece in Dry Trning Using Ann, International Journal of Lean Thinking, 2(2), 2011,
pp.1-16.
[4] Antic, A., Hodolic, & Sokovic, J. M., Development of a Neural-Networks Tool-Wear Monitoring
System for a Turning Process. Jounal of Mechanical Engineering, 52(11), 2006, pp.763-776.
[5] Bajic, D., Lela, B., & Cukor, G. Examination and Modelling of the Influence of Cutting Parameters on
the Cutting Force and the Surface Roughness in Longitudinal Turning. Journal of Mechanical
Engineering, 54(5), 2008, pp.322-333.
[6] Benardos, P.G. & Vosniakos, & G.C., Predicting Surface roughness in machining: a review.International
Journal of Machine Tools & Manufacture, 43, 2003, pp. 833-844.
[7] Bhuiyan,M.S.H., Choudhury, I.A., & Dahari, M., Monitoring the tool wear, surface roughness and chip
formation occurrences using multiple sensors in turning. Journal of Manufacturing Systems,33, 2014,
pp.476-487.
[8] Choudhury, S.K. & Sharath, M.S., On-line control of machine tool vibration during turning operation.
Journal of Materials Processing Technology, 47, 1995, pp.251-259.
[9] Choudhury, S.K., Goudimenko, & N.N., Kudinov,V.A., On-Line Control of Machine Tool Vibration in
Turning. Int. J. Mach. Tools Manufact., 37(6), 1997, pp.801-811.
[10] Eze, S.C., Izelu, C.O., Oreko, B.U., & Edward, B.A., Experimental Study of Induced Vibration and
Work Surface Roughness in the Turning of 41Cr4 Alloy Steel using Response Surface Methodology.
International Journal of Innovative Research in Science, Engineering and Technology, 2(12), 2013,
pp.7677-7684.
[11] Gokkaya, H., The Effects of Machining Parameters on Cutting Forces, Surface Roughness, Built-Up
Edge (BUE) and Built-Up Layer(BUL) During Machining AA2014(T4) Alloy. Journal of Mechanical
Engineering, 56(9), 2010, pp.584-593.
[12] Hessainia, Z., Belbah, A., Yallese, M.A., & Mabrouki, T., On the prediction of surface roughness in the
hard turning based on cutting parameters and tool vibrations. Measurement 46, 2013, pp.1671-1681.
[13] Hung-Chang L., Multi-response optimization using weighted principal component. Int J Adv.
Manuf.Technol 27,2006, pp.720-725.
[14] Kayastha,C., & Gandhi, J.,Optimization of Process Parameter in Turning of Copper by Combination of
Taguchi and Principal Component Analysis Method. International Journal of Scientific and Research
Publications, 3(6), 2013, pp. 1-6.
[15] Krishankant, Taneja, J., Bector, & Kumar, M. R., Application of Taguchi Method for Optimizing
Turning Process by the effects of Machining Parameters. International Journal of Engineering and
Advanced Technology (IJEAT), ISSN:2249-8958, 2(1), 2012, pp.263-274.
[16] Kumar, N.S., Shetty, A. A., Ananth, K., & Shetty, H.,Effect of spindle speed and feed rate on surface
roughness of Carbon Steels in CNC turning. Procedia Engineering, 38, 2012, pp.691-697.
[17] Lu, Chen., Study on prediction of surface quality in machining process. Journal of Materials Processing
Technology, 205, 2008, pp.439-450.
[18] Luo, X., Cheng, K. & Ward, R., The effects of machining process variables and tooling characterization
on the surface generation: modeling, simulation and application promise. International Journal of
Advance Manufacturing Technology, 25, 2005, pp.1089-1097.
[19] Mahapatra, S.S., Patnaik, A. & Patnaik, P.K., Parametric Analysis and Optimization of Cutting
Parameters for Turning Operations based on Taguchi Method. Proceedings of the International
Conference on Global Manufacturing and Innovation, 6, 2006, pp.27-29.
[20] Mazid, A.M., Evaluation of dynamic quality of lathe machines to categories them for better productivity
and accuracy reducing defects. 5th Australasian Congress on Applied Mechanics, ACAM2007, 2007,
pp.10-12.

http://www.iaeme.com/IJMET/index.asp 232 editor@iaeme.com

 Process Optimization in Dry Turning of Steel, Cast Iron and Bakelite Using Low Cost Tool Material

[21] Nayak,S.K., Patro, J.K., Dewangan, S.,& Gangopadhyay, S., Multi-Objective Optimization of
Machining Parameters During Dry Turning of AISI304 Austenitic Stainless Steel Using Grey Relational
Analysis. Procedia Materials Science, 6, 2014, pp.701-708.
[22] Neseli, S., Yaldiz, S., & Turkes, E.,Optimization of tool geometry parameters for turning operations
based on the response surface methodology. Measurement, 44, 2011, pp.580-587.
[23] Noordin, M.Y., Venkatesh,V.C., Shariff, S., Elting, S. & Abdullah, A., Application of response surface
methodology in describing the performance of coated carbide tools when turning AISI1045 steel.
Journal of Materials Processing Technology, 145, 2004, pp.46-58.
[24] Ojha, G.K., Yadav, G.K., & Yadav, P.K.,Optimization Technique For Surface Roughness Prediction in
Turning Operation. S-JPSET : ISSN : 2229-7111, 6(2), 2014, pp.117-124.
[25] Pusavec, F., Krajnik, P. & Kopac, J., High-Speed Cutting of Soft Materials. Journal of Mechanical
Engineering, 52(11), 2006, pp.706-722.
[26] Rajasekaran,T., Palanikumar, K., & Arunachalam, S., Investigation on the Turning Parameters for
Surface Roughness using Taguchi Analysis. Procedia Engineering, 51, 2013, pp.781-790.
[27] Ramesh, M., Elvin, R.P., Palanikumar, K., & Reddy, K.H.,Surface Roughness Optimization of
Machining Parameters In Machining Of Composite Materials. International Journal of Applied Research
in Mechanical Engineering, 1(1), 2011, pp. 26-32.
[28] Rao, C.J., Rao, D.N., & Srihari, P., Influence of Cutting parameters on cutting force and surface finish in
turning operation. Procedia Engineering, 64, 2013, pp.1405-1415.
[29] Reddy, P.M., . Reddy, P.V.B., Reddy,Y.A.K., & Naresh, N., Optimization Of Machining Parameter For
Turning Of EN16 Steel Using Grey Based Taguchi Method. ARPN Journal of Engineering and Applied
Sciences, ISSN 1819-6608, 9 (3), 2014, pp.215-222.
[30] Risbood, K.A., Dixit, U.S, & Sahasrabudhe, A.D., Prediction of surface roughness and dimensional
deviation by measuring cutting forces and vibrations in turning process. Journal of Materials Processing
Technology, 132, 2003, pp.203-214.pp.135-143.
[31] Rogov, V.A., & Siamak, G., Optimization of Surface Roughness and Vibration in Turning of
Aluminium Alloy AA2024 Using Taguchi Technique. Internation Journal of Mechanical, Aerospace,
Industrial and Mechatronics Engineering, 7(11), 2013, pp.1282-1291.
[32] Sahoo, A.K., & Rout, A.K., Investigation of Optimal Parametric Combination for Minimum Cutting
Force in Turning :Response Surface Methodology Approach. Journal of Engineering Innovation And
Research, 1(1),2009, pp 6-13.
[33] Saraswat, N., Yadav, A., Kumar, A., & Srivastava, B.P., Optimization of Cutting Parameters in Turning
Operation of Mild Steel. International Review of Applied Engineering Research, ISSN 2248-9967, 4 (3),
2014, pp.251-256.
[34] Selvaraj, D.P., & Chandramohan, P., Optimization of Surface Roughness of AISI304 Austenitic
Stainless Steel in Dry Turning Operation Using Taguchi Design Method. Journal of Engineering
Technology, 5(3), 2010, pp.293-301.
[35] Sharma,N., Ahmad, S., Khan, Z.A., & Siddiquee, A.N., Optimization Of Cutting Parameters for Surface
Roughness in Turning. IJARET, 3(1), 2012, pp.86-96.
[36] Sharma, S.K., Rizvi, S.A., & Kori, R.P.,Optimization of Process Parameters in Turning of AISI 8620
Steel Using Taguchi and Grey Taguchi Analysis. Int. Journal of Engineering Research and Applications,
ISSN: 2248-9622, 4(3), 2014, pp.51-57.
[37] Singarvel, B., Selvaraj, T., & Jeyapaul, R., Multi Objective Optimization in Turning of EN25 Steel
Using Taguchi Based Utility Concept Coupled With Principal Component Analysis. Procedia
Engineering, 97, 2014, pp.158-165.
[38] Silberschmidt,V.V., Mahdy, M.A.S., Gouda, A.M., Naseer, A., Maurotto, A.,& Roy, A.,Surface
roughness improvement in ultrasonic assisted turning, Procedia CIRP, 13, 2014, pp.49-54.

http://www.iaeme.com/IJMET/index.asp 233 editor@iaeme.com

 Tapas Banerjee, Asish Bandyopadhyay and Pradip Kumar Pal

[39] Srithar, A., Palanikumar, K.,& Durgaprasad, B., Experimental Investigation and Surface roughness
Analysis on Hard turning of AISI D2 Steel using Coated Carbide Insert. Procedia Engineering, 97,2014,
pp.72-77.
[40] Stoic, A., Lucic, M. & Kopac, J., Evaluation of the Stability During Hard Turning. Journal of
Mechanical Engineering, 52(11), 2006, pp.723-737.
[41] Su, C.T. and Tong, L.I., Multi-response robust design by principal component analysis. Total Quality
Management, 8, 1997, pp.409-416.
[42] Thamizhmanii, S., Saparudin, S., & Hasan, S., Analysis of surface roughness by turning process using
Taguchi method. Journal of Achievements in Materials and Manufacturing Engineering, 20(1-2), 2007,
pp.503-506.
[43] Valera, H.Y., & Bhavsar, S.N., Experimental Investigation of Surface Roughness and Power
Consumption in Turning Operation of EN31 Alloy Steel. Procedia Technology, 14, 2014, pp. 528-534.
[44] Velchev, S., Kolev, I., & Ivanov, K., Research on the Influence of the Cutting Speed on the Specific
Cutting Force During Turning. Journal of Mechanical Engineering, 55, 2009, pp.400-405.
[45] Venkataramaiah, P., DharmaReddy, K., & Meramma, P., Analysis on Influence of feed rate and tool
geometry on cutting forces in turning using Taguchi method and Fuzzy Logic. Procedia Material
Science, (5), 2014, pp.1692-1701.
[46] Vinayagamoorthy, R.,& Xavior, M.A., Parametric Optimization on Multi-Objective Precision
TurningUsing Grey Relational Analysis. Procedia Engineering, 97, 2014, pp.299-307.
[47] Wang, H., To, S., & Chan, C.Y., Investigation on the influence of tool-tip vibration on surface
roughness and its representative measurement in ultra-precision diamond turning. International Journal
of Machine Tools & Manufacture, 69, 2013, pp.20-29.
[48] Rahul Davis and Mohamed Alazhari, Analysis and Optimization of Surface Roughness in Dry Turning
Operation of Mild Steel. International Journal of Computer Engineering & Technology (IJIERD), 3(2),
2012, pp. 0109.
[49] Mrs. Deshmukh, V. S. and Dr. Sarda , S.S. The Critical Casting Defect i n Cast Iron: Sand Inclusion A
Review. International Journal of Mechanical Engineering and Technology (IJMET) , 6 (9), 2015, pp.
30-42

http://www.iaeme.com/IJMET/index.asp 234 editor@iaeme.com