SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017
OPTIMIZATION OF CNC MACHINING PARAMETERS FOR
SURFACE ROUGHNESS IN TURNING OF ALUMINIUM 6063 T6
WITH RESPONSE SURFACE METHODOLOGY
1. Mr.B.Radhakrishnan
Assistant professor, Mechanical department
K.Ramakrishnan College of engineering
Trichy, Tamilnadu, India.
Email-radhakrishnankrce@gmail.com
2. Mr.S.Tharun Kumar
UG scholar Mechanical Engineering
K.Ramakrishnan College of engineering
Trichy, Tamilnadu, India.
Email- tharuntylor20@gmail.com
3. Mr.P.Sankarlal
UG scholar Mechanical Engineering
K.Ramakrishnan College of engineering
Trichy, Tamilnadu, India.
Email-sankarlalpulivalam@gmail.com
Abstract- In this research paper represents optimizing
the surface roughness obtained by turning process in
CNC machine using various parameters. In this paper
the machining is carried out using CCMT tool. The
ranges of parameters are selected for the aluminium
6063 before the machining process carried out.
Initially, a three-factor central composite design of
experiment, considering the cutting speed, feed rate and
depth of cut, are conducted in aluminum alloy 6063 T6
and the corresponding surface roughness are obtained.
Then a mathematic model is constructed by the
response surface methodology (RSM) to fit the
relationship between the process parameters and the
surface roughness. The prediction accuracy was
verified by the one-way ANOVA. Finally, the surface
roughness under different combination of process
parameters are obtained and used for the optimum
surface roughness prediction. The results of the
machining experiments were used to optimize the main
factors affecting the surface roughness in the
aluminium material using the response surface
methodology.
Keywords- Aluminium alloy, Surface roughness,
Response surface methodology, Design of experiment,
RSM.
ISSN: 2348 - 8360 www.internationaljournalssrg.org
4. Mr.P.Ramakrishnan
UG scholar Mechanical Engineering
K.Ramakrishnan College of engineering
Trichy, Tamilnadu, India.
Email-sivajiram95@gmail.com
5. Mr.S.Sarankumar
UG scholar Mechanical Engineering
K.Ramakrishnan College of engineering
Trichy, Tamilnadu, India.
Email-ssarankumar95@gmail.com
I .INTRODUCTION
Aluminium alloys are contains the typical alloy
elements such as copper, magnesium, manganese, silicon
and zinc and in which aluminium is the predominant
metal. Here aluminium 6063 is the work piece material
and CCMT is cutting tool. The main properties of
aluminium are light weight, strength, recyclability
corrosion resistance, durability, formability, ductility and
conductivity which make them valuable material.
Surface roughness is one of the important
requirements in machining process. There are many
factors like tool variable work piece variable and cutting
conditions which affect the surface roughness. The tool
variable include tool material, nose radius, rake angle etc.
work piece variables include material, hardness and other
mechanical properties. Cutting condition include speed,
feed rate and depth of cut. The turning process involves
large numbers of parameters very difficult to control the
process and select the optimum cutting conditions for
achieving the required surface quality. Most of the
research articles deals with Average value (Ra), Root
mean square (Rz), Peak to valley (Rt).
Design of experiments is an influential method
to improve manufactured goods design presentation
where it can be used to improve a new process. The
analysis of variance is a powerful statistical tool for test
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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017
of significance ANOVA is a separation of variance
ascribable to one prove of process of the variance
ascribable to other groove.
Response surface methodology (RSM) is a
collection of mathematical and statistical techniques for
empirical model building. By careful design of
experiments, the objective is to optimize a response
(output variable) which is influenced by several
independent variables (input variables). An
experiment is a series of tests, called runs, in which
changes are made in the input variables in order to
identify the reasons for changes in the output response.
An important aspect of RSM is the design of experiments
usually abbreviated as DOE. These strategies were
originally developed for the model fitting of physical
experiments, but can also be applied to numerical
experiments. The objective of DOE is the selection of the
points where the response should be evaluated.
Most of the criteria for optimal design of
experiments are associated with the mathematical model
of the process. The choice of the design of experiments
can have a large influence on the accuracy of the
approximation and the cost of constructing the response
surface.
II. LITERATURE REVIEW
V. Devkumaret al [1] investigated the optimal
cutting conditions for attaining the better surface
roughness using the mathematical modeling and analysis
of machining response and tool wear in the turning of
aluminum alloy 6061. There was process parameters such
as spindle speed, depth of cut and feed rate used to
determine the quality of surface roughness. Experiments
were conducted as per central composite face centered
design. Analysis of variance is used for the comparison
study on tabulated values and experimental values for
surface roughness.
J.Paulo davim et al [2] studied the effects of
turning parameters such as cutting velocity, feed rate on
surface roughness of glass fiber reinforced plastics by
statistical analysis. They concluded that this cutting
parameters is possible to obtain surface with 0.80 to 1.75
µm. arithmetic average roughness (Ra) 4.9 to 9.3 µm of
maximum peak to valley height (Rt, R max). They also
founded surface roughness increases with feed rate and
decreased with cutting velocity. They used two methods
HLU and FW. They found HLU is possible to obtain
smaller values of surface roughness than FW.
C.A.Conceicao Antonio et al [3] investigated the
optimal machining parameters cutting speed, feed, and
depth of cut for attaining better surface roughness when
turning free machining steel 9SMnPb28K with cutting
tool made of cemented carbide using experimental data
ISSN: 2348 - 8360 www.internationaljournalssrg.org
and genetic data. They concluded that maximum cutting
speed and minimum feed is best solution independently
of the criterion used bring analysis except for robustness
coefficients.
chandra shekar et al [4] optimized the
machining parameters speed, feed, depth of cut, nose
radius in turning of Al 6063 T6 in CNC machine through
design of experiments by taguchi method. They
concluded that low surface roughness obtain for the
parameter setting of nose radius value 0.8mm ,feed of
10mm/min, speed of 500 rpm, depth of cut 0.8mm.
Highest material removal rate for nose radius value
0.4mm, feed 70 mm/min, speed 1500 rpm.
P. Jayaraman et al [5] researched on multi
response optimization of machining parameters such as
cutting speed, feed rate, and depth of cut in turning of
AA 6063 T6 using grey relational analysis in Taguchi
method. They conclude from this analysis it is revealed
that feed rate, depth of cut are the prominent factors
which affect the aluminium alloy and feed rate (57.365
%) , depth of cut (25.11%) , speed (17.35%) gives the
optimal surface roughness value.
R. Rudrapathi et al [6] investigated on the
optimization the process parameters using the spindle
speed, feed rate, depth of cut, in CNC turning of
aluminium alloy using RSM and Teaching Learning
Based Optimization. From this analysis they concluded
that second order mathematical model is developed for
surface roughness by RSM. It is found that hybrid RSM
cum TLBO is very useful to optimize surface roughness
in CNC turning of aluminium alloy.
Doreswamy Deepaket al [7] studied the multi
response optimization of process parameters speed, feed,
and depth of cut in CNC turning of aluminium 6061
using grey relational analysis in taguchi L9 array method.
From this analysis they concluded that high feed rate
leads to broken chips and burrs in the surface of the job
and high cutting speed gives more MRR and low feed
and depth of cut gives good surface finish.
Rohit angris et al [8] analyzed surface roughness
in CNC turning of aluminium 6063 using various
parameters speed, feed, depth of cut by taguchi approach.
From this analysis they concluded that feed has more
significant effect on surface roughness (50.9%) and MRR
is maximum at the parametric condition 2500rpm, 50 mm
per rev and 0.1 mm depth of cut.
M.S. Ranganath et al [9] inspected on Surface
Roughness Prediction Model for CNC Turning of EN-8
Steel Using RSM for various parameters speed, feed, and
depth of cut. They form the quadratic equation to
conclude that the cutting speed has the strongest effect on
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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017

the surface roughness and it also inversely proportional to Aluminium 6063T6 contains Si, Fe, Cu, Mn,
depth of cut. Mg, Zn, Ti, Cr, Al in following percentage represented in
table 2.
B.Radha Krishnan [10] Review of prediction of
surface roughness in machine vision system by using Table 3 CHEMICAL COMPOSITION OF
various parameters like speed , feed rate, depth of cut . in ALUMINIUM 6063T6
this paper as detailed explanation about measuring
objective parameters these are surface roughness , peak Element (%)
to valley, root mean square and list out the methodology
Si 0.2 to 0.6
for the machine vision system.
Fe 0.0 to 0.35
III.MATERIALS AND EQUIPMENTS
Cu 0.0 to 0.1
A) MATERIALS PROPERTIES
Mn 0.0 to 0.1
1) Work piece material:
Mg 0.45 to 0.9
In this experiment work Al6063 is used as a material. It
has generally good mechanical properties and is heat Zn 0.0 to 0.1

treatable and weld able. It is similar to the British Ti 0.0 to 0.1

aluminium alloy HE9. The table 1 represents the physical
properties of Al6063T6 Cr 0.1 max

Al Balance

Table 1 MECHANICAL PROPERTIES OF

ALUMINIUM 6063T6
Aluminium 6063T6 has following mechanical properties
Tensile strength 220 Mpa tensile strength, elongation, and proof stress in following
units represented in table 3.
Elongation 5%
2) Working tool material:
Proof stress 190Mpa
The CCMT is cemented carbide tool used for
machining the work piece as per the given input values.
The carbide inserts are replaceable and usually indexable
bits of cemented carbide used in machining steels, cast
iron, aluminium, high temperature alloys. They allow
Table 2 PHYSICAL PROPERTIES OF ALUMINIUM faster machining and make better surfaces on the material
6063T6 parts. The CCMT is stands the following meanings.
PROPERTY VALUE
C= tool shape- 60 degree diamond shape
Melting Point 655 °C
C= tool clearance angle- 7 degree tool rake
Density 2.70 g/cm³
M= tolerance = +/- 0.002
Thermal Expansion 23.5 x10^-6 /K
T= cutting style- (40 to 60 degree) one countersink
Modulus of Elasticity 69.5 GPa
B) Equipment
Thermal Conductivity 201 W/m.K
1) Stylus probe:
Electrical Resistivity 0.033 x10^-6 Ω .m
Stylus probe was traditional surface roughness measuring
method in industries. In contact method stylus probe
was very sensitive, and the diamond stylus probe could
scratch the surface particularly when the materials are

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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017

soft. A common drawback of this approach is the small Processor With Siemens 802D SI control with
standard equipments
area using which the roughness is evaluated at any one
time and also the transducer is very sensitive and the Power supply 3 phase 415 volt AC 12 KVA
stylus tip is fragile. Therefore, the instrument must be
Axis travel Length –x –axis-190 mm
handled carefully in a fairly, clean environment. Another
problem with the stylus measurement technique is the Z – axis- 210 mm
size of the stylus radius and the crevices of the surface. If
the crevices are narrow such that the stylus cannot Total cost Rs 913943

penetrate all the way to the bottom, the measurement will

Table 4 CNC lathe specifications
not be accurate.

Fig.1.Stylus probe Fig.2.Machining on CNC lathe during operation

2) CNC lathe The cutting variables and their levels are given in table.
The experimental was carried out on the CNC center Parameters Units Level 1 Level 2
turning MTab using CCMT cutting tool. The following
diagram clearly shows the experiment setup of CNC Spindle speed RPM 1200 2000
turning center
Feed mm / rev 0.1 0.2
The CNC machine is checked and prepared for
Depth of cut Mm 0.5 1.5
performing of designed experimental machining
operation suitably. The machining of aluminium 6063 is
accomplished by varying the cutting parameters such as Table 5 various parameters and levels of material
speed, feed rate, depth of cut. After the machining
IV. RESPONSE SURFACE METHODOLOGY
operation the surface finish of the specimen is carried out
by using the stylus probe apparatus. In Response Surface Methodology the factors
that are considered as most important are used to build a
The specification of the machine is given in table.
polynomial model in which the independent variable is
Machine CNC LATHE the experiment’s response. RSM is the collection of
mathematical and statistical techniques that are useful for
Machine make M – Tab the modeling and analysis of problems in which a
response of interest is influenced by several variables and
Year 2011 the objective is to optimize the response. In many
engineering fields, there is a relationship between output
Model Flux turn
variables ‘y’ of interest and a set of controllable input
variables. In some system, the nature of the relationship

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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017

between and values may be known. Then, a model can

be written in the form,
V. RESULTS AND DISCUSSION

The main objective of the experiment is to

optimize the machining parameters to achieve the high
Where € represents error observed in the response . surface finish. The RSM is the method is not only used to
judge and determine effect of individual parameters on
entire process. Contribution of individual parameters of
the process can be determined using ANOVA. Minitab
If we denote the expected response as then the surface software of ANOVA module was used to proceed the
represented by, machining parameters speed, feed, depth of cut. The
experimental data for the surface finish values are
tabulated as follows.
Work Speed Feed Depth Rz Ra
piece (rpm) (mm/min) of cut (µm) (µm)
(mm)
1.15
1 1200 0.1 0.5 4.84

1.78
2 1300 0.2 0.6 6.9

0.85
3 1400 0.1 0.7 4.14

1.62
4 1500 0.2 0.8 6.65

0.87
5 1600 0.1 0.9 4.47

Fig.3.Aluminium 6063T6 Before machining 6 1700 0.2 1 7.79

1.79

1.93
7 1800 0.1 1.1 7.24

1.41
8 1900 0.2 1.2 7.45

1.18
9 2000 0.1 1.3 5.38

1.44
10 1200 0.2 1.4 5.96

0.96
11 1300 0.1 1.5 4.8

1.67
12 1400 0.2 1.5 6.56

1.103
13 1500 0.1 1.4 5.486

1.24
14 1600 0.2 1.3 6.32
Fig.4.Aluminium 6063T6 after machining
1.21
15 1700 0.1 1.2 5.96

1.84
16 1800 0.2 1.1 7.33

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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017

ANOVA for Response Surface Linear ModelAnalysis of variance table [Partial sum of
squares] on Ra :

Table 7 ANOVA table for the data of Ra

P – value > F
Source Sum of squares Df Mean square F – value
0.0425
Model 0.93 3 0.31 3.71

A – Speed 0.2454
0.12 1 0.12 1.49

0.0084
B – Feed 0.83 1 0.83 9.91

0.5613
C - Depth of cut 0.030 1 0.030 0.36

Residual 1.00 12 0.084

Cor Total 1.93 15

Final Equation in Terms of Coded Factors: dimensional contour plots. The analysis values on the
data of Ra as plotted as per the given values and
Ra =+1.41+0.15 * A+0.23* B-0.072* C shown in the following diagrams. The residual graph
indicates that the decreases of the feed and depth of
Final Equation in Terms of Actual Factors: cut with the increase of speed will get the high
surface finish.
Ra=+0.26631+3.77608E-004*S+4.56384*F-
0.14438*D Design-Expert® Software
Ra Normal Plot of Residuals
Color points by value of
The Model F-value of 3.71 implies the model is Ra:
P r o b a b ility

1.93
significant. There is only a 4.25% chance that 0.85a 99

"Model F-Value" this large could occur due to noise. 95

90
Values of "Prob > F" less than 0.0500 indicate model
80
terms are Sgnificant. In this case B are significant 70
N o rm a l %

model terms. Values greater than 0.1000 indicate the 50

model terms are not significant. 30

20

10
Response surfaces were developed for the empirical 5

relationship, taking two parameters in the ‘X’ and ‘Y’

1
axis and response in ‘Z’ axis. The response surfaces
clearly indicate the optimal response point. The
different colored surfaces show that the value of -2.00 -1.00 0.00 1.00 2.00 3.00

surface roughness obtained for the corresponding

Internally Studentized Residuals
values of input parameters. The relationship between
independent and dependent variables was graphically
represented by three dimensional response surface Fig.5.Nominal plot residuals graph for Ra
graphs and two

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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017

In te r n a lly S tu d e n tiz e d R e s id u a ls
Design-Expert® Software Design-Expert® Software
Ra Residuals vs. Run Factor Coding: Actual Ra
Ra 0.20
Design Points
Color points by value of 3.00 1.93
Ra:
1.93 0.85
1.6
0.85
2.00 0.18
X1 = A: Speed

B : F e e d R a te
X2 = B: Feed Rate

Actual Factor
1.00 C: Depth of Cut = 1.00

0.15 1.4
0.00

-1.00
0.13
1.2

-2.00

0.10
-3.00 1200 1400 1600 1800 2000

1 4 7 10 13 16 A: Speed

Run Number Fig.7.Feed rate vs. speed for Ra data

Fig.6.Residual vs. Run graph for Ra
Design-Expert® Software
Factor Coding: Actual
Ra
Design points above predicted value
Surface interaction dimensional views and direct 1.93

0.85

effect views of feed rate and speed over X1 = A: Speed

X2 = B: Feed Rate
2.5

surface roughness of Ra: Actual Factor

C: Depth of Cut = 1.00
2

The figure explains that the feed rate and speed on 1.5

Ra
1
the surface roughness of turning process has a
0.5
significant effect on Ra. It has been concluded that
higher feed rate and speed was increase the surface 0.20 2000
0.18 1800

roughness whereas lower feed rate and speed 0.15

0.13 1400
1600

B: Feed Rate A: Speed

0.10 1200
decrease the surface roughness.

Fig.8.Feed rate vs. speed for Ra data on 3d view

ANOVA for Response Surface Linear ModelAnalysis of variance table [Partial sum of
squares] on Rz :

Source Sum of squares Df Mean square F – value P – value > F

Model 13.47 4.49 9.16 0.0020

3

A – Speed 3.43 0.0214

1 3.43 6.99

0.0006
B – Feed 10.29 1 10.29 20.98

0.8429
C - Depth of cut 0.020 1 0.020 0.041

Residual 5.88 12 0.49

Cor Total 19.35 15

Table 8 ANOVA table for the data of Rz

Final Equation in Terms of Coded Factors: Rz =+6.19+0.79* A+0.80 * B -0.059 * C

Final Equation in Terms of Actual Factors: Rz =+0.73029+1.97947E-003 * S+16.07938 * F

-0.11851 * D

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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017

Design-Expert® Software
Factor Coding: Actual Rz
Rz 0.20
Design Points
7.79

The Model F-value of 9.16 implies the model is 4.15

7
X1 = A: Speed 0.18

B : F e e d R a te
significant.There is only a 0.20% chance that a X2 = B: Feed Rate

Actual Factor
C: Depth of Cut = 1.00
Model F-Value" this large could occur due to noise. 0.15

Values of "Prob > F" less than 0.0500 indicate model 6

terms are significantIn this case A, B are significant 0.13

model terms. Values greater than 0.1000 indicate the 5

model terms are not significant. 0.10

1200 1400 1600 1800 2000

The analysis values on the data of Rz as plotted as per A: Speed

the given values and shown in the following diagrams.

The residual graph indicates that the decreases of the Fig.10.Feed rate vs. speed for Rz data in graphical
feed and depth of cut with the increase of speed will model
get the high surface finish on the material.
Design-Expert® Software
Factor Coding: Actual
Rz
Design-Expert® Software Design points above predicted value

Rz Normal Plot of Residuals 7.79

4.15
8
X1 = A: Speed
Color points by value of X2 = B: Feed Rate
Rz:
Actual Factor 7
P r o b a b ility

7.79 C: Depth of Cut = 1.00

99
6
4.15

Rz
95 5

90
4

80
70
0.20 2000
N o rm a l %

0.18 1800
50 0.15 1600
0.13 1400
B: Feed Rate A: Speed
30 0.10 1200

20

10
5
Fig.11.Feed rate vs. speed for Rz data on 3d view
1

VI. CONCLUSION

-2.00 -1.00
Internally Studentized Residuals
Fig.9.Nominal plot residuals graph for Rz
Surface interaction dimensional views and direct
effect views of feed rate and speed over surface
roughness of Rz:
The figure explains that the feed rate and
speed on the surface roughness of turning process has
a significant effect. It has been concluded that
increases of feed rate and speed was increase the
surface roughness whereas decreases of feed rate and
speed was decrease the surface roughness.
0.00 1.00 2.00 3.00 The operational design was carried out using
response surface methodology to reduce the number
of experiments and to achieve high accuracy results.
This process has been conducted to optimize the
cutting parameters for turning of aluminium alloy
Al6063T6 on a CNC machine.
In RSM following parameters like surface roughness,
peak to valley was determined by the optimum
machining parameters setting in the statistical
analysis we can conclude that
 The lowest surface roughness value is optained for
a parameter setting of speed 1400rpm, feed rate 0.1
mm/min and depth of cut 0.7 mm (Ra=0.85)
 The worst surface roughness value is optained for a
parameter setting of speed 1800 rpm, feed rate 0.2
mm/min, depth of cut 1.1 mm (Ra=1.84)

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 SSRG International Journal of Mechanical Engineering - (ICCREST'17) - Special Issue - March 2017

 The lowest Rz value optained for a parameter 7. Doreswamy deepak, rajendra beedu,, multi
setting of speed 1400rpm, feed rate0.1mm/min, response optimization of process parameters
depth of cut 0.7 mm(Rz=4.14) using grey relational analysis for turning of al-
 The highest Rz value is optained for a parameter 6061
setting of speed 1400 rpm, feed rate 0.2 mm/min,
depth of cut 0.1 mm (Rz=7.79) 8. Rohit angiras, onkar singh bhatia,, analysis of
surface roughness during turning operation of
VII. REFERENCES aluminium-6063 using taguchi approach,
international journal of advance research in
1. V. Devkumar, e. Sreedhar, m.p. Prabakaran ,
science and engineering, ijarse, vol. No.4, issue
optimization of machining parameters on al
06, june 2015
6061alloy using response surface methodology ,
ijar 2015; 1(7): 01-04 9. Ranganath m. S, vipin, r. S. Mishra, prateek,
nikhil, optimization of surface roughness in
2. J. Paulo davim and francisco mata , influence of
CNC turning of aluminium 6061 using taguchi
cutting parameters on surface roughness in
techniques, ijmer / issn: 2249–6645 /vol. 5 /iss.
turning glass-fiber-reinforced plastics using
5 / May 2015 / 42.
statistical analysis, industrial lubrication and
tribology volume 56 · number 5 · 2004 · pp. 270– 10. B.Radha Krishnan, Dr.G.Senthilkumar, Review
274 of prediction of surface roughness in machine
vision system by using various parameter.
3. C.a. Conceicao antonio, andj.p. Davim, optimal
machining parameters based on
surface roughness experimental data and genetic
search, industrial lubrication and tribology 57/6
(2005) 249–254

4. Chandra shekar, n b d pattar, y vijaya kumar,

optimization of machining parameters in turning
of al6063t6 through design of experiments ,
international journal of mechanical engineering
and technology (IJMET) volume 7, issue 6,
November–December 2016, pp.96–104, article id:
IJMET_07_06_010

5. P. Jayaraman, l. Mahesh kumar, multi-response

optimization of machining parameters of turning
aa6063 t6 aluminium alloy using grey relational
analysis in taguchi method, procedia engineering
97 ( 2014 ) 197 –204

6. R rudrapati1 , p sahoo2 and a bandyopadhyay3,

optimization of process parameters in CNC
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cum tlbo approach, op conf. Series: materials
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