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a r t i c l e
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Article history:
Received 20 January 2011
Received in revised form 14 June 2011
Accepted 5 July 2011
Available online 23 July 2011
Keywords:
Hard turning
Taguchi method
Surface roughness
DOE
a b s t r a c t
This study focuses on optimizing turning parameters based on the Taguchi method to minimize surface roughness (Ra and Rz). Experiments have been conducted using the L9
orthogonal array in a CNC turning machine. Dry turning tests are carried out on hardened
AISI 4140 (51 HRC) with coated carbide cutting tools. Each experiment is repeated three
times and each test uses a new cutting insert to ensure accurate readings of the surface
roughness. The statistical methods of signal to noise ratio (SNR) and the analysis of variance (ANOVA) are applied to investigate effects of cutting speed, feed rate and depth of
cut on surface roughness. Results of this study indicate that the feed rate has the most signicant effect on Ra and Rz. In addition, the effects of two factor interactions of the feed
rate-cutting speed and depth of cut-cutting speed appear to be important. The developed
model can be used in the metal machining industries in order to determine the optimum
cutting parameters for minimum surface roughness.
2011 Elsevier Ltd. All rights reserved.
1. Introduction
Hard turning is a turning process in which work pieces
whose hardness ranges between 50 and 70 HRC are
machined by using single point cutting tools which have
high hardness and wear resistance. The hard turning
exhibits a unique behavior, which is different than conventional turning operations. The application of hard turning
technology can be improved by utilizing advanced optimization algorithms, which helps manufacturers to make
educated decisions in the presence of multiple objectives
that need to be satised [1,2].
Signicant advances have been seen in cutting tools and
machine tools in recent years. Cutting parameters may be
specied according to hardness of materials and roughness
of the surface of a work piece. The advantages in machining
materials with higher hardness are decreasing machining
costs, saving time, improving surface quality, and eliminating of deformities in parts caused by temperature [3,4].
Corresponding author. Tel.: +1 317 464 30 86; fax: +1 317 274 97 44.
_ Asiltrk).
E-mail address: iasilturk@yahoo.com (I.
0263-2241/$ - see front matter 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.measurement.2011.07.003
Aslan et al. [4] conducted an optimization study by machining a hardened AISI 4140 grade (63 HRC) steel on a lathe by
using Al2O3 + TiCN coated ceramic inserts. They determined that Al2O3-base ceramics are required for cutting
tools in machining hard steels during wear resistance and
high hardness. They ensured optimization in their experimental studies by using the Taguchi method. The experimental parameters chosen were: three different cutting
speeds, feed rates and depths of cut. Blank wear (VB) and
surface roughness were chosen as criteria for performance.
The obtained results were analyzed by using variance analysis (ANOVA). As a result, it was seen that the VB value decreased as the cutting speed and the depth of cut increased;
however, it rst decreased and then increased as the feed
rate increased. On the other hand, the surface roughness
decreased as the cutting speed increased. In contrast surface roughness increased when the feed rate increased.
Ucun and Aslantas [5] investigated the effects of the
cutting parameters on surface roughness in hard turning.
They examined machining performance with respect to
tool wear and surface roughness in machining hardened
AISI 52100 grade bearing steels with coated carbide cutting
1698
1699
TURNING
SURFACE
ROUGHNESS
SOFTWARE
CUTTING
PARAMETERS
OPTIMIZED
PARAMETERS
USER
1700
Table 1
Cutting parameters.
Symbol
Cutting parameters
Level 1
Level 2
Level 3
A
B
C
90
0.18
0.2
120
0.27
0.4
150
0.36
0.6
1. Control factors, which affect process variability as measured by the S/N ratio.
2. Signal factors, which do not inuence the S/N ratio or
process mean.
3. Factors, which do not affect the S/N ratio or process
mean.
In practice, the target mean value may change during
the process development. Two of the applications in which
the concepts of S/N ratio are useful are the improvement of
quality through variability reduction and the improvement
of measurement. The S/N ratio characteristics can be divided into three categories given by Eqs. (1)(3), when
the characteristic is continuous [27]:
Nominal is the best characteristic,
y
S
10 log 2
N
Sy
S
1 X 2
10 log
y
N
n
S
1 X1
log
N
n
y2
Table 2
The results of experiments and S/N ratios values.
Experimental number
Ra
Rz
1
2
3
4
5
6
7
8
9
1
1
1
2
2
2
3
3
3
1
2
3
1
2
3
1
2
3
1
2
2
2
2
1
3
1
2
1.6
1.79
4.22
1.21
2.47
3.78
1.17
2.21
2.51
8.79
14.22
19.87
8.62
11.72
15.94
8.66
9.25
12.12
4.23
3.37
12.48
2.32
7.87
10.79
3.37
6.99
7.76
18.88
23.058
25.964
18.75
21.379
24.05
18.76
19.323
21.67
Table 3
S/N response table for Ra factor.
Level
1
2
3
D
6.343
7.709
6.039
1.67
4.024
5.723
10.344
6.32
7.338
4.846
7.907
3.06
1701
-4
Mean of SN ratios
-6
-8
-10
1
2
C
-4
-6
-8
-10
3
1702
Table 4
The interaction between S/N cutting speed for Ra factor.
Ra V
Between groups
(Combined)
Linearity
Deviation from linearity
Within groups
Total
Sum of squares
df
Mean square
4.747
0.138
4.609
89.369
94.116
2
1
1
6
8
2.374
0.138
4.609
14.895
0.159
0.009
0.309
0.856
0.926
0.598
Sum of squares
df
Mean square
64.174
59.908
4.266
29.942
94.116
2
1
1
6
8
32.087
59.908
4.266
4.990
6.430
12.005
0.855
0.032
0.013
0.391
Table 5
The interaction between S/N feed rate for Ra factor.
Ra f
Between groups
(Combined)
Linearity
Deviation from linearity
Within groups
Total
Table 6
The interaction between S/N depth of cut for Ra factor.
Ra a
Between groups
(Combined)
Linearity
Deviation from linearity
Within groups
Total
Sum of squares
df
Mean square
12.675
7.741
4.934
81.441
94.116
2
1
1
6
8
6.338
7.741
4.934
13.573
0.467
0.570
0.364
0.648
0.479
0.569
Table 7
S/N response table for Rz factor.
Level
1
2
3
D
22.63
21.39
19.9
2.73
18.78
21.25
23.89
5.11
20.75
21.16
22.02
1.27
cutting speed, 0.18 mm/rev for feed rate and 0.2 mm for
depth of cut.
The interaction between cutting parameters was determined through variance analysis, while optimum cutting
conditions were determined from S/N ratio obtained
through the Taguchi method. The variance analysis of the
interactions of the S/N-cutting speed, the S/N-feed rate
and the S/N-depth of cut were evaluated. The results of
the conducted S/N analysis (ANOVA) are given in Tables
810.
Table 8 shows the interactions between the S/N and cutting speed, do not produce a signicant level within the
reliability interval of 95%. According to Table 9, P value is
effective for every three feed rate levels at the reliability level of 95%, because the results are lower than 0.05. Effectiveness was observed at three depth levels at a
reliability level of 95% according to Table 10. Previous
researchers suggested similar results. They claimed that
the surface roughness was affected signicantly by the
feed rate. The cutting speed had a lower effect on the surface roughness [1,3,4,6,20,27,28].
1703
Mean of SN ratios
-20
-22
-24
1
2
C
-20
-22
-24
Table 8
The interaction between S/N cutting speed for Rz factor.
Rz V
Between groups
Within groups
Total
(Combined)
Sum of squares
df
Mean square
11.235
44.287
55.522
2
6
8
5.617
7.381
0.761
0.508
Sum of squares
df
Mean square
39.252
16.270
55.522
2
6
8
19.626
2.712
7.238
0.025
Sum of squares
df
Mean square
11.346
44.176
55.522
2
6
8
5.673
7.363
0.771
0.504
Table 9
The interaction between S/N feed rate for Rz factor.
Rz f
Between groups
Within groups
Total
(Combined)
Table 10
The interaction between S/N depth of cut for Rz factor.
Rz a
Between groups
Within groups
Total
(Combined)
5. Conclusion
The Taguchi experimental design was used to obtain
optimum cutting parameters on hard turning. Experimental results were analyzed using ANOVA. The results obtained in this study are given below:
L9 orthogonal array was selected for three different levels of cutting speed, feed rate and depth of cut, which
were cutting factors, by using the Taguchi method. As
1704
Acknowledgment
This study is supported by Scientic Research Projects
Coordinators (BAP) of Selcuk University. This support is
greatly appreciated.
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