Journal of Cleaner Production xxx (2013) 1e9

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Journal of Cleaner Production

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Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA
Carmita Camposeco-Negrete
ITESM Campus Estado de Mxico, Carretera Lago de Guadalupe km. 3.25, 52926 Atizapn de Zaragoza, Estado de Mxico, Mexico

a r t i c l e i n f o
Article history: Received 14 January 2013 Received in revised form 11 March 2013 Accepted 24 March 2013 Available online xxx Keywords: ANOVA Energy consumption reduction Turning Taguchi methodology

a b s t r a c t
Machine tools are responsible for environmental impacts owing to their energy consumption. Cutting parameters have been optimized to minimize cutting power, power consumed or cutting energy. However, these response variables do not consider the energy demand that ensures the readiness of the machine tool. The present paper outlines an experimental study to optimize cutting parameters during turning of AISI 6061 T6 under roughing conditions in order to get the minimum energy consumption. An orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) were employed to analyze the effects and contributions of depth of cut, feed rate and cutting speed on the response variable. A comparison was done to highlight the importance of correctly selecting the response variable to be analyzed, due to the difference of the values of cutting parameters needed to optimize cutting power, cutting energy, power consumed and energy consumed during the machining process. Additional, the relationship between cutting parameters, energy consumption, and surface roughness was analyzed in order to determine the levels of the cutting parameters that lead to minimum energy consumption and minimum surface roughness. The results of this research work showed that feed rate is the most signicant factor for minimizing energy consumption and surface roughness. Nevertheless, the level of this factor needed to achieve minimum energy consumption is not the same as the one needed to obtain minimum surface roughness. Higher feed rate provides minimum energy consumption but will lead to higher surface roughness. 2013 Elsevier Ltd. All rights reserved.

1. Introduction Preliminary environmental studies for machine tools used in discrete part manufacturing (e.g. turning and milling) indicate that more than 99% of the environmental impacts are due to the consumption of electrical energy (Li et al., 2011). It is necessary to improve manufacturing processes. As a result, many companies are adopting the concept of cleaner production. Cleaner production relies on the creation of products using systems that do not pollute and conserve natural resources. The model should be attractive for consumers and be economically viable, safe and healthful (Pusavec et al., 2010b). Companies that owe machine tools will save money and achieve a better sustainability performance if their energy consumption is reduced. Many of them do not consider energy efciency as a high priority to improve their prots. For example, an estimated of two-

E-mail addresses: carmitacamposeco@gmail.com, A01100028@itesm.mx. 0959-6526/$ e see front matter 2013 Elsevier Ltd. All rights reserved. http://dx.doi.org/10.1016/j.jclepro.2013.03.049

thirds of the electrical energy used by the machining industry is for running motors and drives for cutting tools (Pusavec et al., 2010b). Improving energy efciency of manufacturing processes requires knowledge about the energy consumption as a function of the machine tool and cutting process itself (Li et al., 2011). One of the processes widely used in manufacturing is turning. Despite decades of optimizing this process based on cost and productivity, optimizing it using the energy consumption criterion has not received signicant attention. Applications of Taguchi techniques and statistical analysis have been used to optimize machining processes. Taguchi used experimental design for minimizing variation around a target value and for designing processes to be robust to environmental conditions and to component variations (Ross, 1996). Analysis of variance (ANOVA) is used to interpret experimental data. Machine tools comprise numerous motors and auxiliary components whose energy consumption can vary strongly during machining. The main spindle drive, for example, and the coolant system work near their rated power during roughing, while the

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9

power consumption during nishing is signicantly lower (Heidenhain, 2010). Therefore, this research work focuses on the energy consumed only in roughing due to the fact that is a part of the process in which a large amount of material from the workpiece is removed, so the energy needed to perform the operation is greater than the consumed to remove material during nishing turning. In the present work, aluminum was employed to perform the experimental trials. This metal is chosen by different industries (e.g. construction, transport) due to its lightness, corrosion resistance, yield resistance, conductivity and ductility, among other properties. Also, aluminum is a 100% recyclable metal. A key element to maximize sustainability performance is to choose materials that are both in abundant supply and have the potential for recycling and re-use with no signicant environmental impact. According to Pusavec et al. (2010a), aluminum has the best sustainability evaluation, compared to steel, stainless steel, cast iron, titanium and copper alloys. This sustainability evaluation covered several factors: abundance of raw material, pollution during machining, ease of recycling, life of metal and cost of nished product. This paper presents a work done using the Taguchi methodology for optimizing a roughing turning process. The objective of the experiment was to optimize cutting parameters so as to get the lowest value of energy consumed by the machine during all the machining process, not only in material removal. In order to demonstrate the difference in the values of the cutting parameters needed for minimize energy or power consumption, two comparisons are presented: the former between cutting power and power consumed by the machine and the latter between cutting energy and energy consumed by the machine. In addition, the relationship between cutting parameters, energy consumption and surface roughness was analyzed. 2. Energy consumption of machine tools According to ODriscoll and ODonnell (2013), demand for energy has become so intense that it has outgrown supply so the difcult task of guaranteeing a secure energy supply arises. Complex manufacturing facilities consume a signicant amount of the industrial sectors electrical energy; it is used to power motors, compressors and machine tools. The energy consumed in the manufacturing sector is used in production processes which mainly emerge from production equipments. Machine tool is one of the typical production equipments widely used in the industry (Cao et al., 2012). Balogun and Mativenga (2013) reported that the use of carbon rich electricity generation sources is of global concern because these processes produce CO2 emissions. Therefore, the higher the consumption of electricity in manufacturing industries, the higher the carbon footprints related to the manufactured products. The industrial sector currently accounts for about one-half of the worlds total energy consumption, and the consumption of energy by the sector has almost doubled over the last 60 years (Fang et al., 2011). Moreover, global energy demand is expected to grow by 53% between 2008 and 2035 (Diaz et al., 2012). Optimizing energy demand in manufacturing is important for reducing the energy intensity of products and their vulnerability to escalating energy prices (Mativenga and Rajemi, 2011). The adoption of sustainable development in production offers industry a cost effective route to improve economic, environmental, and social performance, the three pillars of sustainability. In the view of production technologies, one of the ways to improve the sustainability performance is to reduce machining processes energy consumption (Pusavec et al., 2010a).

The work of Deif (2011) stated that environmental and green attempts in manufacturing should move from being an environmental management approach to an environmental strategy. In that way, a win e win situation is created, by which manufacturers can improve their environmental performance while achieving economic gains. In machining processes, saving money and improving sustainability performance can be achieved by reducing energy consumption because energy is an essential resource for production. The cost of energy used over a ten-year period is about 100 times higher than the initial purchase cost of the machine tools used to manufacture products. Therefore, if energy consumption is reduced, the operating cost and the environment impact generated from energy production are diminished (Pusavec et al., 2010a). The energy consumed for non-cutting operations in machining, dominates the total energy consumption (Mativenga and Rajemi, 2011). In consequence, machine selection is important in reducing the energy consumed. However, industries may not have nancial resources to acquire new energy efcient machines. Thus, an improvement of energy efciency is necessary at the level of existing machines (Hana et al., 2012). The power demand of a machine tool is comprised of cutting, variable and constant power components. Energy consumption of the machine tool was found to be dependent on the average power demand and the processing time dictated by the cutting parameters (Diaz et al., 2011). The aim of the work reported by Lee and Tarng (2000), was to develop a turning machining model constructed based on a polynomial network that learned relationships between cutting parameters (cutting speed, feed rate and depth of cut) and cutting performance (surface roughness, cutting force and tool life). The material turned was S45C (AISI 1045) steel bars. An optimization algorithm was applied to the polynomial network to determine optimal cutting parameters subjected to an objective function of maximum production rate or minimum production cost. Bhattacharya et al. (2009) investigated the effects of cutting parameters on surface roughness and power consumption by employing Taguchi techniques during high speed machining of AISI 1045 steel. An orthogonal array and analysis of variance (ANOVA) were employed to analyze the contribution and effects of cutting speed, feed rate and depth of cut on surface roughness and power consumption. In the work of Fratila and Caizar (2011), the Taguchi optimization methodology was applied to optimize the cutting parameters (depth of cut, feed rate and cutting speed) in face milling when machining AlMg3 with high speed steel (HSS) tool under seminishing conditions in order to achieve the best surface roughness and the minimum cutting power. The machining operations were performed under dry cutting, minimal quantity lubrication and ood lubrication. An orthogonal array, signal-to-noise ratio (S/N) and analysis of variance (ANOVA) were employed to analyze the effect of cutting parameters in surface roughness and cutting power. Mativenga and Rajemi (2011), used an objective function to calculate an optimum tool life for minimum energy footprint during turning of EN8 (AISI 1040) steel billets. The optimization was done within a process window in order to select a feasible combination of depth of cut, feed rate and cutting velocity. According to the data, when a large value of depth of cut and feed rate is selected, the specic energy is reduced. The aim of the work reported in Asiltrk and Neseli (2011), was to model the surface roughness in turning of AISI 304 austenitic stainless steel under dry conditions, using the Response Surface Methodology (RSM). An orthogonal array was applied to study the inuence of cutting parameters (cutting speed, feed rate and depth of cut) on the surface roughness.

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9

Hana et al. (2012), optimized cutting parameters in machining of PEEK-CF30 using TiN tools under dry conditions, to achieve minimum power consumption and the best surface quality. Taguchi optimization and grey relational theory were used in the optimization process. Helu et al. (2012), quantied the impact of green machining strategies, such as process time reduction and lack of coolant at the toolechip interface, on the achieved surface quality of turned titanium. The material removal rate was increased to reduce the processing time by varying the cutting speed, feed rate and depth of cut. Each piece test was turned using rough and nish cuts, and the results indicate that it is best to focus greening efforts on the rough cuts since the nish cuts are responsible for the nal surface quality. The work of Bhushan (2013), presents experimental investigations into the effects of cutting speed, feed rate, depth of cut and nose radius in CNC turning of 7075 Al alloy SiC composite. The cutting parameters were optimized by multi-response considerations namely power consumption and tool life. Response Surface Methodology (RSM) and desirability analysis were used to found out the optimum values of cutting parameters that minimize power consumption and maximize tool life. The works mentioned above show that efforts have been made toward optimization of cutting parameters to minimize power consumption, production cost or surface roughness, or maximize tool life in machining of steel and aluminum. Nevertheless, no efforts have been made toward the optimization of cutting parameters in order to minimize the energy consumed in the process of aluminum turning. Estimation of cutting energy or power based on process parameters only captures the energy or power needed for material removal, disregarding the energy demand that ensures the readiness of the machine tool. Therefore, in this paper a comparison was done to highlight the importance of correctly selecting the response variable to be analyzed due to the fact that the optimum values of the factors that minimize cutting energy, cutting power or average power consumed are not the same as the ones that minimize the total energy consumed. Total energy consumed is the variable that includes all types of energy needed to perform the machining operation, not only the energy needed for material removal. Therefore, this variable must be chosen for the optimization process in order to obtain products with a smaller footprint. In the present work, cutting parameters (cutting velocity, depth of cut and feed rate) are optimized to minimize energy consumption during turning of AISI 6061 T6 under roughing conditions. Optimum values of cutting parameters have been found out by an orthogonal array, analysis of variance and signal to noise ratios. Surface roughness is a measure of the quality of the nal product. Consequently, surface roughness was analyzed and the values of the cutting parameters that minimize this variable were compared to the values of the cutting parameters that minimize the total energy consumption. Then, a relationship between these two variables was established.

The quality engineering method known as Taguchi method or Taguchi approach is an experimental strategy in which a modied and standardized form of Design of Experiment (DOE) is used. Taguchi created a number of special orthogonal arrays and to analyze the results he introduced the use of the signal-to-noise ratio (S/N ratio) to assure a design that is immune to the inuence of uncontrollable factors. Taguchi analyzed results based in the deviation from the target. Consequently, selection of the design condition which leads to improved quality is allowed (Roy, 2001). 3.1. Orthogonal arrays Taguchi showed that if experimental runs are chosen appropriately, there is no need to run full factorial experiments. The bases for Taguchis method are the orthogonal arrays, which show what factor levels must be selected each time to do the fewest possible runs. The main idea is to concentrate only on those few runs that are vital for the analysis. 3.2. Robust design: S/N ratio and S/N plots Robust design is an engineering methodology whose objective is to create high-quality, cost-effective products that perform well during its useful life independently of how and under which circumstances are used. These external circumstances that are outside the control of the design engineering are called noises. Robust design increases the quality of products minimizing the effect of noise on the performance of the product. The robust design methodology relies on two powerful tools: orthogonal arrays to carry out designed experiments, and signal-to-noise ratios to measure quality. The S/N ratio is a function that can be classied into three categories: nominal is the best characteristic, smaller the better characteristic and larger the better characteristic. For each of these categories, the optimal level of a process parameter is the level which results in the highest value of S/N ratio transformation. When a critical quality characteristic deviates from the target value, it causes a loss. An S/N ratio combines a performance characteristic with its sensitivity to noise factors to measure the quality of a design. Additional to this, S/N plots are used to determine the levels that keep the process in its target value, in a visual way. The S/N ratio employed in this work is calculated based on the smaller the better characteristic because the purpose of the experiment is to nd the values that minimize cutting power, cutting energy, power consumed, energy consumed and surface roughness. The S/N ratio was calculated as

i h  S=N 10log 1=n* Sy2

(1)

where y is the observed data and n is the number of observation. 3.3. Analysis of variance (ANOVA) and main effects plots Analysis of variance (ANOVA) is the statistical method used to interpret experimental data. ANOVA is used for detecting differences in average performance of groups of items tested. It breaks total variation down into accountable sources. The main objective of ANOVA is to extract from the results how much variation each factor causes relative to the total variation observed in the result (Rutherford, 2001). Main effects plots allow to identify the level of each factor that provides the minimum response value. Analysis of variance (ANOVA) and percentages of inuence are used to detect the factors that are not signicant so they could be adjustment factors whose

3. Taguchi methodology Most of the investigations presented in Section 2 employed Taguchi techniques, such as orthogonal arrays and S/N ratio analysis in order to nd out the optimal values of cutting parameters that minimize the response variable. Taguchi methodology allows obtaining results using fewer experimental runs than other techniques. The results obtained may be not optimal, but when these results are implemented, process is improved. Therefore, less money and time are spent when Taguchi techniques are employed.

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9 Table 3 L9 orthogonal design matrix. Experiment no 1 2 3 4 5 6 7 8 9 A 1 1 1 2 2 2 3 3 3 B 1 2 3 1 2 3 1 2 3 C 1 2 3 2 3 1 3 1 2

Table 4 Power consumed during machining. Fig. 1. HAAS SL10 lathe. Exp no. 1 2 3 4 5 6 7 8 9 A 1 1 1 2 2 2 3 3 3 B 1 2 3 1 2 3 1 2 3 C 1 2 3 2 3 1 3 1 2 Trial 1 [kW] 2.753 4.143 5.659 3.804 5.628 4.008 5.262 3.871 5.170 Trial 2 [kW] 2.974 4.495 5.904 4.138 5.893 4.202 5.483 4.014 5.419 Trial 3 [kW] 2.696 4.140 5.601 3.857 5.717 4.046 5.329 3.889 5.232 Average [kW] 2.808 4.259 5.721 3.933 5.746 4.085 5.358 3.924 5.274 S/N ratio [dB] 8.976 12.593 15.152 11.900 15.189 12.227 14.581 11.877 14.444

Table 1 Cutting tool specications. Tool manufacturer Tool ID Depth of cut (ap) Feed rate (f) Cutting velocity (vc) Indexable insert form Tool clearance Corner radius Cutting material Sandvik Coromant Coroturn 107 DCGX 11 T304-AL H10 0.50e5.50 mm 0.10e0.30 mm/r 250e2500 m/min D 7 0.4 mm Silicon carbide, reinforced ceramic grade

4.2. Power and roughness measurement system levels would be the appropriate for easiness and reduction of the cost of the machining operation. 4. Turning process: experimental procedure 4.1. Selection of process parameters In turning process, the geometry cutting knowledge and cutting parameters control allows to guarantee the quality of machined components and to optimize costs (Correia and Davim, 2011). Process parameters that affect the characteristics of turned parts are cutting tool parameters (tool geometry and tool material) and cutting parameters (cutting velocity, feed rate, depth of cut). These parameters depend on the workpiece material and the machine tool chosen to perform the turning operation. 4.1.1. Workpiece material and machine tool specications Turning experiments were performed on 100 mm length AISI 6061 T6 aluminum cylindrical billets (L/D 4). Cutting length was equal to 50 mm. The experimental investigation was carried out on a 10 hp HAAS SL10 lathe (Fig. 1), with a maximum spindle speed of 6000 RPM. 4.1.2. Cutting tool related parameters The cutting tool used was a carbide insert, manufactured by Sandvik (Table 1). Cutting condition was conventional ood lubrication. It is widely accepted that before energy consumption in manufacturing facilities can be reduced it is necessary to quantify the amount of energy needed, to determine the degrees of freedom for an optimization (ODriscoll and ODonnell, 2013). Power required from the grid during the turning process was measured through a LabVIEW interface, and it was recorded each 0.1 s from the main switch of the lathe. This measure was performed three times for each row of the L9 orthogonal design matrix (Table 3). Once these measures were done, power required was recorded while running the toolpath without workpiece. This way, cutting power is the difference between power with material removal and power without it. In order to obtain the value of energy consumed, average power is computed and then is multiplied by the cycle time. Surface roughness was measured by the surface roughness tester Mitutoyo model SJ-201. This device allows the measurement of Ra roughness (arithmetic average of absolute values of roughness prole), which is the most widely used. The Ra values were measured three times on each turned surface.

Table 5 Cutting power consumed. Exp no. 1 2 3 4 5 6 7 8 9 A 1 1 1 2 2 2 3 3 3 B 1 2 3 1 2 3 1 2 3 C 1 2 3 2 3 1 3 1 2 Trial 1 [kW] 0.663 0.975 1.141 0.979 1.365 1.633 1.409 1.660 1.886 Trial 2 [kW] 0.884 1.326 1.386 1.312 1.630 1.827 1.630 1.803 2.134 Trial 3 [kW] 0.606 0.972 1.084 1.031 1.455 1.672 1.477 1.678 1.948 Average [kW] 0.718 1.091 1.204 1.107 1.483 1.711 1.505 1.714 1.989 S/N ratio [dB] 2.762 0.857 1.661 0.962 3.449 4.674 3.570 4.685 5.986

Table 2 Cutting parameters and their levels. Level 1 ap [mm] f [mm/rev] vc [m/min] 1.0 0.1 150 Level 2 2.0 0.2 200 Level 3 3.0 0.3 250

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9 Table 6 Energy consumed during machining. Exp no. 1 2 3 4 5 6 7 8 9 A 1 1 1 2 2 2 3 3 3 B 1 2 3 1 2 3 1 2 3 C 1 2 3 2 3 1 3 1 2 Trial 1 [kJ] 53.687 38.949 36.779 59.718 45.573 34.460 68.399 44.509 37.738 Trial 2 [kJ] 57.999 42.248 38.367 64.960 47.719 36.130 71.269 46.155 39.551 Trial 3 [kJ] 52.567 38.914 36.403 60.548 46.299 34.791 69.275 44.720 38.190 Average [kJ] 54.751 40.037 37.183 61.742 46.530 35.127 69.648 45.128 38.493 S/N ratio [dB] 34.776 32.056 31.409 35.818 33.356 30.915 36.859 33.090 31.709 Table 8 Surface roughness Ra. Exp no. 1 2 3 4 5 6 7 8 9 A 1 1 1 2 2 2 3 3 3 B 1 2 3 1 2 3 1 2 3 C 1 2 3 2 3 1 3 1 2 Trial 1 [mm] 0.900 2.870 7.697 0.913 2.883 6.167 0.980 3.690 7.753 Trial 2 [mm] 0.940 2.813 7.573 0.923 2.893 6.573 1.177 2.783 7.073 Trial 3 [mm] 0.843 2.800 7.523 0.950 2.840 5.873 0.990 3.203 6.573 Average [mm] 0.894 2.828 7.598 0.929 2.872 6.204 1.049 3.226 7.133 S/N ratio [dB] 0.958 9.032 17.617 0.622 9.166 15.880 0.520 10.236 17.107

4.3. Design of experiment 4.3.1. Cutting parameters The levels of cutting parameters where chosen according to the cutting tool and CNC lathe specications (Table 2). 4.3.2. Orthogonal array In this study, a factorial design was used to identify the main effects of three factors (cutting parameters) on ve responses: average power per process, cutting power, energy consumed per machining cycle, cutting energy and surface roughness Ra. The fractional factorial design selected was an L9 orthogonal array, with three factors (A, B, C) and three levels for each factor. In the matrix shown in Table 3, the three levels are represented by 1, 2 and 3, where 1 is the lowest level and 3 is the highest. For each experiment, 27 machining trials were carried out. The factors considered were depth of cut [mm] (Factor A), feed rate [mm/rev] (Factor B) and cutting velocity [m/min] (Factor C). Their levels were chosen according to the cutting tool specications (Table 2). 5. Results and data analysis The results obtained from the experimental runs carried out, according to the orthogonal array shown in Table 3 are presented in this section. Table 4 shows data for power consumed, the average of each level and its S/N ratio. Table 5 contains data for cutting power, average and S/N ratio for each level. Energy consumed from the grid was obtained from multiplying power consumed and cycle time (Table 6). The same procedure was done in order to compute energy consumed only in material removal (Table 7). Table 8 shows data for surface roughness Ra. The main effects analysis is used to study the trend of the effects of each of the factors. Main effects plots for the three factors considered (depth of cut, feed rate and cutting velocity) versus average power consumed, energy consumed, average cutting power and energy consumed in the cutting process have been shown in Figs. 2e5.
Table 7 Cutting energy consumed. Exp no. 1 2 3 4 5 6 7 8 9 A 1 1 1 2 2 2 3 3 3 B 1 2 3 1 2 3 1 2 3 C 1 2 3 2 3 1 3 1 2 Trial 1 [kJ] 12.930 9.167 7.418 15.362 11.056 14.041 18.321 19.087 13.765 Trial 2 [kJ] 17.242 12.467 9.007 20.604 13.202 15.711 21.191 20.733 15.578 Trial 3 [kJ] 11.810 9.133 7.042 16.193 11.781 14.373 19.197 19.298 14.218 Average [kJ] 13.994 10.256 7.823 17.387 12.013 14.708 19.570 19.706 14.520 S/N ratio [dB] 23.039 20.319 17.918 24.880 21.617 23.362 25.848 25.898 23.252

Fig. 2. Mean effects plot for average power consumed per machining cycle.

The S/N ratio measures performance characteristics of the process and helps to reduce its variance and prevent its deviation from the target value. S/N ratio plots for the three factors are shown in Figs. 7e10. Fig. 6 shows the main effects plot for surface roughness. The S/N ratio plot for surface roughness, Ra, is shown in Fig. 11. According to main effect plots, average power consumed per machining process is the lowest at levels A1, B1, C1 (Fig. 2). As concluded by Bhushan (2013), the values needed for minimizing average power consumed are the minimum values of cutting velocity, feed rate and depth of cut. For the case of cutting power, its minimum value is obtained at the same levels as the ones required for obtaining the minimum value of average power consumed (A1, B1, C1) (Fig. 3). In the work of Hana et al. (2012), it is stated that cutting power is minimized

Fig. 3. Mean effects plot for cutting power consumed.

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9

Fig. 4. Mean effects plot for energy consumed per machining cycle.

Fig. 7. S/N ratio plot for average power consumed per machining cycle.

Fig. 5. Mean effects plot for cutting energy consumed.

when the smallest values of depth of cut, feed rate and cutting velocity are selected. The energy consumed per machining process decreases with levels A1, B3, C1 (Fig. 4). Cutting energy is the lowest at levels A1, B3, C3 (Fig. 5). In all the previous cases, level 1 of factor A (minimum depth of cut) is necessary for obtaining the minimum power/energy consumed in the machining operation and in cutting process. An increment of this factor implies a higher material removal rate so

the system is forced to spend more power. As depth of cut increases, heat generated at the tool workpiece interface also increases. The minimum value of average power consumed in process and the minimum value of cutting power can be achieved if depth of cut, feed rate and cutting velocity are at their lowest values. Less power is required from the grid when these values are lower because when a higher value of feed rate is indicated, axis motors need to move faster and consume more power. The same occurs with a higher value of cutting velocity, due to the movement of the spindle. Energy consumed per machining process is lower when the values of depth of cut and cutting velocity are diminished and feed rate is increased. The value of energy consumed was computed taking into account machining time. Therefore, a higher value of feed rate reduces the time required to machine the material and, as a consequence, less energy is needed to perform the operation. Sandvik Corokey (2010) points out that cutting velocity is the parameter that reduces tool life the most. Furthermore, this parameter at higher values increases energy consumption. Cutting velocity must be kept at its minimum value (150 m/min), to optimize energy consumption and to avoid excessive tool wear. Cutting energy was at its minimum value when feed rate and cutting velocity are at their maximum level. At higher cutting velocities more material is removed, and then the cutting time is reduced. Although a higher value of cutting velocity implies more energy to move the spindle from rest to the indicated value of RPMs, this energy is not added to the cutting energy due to the fact

Fig. 6. Mean effects plot for surface roughness Ra.

Fig. 8. S/N ratio plot for cutting power consumed.

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9 Table 9 ANOVA e average power consumed per machining cycle. Factor A B C Error Total DOF 2 2 2 20 26 SS 1.5679 4.5228 18.1283 0.4018 24.6209 Adj SS 1.5679 4.5228 18.1283 0.4018 Adj MS 0.7840 2.2614 9.0642 0.0201 F 39.02 112.56 451.16 P 0.000 0.000 0.000

Table 10 ANOVA e cutting power consumed. Factor A B C Error Total Fig. 9. S/N ratio plot for energy consumed per machining cycle. DOF 2 2 2 20 26 SS 2.43591 1.25671 0.00156 0.41110 4.10527 Adj SS 2.43591 1.25671 0.00156 0.41110 Adj MS 1.21795 0.62836 0.00078 0.02055 F 59.25 30.57 0.04 P 0.000 0.000 0.963

Fig. 10. S/N ratio plot for cutting energy consumed.

that the acceleration of the spindle occurs before the cutting is started so this energy is not considered. According to S/N ratio plots (Figs. 7e10), the levels of each of the three factors that should be used in order to reduce process variance are the same as the ones indicated by the mean effect plots for the four responses (average power consumed, cutting power, energy consumed per machining cycle and cutting energy). These

levels decrease each one of the response values and ensure the process will stay in its target value. Optimum machining conditions require a low value of surface roughness. In the case of the levels of the cutting parameters and their values for this experiment, the minimum value of surface roughness, Ra, is obtained with the second level of depth of cut and rst level of feed rate and cutting velocity (Fig. 6). For surface roughness, the levels that ensure the process will be in its target value are level 1 of feed rate and cutting velocity and level 2 of depth of cut (Fig. 11). These values are the same as the ones needed for obtaining the minimum value of the response. According to the work of Hana et al. (2012), the smallest the values of feed rate and cutting velocity, the lowest is the value of surface roughness. Analysis of Variance (ANOVA) and F test were performed to prove the signicance of each factor. This analysis was carried out for a signicance level of a 0.05 (condence level of 95%). If the F value of a factor exceeds the F0.05 value, the contribution of that factor is insignicant. ANOVA tables for the ve cases previously described are presented in Tables 9e13. From F results of ANOVA, percentages of inuence of each factor were computed and they are shown in Table 14. According to ANOVA analysis, in the case of cutting power consumed, the cutting velocity is not signicant due to its P value (P values greater than 0.05 are insignicant); therefore it does not contribute to the evaluation of the response. In the other cases, all the factors are signicant. There are factors that are more signicant than others, referring to their percentage of inuence (Table 14). The values of the factors that slightly contribute to the evaluation of the response or are almost insignicant, according to the percentage of inuence of each factor (Table 14), must be kept in levels that provide an economic benet or ease for the machines operator. In cases when cutting velocity, feed rate or depth of cut are not relevant factors their levels should be small but appropriate for the material to be machined and for the tool to be used owing to higher values of these factors increase tool wear.
Table 11 ANOVA e energy consumed per machining cycle. Factor A B C Error Total DOF 2 2 2 20 26 SS 227.19 3025.563 178.66 68.25 3499.62 Adj SS 227.19 3025.563 178.66 68.25 Adj MS 113.60 1512.76 89.33 3.41 F 33.29 443.33 26.18 P 0.000 0.000 0.000

Fig. 11. S/N ratio plot for surface roughness Ra.

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

8 Table 12 ANOVA e cutting energy consumed. Factor A B C Error Total DOF 2 2 2 20 26 SS 236.876 99.328 42.556 65.312 444.072 Adj SS 236.876 99.328 42.556 65.312

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9 Table 15 Energy consumed per machining cycle at optimum cutting parameters. Adj MS 118.438 49.664 21.278 3.266 F 36.27 15.21 6.52 P 0.000 0.000 0.007 Exp no. 10 A 1 B 3 C 1 Trial 1 [kJ] 33.288 Trial 2 [kJ] 33.448 Trial 3 [kJ] 32.680 Average [kJ] 33.138

100% 90%

Table 13 ANOVA e surface roughness Ra. Factor A B C Error Total DOF 2 2 2 20 26 SS 3.702 507.167 2.142 12.890 525.900 Adj SS 3.702 507.167 2.142 12.890 Adj MS 1.851 253.583 1.071 0.174 F 10.63 1455.84 6.15 P 0.000 0.000 0.003

80% 70% 60% 50% 40% 30% 20% 10% 0% 1 2 3 4 5 6 7 8 9 10 Cutting Energy Air Cutting Energy

There is a difference in the values of the cutting parameters needed for minimize each one of the four possible response values (power or energy). Consequently, its important to select adequately the response to be minimized. The response that should be selected for the optimization process is the energy consumed in the machining process. Due to the fact this response takes into account the cycle time and all the events occurred since the machine is ready to start the program until it is nished, it includes all the energy needed to perform the operation, including the material removal. Conicting results were obtained when comparing optimum levels that lead to less energy consumption and those used to achieve minimum surface roughness. Feed rate is the most significant factor for both responses, but the level required for optimizing the response is not the same for both cases. Higher feed rate provide minimum energy consumption but will lead to higher surface roughness. Finishing machining requires higher surface nish. Also, is a process whose cycle time is smaller than cycle time of roughing. Owing to that, during roughing process feed rate must be high to reduce machining time and energy consumption. During nish, optimum parameters that ensure minimum surface roughness must be used despite energy consumption because if surface roughness is not adequate, quality is diminished and the piece will be classied as scrap. Scrap means more energy consumption due to the fact that the piece must be machined again. Using the Taguchi methodology, results were obtained using fewer experimental runs. According to Aggarwal et al. (2008), time required for conducting experiments using RSM technique is almost twice as the needed using Taguchis technique, and both techniques give similar results. Consequently, this methodology allows nding out values that are closer to the ones that optimize the response variable or variables being studied, spending less time.
Table 14 Percentage of inuence of factors A, B and C. Factor A B C Case 1 [%] 6.47 18.65 74.76 Case 2 [%] 65.23 33.65 0.04 Case 3 [%] 6.59 87.79 5.18 Case 4 [%] 60.65 25.43 10.90 Case 5 [%] 0.72 98.06 0.41

Fig. 12. Comparison between cutting and air cutting energy.

5.1. Conrmation test In order to validate conclusions obtained in this section, an experimental run was done with the optimum cutting parameters according to main effects and S/N ratio analysis. The results obtained are shown in Table 15. Referring to the experimental results shown in Table 15, energy consumed per machining cycle is at its minimum value when optimum cutting parameters are used, compared to energy consumed using the cutting parameters levels showed in Table 3. Relating to the experiments carried out (Table 3), the energy consumed for non-cutting operations (air cutting energy) is greater than the cutting energy needed to perform the turning process for all the experiments, including the test carried out with the optimum cutting parameters (Fig. 12). 6. Conclusions Taguchi methodology was employed for optimizing a roughing turning process, involving aluminum AlSI 6061 T6 as the material to be machined and a cutting tool made of silicon carbide, reinforced ceramic grade. Optimum values of cutting parameters were found out in order to minimize cutting power, cutting energy, power and energy consumed during the machining process, and surface roughness Ra. The energy consumed per machining cycle is the response variable that should be analyzed because it comprises cutting energy and air cutting energy. According to the analysis showed in Fig. 11, cutting energy only contributes with less of 50% of the total energy in all the experimental runs. For minimizing the total energy consumed, feed rate is the most signicant factor (87.79%) followed by depth of cut (6.59%) and cutting velocity (5.18%). The most optimal results for energy consumption were observed when the feed rate was set at 0.3 mm/rev, depth of cut of 1 mm and cutting speed of 150 m/min. Higher feed rate, minimum depth of cut and cutting velocity leads to minimum energy consumption and less variation of the process from the target value.

Factor A: Depth of cut [mm]. Factor B: Feed rate [mm/rev]. Factor C: Cutting velocity [m/min]. Case 1: Average power consumed per machining cycle. Case 2: Cutting power consumed. Case 3: Energy consumed per machining cycle. Case 4: Cutting energy consumed. Case 5: Surface roughness Ra.

Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049

C. Camposeco-Negrete / Journal of Cleaner Production xxx (2013) 1e9

For minimizing surface roughness, feed rate is the most significant factor (98.06%). The most optimal results for this response variable were obtained when the feed rate was set at 0.1 mm/rev, depth of cut of 2 mm and cutting velocity of 150 m/min. The optimal solution for minimizing energy consumption and surface roughness is an approximation of the real optimal solution. Therefore, in order to increase accuracy and nd the values that lead to a reduction of the response variables studied, it is necessary to conduct turning experiments in the vicinity of the actual optimum and within the process parameters window. Acknowledgments The author would like to thank the Consejo Nacional de Ciencia y Tecnologa (CONACyT) and the ITESM Campus Estado de Mxico for providing nancial resources. References
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Please cite this article in press as: Camposeco-Negrete, C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production (2013), http://dx.doi.org/10.1016/j.jclepro.2013.03.049