A Statistical Study On Effects of Fundamental Machining Parameters On Surface Topography

IDL - International Digital Library Of
Education & Research

Volume 1, Issue 3, Mar 2017 Available at: www.dbpublications.org
International e-Journal For Education And Research-2017
A Statistical study on effects of fundamental

machining parameters on surface topography
Manikandan H 1 (Author), Saurabh Jagtap2 (Author), Tufan Chandra Bera3 (Author)
Dept.of Mechanical Engineering,Birla Institute of Technology and Science,Pilani,Rajasthan,India
1
Birla Institute of Technology and Science,Pilani,Rajasthan,India
2
3
Pilani,India
1
manikandan.h@pilani.bits-pilani.ac.in
Abstract: Roughness consists of the irregularities

of the surface texture, usually including those Keywords: Surface Roughness, Taguchi Method,
Orthogonal Arrays, Design of experiments,
irregularities that result from the actions involved in
Response Surface Method
the production process. Surface roughness is an
important measure of the quality of a machined
product and a factor that greatly determines 1. INTRODUCTION
manufacturing cost. In this work,in order to estimate
surface quality and dimensional precision properties in The surface finish of machined components has
advance, theoretical models are employed making it considerable impact on some properties such as wear
feasible to do prediction in function of operation and fatigue strength. Thus, the quality of the surface is
conditions and machining parameters such as feed truly important in the evaluation of the productivity of
speed and depth of cut etc. The need for statistical machine tools and mechanisms of production, and
method like DOE for studying the relationship mechanical components. Fixing a proper cutting
between the machining parameters is because of this condition is really important regarding this because
need for prediction. It is a analysis technique which these determine surface quality of manufactured
uses the regression method to find out the relationship components. In order to know surface quality and
between various factors in a DOE setup depending dimensional precision properties in advance, it is
upon the interactions of the predictor variables and the always better to employ mathematical models making
response variables which is performed in the it easier to do prediction in function of operation
experiments. The research in this domain will help conditions.The mechanism for the finalisation of
advance further investigations into the relationship surface roughness is very dynamic, complicated, and
between the machining factors and the surface quality process dependent so that it is very difficult to
of the machined components. The DOE using calculate its value through theoretical or calculation
Taguchis method and statistical study of the based analysis.This presents the need for statistical
experimental data helps to understand the interaction method like DOE for studying the relationship
between various factors like speed, feed and depth of between the machining parameters and roughness of
cut in the machining. surfaces.
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Nomenclature Baradie [3] developed a response model (surface

Ra Roughness average of the measured surface. roughness) utilizing factorial design of experiment and
h Height of the wall specimen used response surface methodology. They used 2^3
t Thickness of the wall specimen used factorial design with a centre composite design- 12
l Length of the wall specimen used experiments altogether.Yusuf Sahin and A. Riza
DOE Design of Experiments Motorcu [2]used Taguchi method with L18 orthogonal
RSM Response Surface Method array 3 factors and 5 level CCD First-order and
second-order model predicting equations for surface
roughness have been established by using the
experimental data.
Roughness consists of the irregularities of the surface
Julie Z. Zhang , Joseph C. Chenb, and E.
texture, usually including those that result from the
Daniel Kirby [4]used Taguchi method using L9 array
actions included in the manufacturing process. There
and ANOVA analysis.They were using Taguchi
are number of parameters that can be used to define
design application to optimize surface quality in a
the surface roughness but we choose Roughness
CNC face milling operation.M.Y. Noordin, V.C.
Average.
Venkatesh , S. Sharif , S. Elting and A. Abdullah
worked with DOE[5] using RSM in 2^3 factorial
Figure 1. Parameters in Surface Roughness
design to establish a 2nd order model using Least
square method and ANOVA method.
The research in this domain will help advance
further investigations into the relationship between the
machining parameters and the surface quality of the
machined components. The DOE using Taguchis
method and statistical analysis of the experimental
data helps to understand the interaction between
various factors in the machining.
1.2 Roughness average (Ra)
This parameter is also known as the
arithmetic mean roughness value, AA (arithmetic
average) or CLA (center line average). Ra is
universally recognized and the most used international
1.1 Literature Review
parameter of roughness.
Many researchers have investigated the
impact of machining parameters on the surface quality
of various materials by using numerous methods of
DOE (design of experiments) to find out the empirical
relationship between various factors affecting the
surface quality of a machined surface.
Where Ra = the arithmetic average deviation from the
Sleyman Nes eli , Sleyman Yaldz and
mean line
Erol Trkes determined RSM method [1] to estimate
L = the sampling length
the surface roughness in turning of mild steel by
making use of Taguchi L27 orthogonal array.
Mohamed A. Dabnun, M.S.J. Hashmi and M.A. El-

1.3 Factors affecting surface roughness 2.3 Taguchi Method using Orthogonal Array
The depth of cut ,the feed rate per cutter ,the Orthogonal arrays are special standard
cutting ,the engagement of the cutting tool (ratio of experimental design which requires only a small
cutting width to cutting tool diameter,the cutting tool number of experimental trials to find the main effects
,the use of cutting and the three components of the of factors on output. It is a highly fractional
cutting force. orthogonal design that is based on a design proposed
by Genichi Taguchi and allows you to consider a
2. METHODOLOGY selected subset of combinations of multiple factors at
2.1 DOE- Design of Experiments multiple levels. Taguchi Orthogonal arrays are
balanced to ensure that all levels of all factors are
The response surface methodology (RSM) considered optimally.
and Taguchi techniques for design of experiments Planning phase:
(DoE) are most wide-spread techniques for the State the problem.
prediction of surface roughness. State the objectives of the experiment.
2.2 Full Factorial Method Select the quality characteristics and the measurement
systems.
When there are two or more factors each at Select the factors that may inuence the quality
two or more levels, a treatment is defined as a characteristics.
combination of the levels of each factor. In a factorial Select levels for the factors.
experiment, all possible combination of the levels of Select the appropriate Taguchi fractional matrices or
each factors are represented for each complete orthogonal arrays (OAs).
experimentation. The number of experiments is equal Select the interactions that may inuence the response
to the product of the number of factor levels and can variable.
therefore become very big when either the factors are Assign factors to OAs and locating interactions.
more or the levels are numerous. Select and mention the noise factors.
Method includes Execution phase:
Planning phase: Conduct the experiment as described by the OAs.
State the problem. Analysis phase:
State the objectives of the experiment. Analyse the experimental results, e.g. using analysis of
Select the factors that may inuence the quality variance (ANOVA), response surface method (RSM).
characteristics. Conduct a conrmation experiment.
Select levels for the factors.
Determine the number of experiments to be carried 2.4 RSM Response Surface Methods
out. RSM is a statistical technique based on
Execution phase: multiple regressions. With RSM, the effect of two or
Conduct the experiment as described by the full more parameters on quality criteria can be calculated
factorial design. and real values are obtained in RSM. In this way, the
Analysis phase: values that are not actually tested using experimental
Analyse the experimental results, e.g. using analysis of sets of values themselves can be estimated and the
variance (ANOVA), response surface method (RSM). combinations help in doing this. The results can
Conduct a conrmation experiment. expressed in 3D series or counter map.It is a analysis
technique which uses the regression method to find
out the relationship between various factors in a DOE
setup.

2.5 DOE using Minitab 16 Symbol Factor Unit

Minitab 16 is a useful tool for design and r Nose Radius mm
analysis of experiments. It is possible to setup a DOE
if one has decided the number of factors and there k Approach Angle Degree( 0 )
corresponding levels. Following flowchart represents
the method for setup of DOE in Minitab 16. y Rake Angle Degree( 0 )
2.6 Flowchart Symbol Level 1 Level 2 Level 3

r 0.4 0.8 1.2
k 60 75 90
y -9 -6 -3
3.2 Experiments
Step 1
Select the Stats DOE Taguchi Create Taguchi
design
Figure 2. Selecting the levels in minitab
3. EXPERIMENTAL DETAILS
3.1 The sample data
The sample data is used (for check only) from
[1] where it presents the DOE analysis using RSM for
Step 2
establishing the empirical relationship between the
machining factors like Nose radius (r), Approach angle Select the Levels factors select the design L27
(k) and Rake angle (y). enter the values of factors
Table 1. Independent Variables and Levels for Model Figure 3. Entering the values of factors3
Body

0.8 90 -9 5.01
0.8 90 -6 7.944
0.8 90 -3 7.99
1.2 60 -9 4.475
1.2 60 -6 5.065
1.2 60 -3 5.967
1.2 75 -9 4.796
Step 3
Following experimental data is selected 1.2 75 -6 7.662
Table 2. Experimental Data
1.2 75 -3 8
r k y Ra
1.2 90 -9 5.874
0.4 60 -9 2.025
1.2 90 -6 8.665
0.4 60 -6 2.283
1.2 90 -3 8.951
0.4 60 -3 2.892
Step 4
0.4 75 -9 2.358
Select the Stats DOE Response Surface
0.4 75 -6 2.85
Method Define Custom Response Surface design
0.4 75 -3 3.962 select the factors select the response variable ok.
Figure 4. Selecting the response variable
0.4 90 -9 3.509
0.4 90 -6 4.099
0.4 90 -3 4.876
0.8 60 -9 4.225
0.8 60 -6 5.142
0.8 60 -3 5.692
0.8 75 -9 4.308
4.Design,Modelling and Manufacturing of
0.8 75 -6 6.066 Experimental specimen.
With the literature review and the study of the DOE
0.8 75 -3 6.563
models it was planned to carry out the experimentation

to determine the effects of the following machining

parameters.
Radial depth of cut
Axial depth of cut
Feed per tooth
Each factor to have 3 levels. Taguchi model for DOE
is selected with L9 orthogonal array.
The experimental model is designed to
acquire data for the statistical analysis and establish
the relationship between the machining parameters.
The thin wall model is considered with aluminium as
the material parameters of design as defined below Figure 5(c). Specimen
For thin wall consideration
Wall height in mm
Wall thickness in mm
Wall length in mm
With the available material block we have wall length
of 75 mm, wall thickness of 5mm and height as 40
mm as per the above mentioned formula.The detailed
design of the block is mentioned below with
dimensions (all dimensions in mm)
Figure 5(d).Experimental Setup( including Renishaw
Figure 5(a) Drawing of the part
touch trigger Probe)
Figure 5(b). Model
4. RESULTS AND DISCUSSION

Step 6 To get the graphs of main effect
Results of the RSM analysis are obtained as seen Select the Stats DOE Taguchi Define Custom
Taguchi design select the factors select the
response variable ok.
Select the Stats DOE Taguchi Analyse the

Taguchi design select the factors select the
response variable ok.
Figure 6. Results
Figure 8. Plots
Figure 7. Results
Step 8
To get the graphs of Interaction effects
Select the Stats ANOVA Interaction Plots

select the factors select the response variable select
full interaction matrix ok.
Step 9
To get the Response Surface plots

Select the Graphs 3D surface plot select the

factors select the response variable ok.
Figure 9. Ra Plots
5.CONCLUSION
Tasks were completed during experimentation and
analysis.Initially a study about the design of
experiments and application of same was conducted.
Then selection of DOE method depending on the
number of factors and levels were carried out,
afterwhich the design of workpiece for
experimentation was done.MINITAB analysis of data
generated from sample data set was performed and the
relationship between the machining parameters and
roughness was established. So predicting optimal
value of surface roughness for given set of machining
parameters became possible.
Figure 10. Ra Plots
6.ACKNOWLEDGEMENTS
The author thank and acknowledge the Science and
Engineering Research Board (SERB), Department of
Science and Technology, Government of India for
financial support to carry out this research work
(Project No: SERB/ETA-0003/2013).
7.REFERENCES
[1] Neeli, S., Yaldz, S., & Trke, E. (2011).
Optimization of tool geometry parameters for turning
Figure 11. Ra Plots
operations based on the response surfac
methodology.Measurement, 44(3), 580-587.

[2] Sahin, Y., & Motorcu, A. R. (2005). Surface

roughness model for machining mild steel with coated
carbide tool. Materials & design, 26(4), 321-326.
[3] Dabnun, M. A., Hashmi, M. S. J., & El-Baradie,

M. A. (2005). Surface roughness prediction model by
design of experiments for turning machinable glass
ceramic (Macor). Journal of Materials Processing
Technology, 164, 1289-1293.
[4] Zhang, J. Z., Chen, J. C., & Kirby, E. D. (2007).

Surface roughness optimization in an end-milling
operation using the Taguchi Arbizu, I. P., & Perez, C.
L. (2003). Surface roughness prediction by factorial
design of experiments in turning processes. Journal of
Materials Processing Technology, 143, 390-396.
[5] Noordin, M. Y., Venkatesh, V. C., Sharif, S.,

Elting, S., & Abdullah, A. (2004). Application of
response surface methodology in describing the
performance of coated carbide tools when turning
AISI 1045 steel. Journal of Materials Processing
Technology, 145(1), 46-58.
[6] Amitava Mitra ,Fundamentals of Quality Control

and Improvement 3rd edition. Wiley publication.
[7] Mohanta D K(2012).Prediction of Surface

roughness in turning of low carbon steel with coated
and uncoated inserts.International journalof advanced
materials manufacturing and characterization March
2012 Vol 1 Issue 1
[8] Vikas,Apurba Kumar Roy,Kaushik

Kumar(2014).Effect and Optimization of various
machine process parameters on the surface roughness
in EDM for an EN41 material using Grey-
Taguchi.Third International Conference on Materials
Processing and Characterization(ICMPC 2014),385-
390

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IDL - International Digital Library Of

Education & Research

International e-Journal For Education And Research-2017