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Experimentation and prediction of CNC Turning

Process Parameters on AL6069 Using response
surface methodology

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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

Experimentation and prediction of CNC Turning Process Parameters on

AL6069 Using response surface methodology

R.Clinktan Selva Ganesh Kumar N.Muthu Prakash N.Zeelan Basha

M.E Scholar/Mech Assistant Professor/Mech Assitant Professor/Mech Ph.D Research Scholar/Mech
Coimbatore Institute Of Technology Wollega University Coimbatore Institute Of Coimbatore Institute Of
clinktan.Prince@gmail.com lectselva@gmail.com Engineering Technology Technology
prakash1988cbe@gmail.com zeelu6@gmail.com

Abstract
In this study a series of tests were conducted in order to investigate the machinability evaluation of Alumunium 6069 in the
turning process. The factors investigated were spindle speed, feed rate and depth of cut. The parameters that affect the turning
operation are vibration, tool wear, surface roughness etc. Among this surface roughness is an important factor that affects the
quality in manufacturing process. The main objective of this paper is to predict the surface roughness on Al 6069, by optimizing
the input parameters such as spindle speed (), feed rate () and depth of cut () by using carbide tool. A second order
mathematical model is developed using regression technique and optimization is carried out using Box-Behnken of response
surface methodology. The experimental results indicate that the proposed mathematical models suggested could adequately
describe the performance indicators within the limits of the factors that are being investigated. The spindle speed is the most
significant factor that influences the surface roughness and. However, there are other factors that provide secondary
contributions to the performance indicators. Therefore, this study attempts the application of response surface methodology to
find the optimal solution of the cutting conditions for giving the minimum value of surface roughness using Response surface
methodology.

Key words: Anova, CNC Machine, Depth of cut, feed rate, Optimization, RSM, Spindle speed, Surface roughness

models, evaluate the effects of several factors mand

I. INTRODUCTION
Aluminum 6069 applications are high pressure seamless
gas containers formed by either hot or cold impact
extrusion and tubing for light weight bicycle frames.
For more than a decade, the hard turning technology has
become one of the important and widely used
manufacturing processes in a range of industrial
application. Due to the complexity of hard turning
technology, numerous mathematical models have been
proposed and extensively developed by a growing
numbers of papers for the analysis of the machinability
evaluation (Jenn-Tsong Horng, 2008)
Response Surface Methodology (RSM): Response
surface methodology is a specialized DOE technique
that may be used to detail and optimize transfer
functions of a DFSS project .The method can be used in
the optimization phase of the DFSS algorithm.
Response surface methodology (RSM) is a combination
of statistical and optimization methods that can be used
to model and optimize designs. It has many applications
in design and improvement of products and processes.
And it is a fundamental method to derive the
relationship between the different parameters affecting
the process. RSM works by applying different designed
experiments to obtain a polynomial model of the
process keeping the independent variable as the system
output which is minimized. RSM which is a technique
for designing experiment helps researchers to build
1
achieve the optimum conditions for desirable responses
in addition to reducing the number of experiments
.Analysis of variance (ANOVA) provides the Statistical
results and diagnostic checking tests which enables
researchers to evaluate adequacy of the models (Khaider
Bouacha, 2009). After analysing each response,
multiple response optimization was performed, either by
inspection of the interpretation plots, or with the
graphical and numerical tools provided for this purpose.
It was mentioned previously that RSM designs also help
in quantifying the relationships between one or more
measured responses and the vital input factors. In order
to determine if there exist a relationship between the
factors and the response variables investigated, the data
collected must be analysed in a statistically sound
manner using regression(M.Y. Noordin, 2004).The
relationship is expressed in the form of an equation
connecting the response or dependent variable (y),and
one or more independent variables,x1,x2,x3,..xn.
II. LITERATURE REVIEW
The combined effects of four machining parameters,
including cutting speed, feed rate, depth of cut and tool
corner radius, on the basis of two performance
characteristics flank wear (VBmax) and surface
roughness (Ra), were investigated and the centered
central composite design (CCD) and the analysis of
variance (ANOVA) were employed. The quadratic
model of RSM associated with the sequential
 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

approximation optimization (SAO) method was used to roughness in turning of Al 6069 with carbide tool using
find optimum values of machining parameters. Results the RSM. Optimum cutting conditions with respect to
show that the flank wear is influenced principally by the the surface roughness parameters with the help of
cutting speed and the interaction effect of feed rate with response optimization technique are proposed
nose radius of tool, and the cutting speed and the tool
corner radius have statistic significance on the surface III. METHODOLOGY
roughness (Jenn-Tsong Horng, 2007).
The main objectives are firstly focused on delimiting
the hard turning domain and investigating tool wear and
forces behaviour evolution versus variations of
workpiece hardness and cutting speed. Secondly, the
relationship between cutting parameters (cutting speed,
feed rate and depth of cut) and machining output
variables (surface roughness, cutting forces) through the
response surface methodology (RSM) are analysed and
modeled. The combined effects of the cutting
parameters on machining output variables are
investigated while employing the analysis of variance
(ANOVA). The quadratic model of RSM associated
with response optimization technique (Khaider
Bouacha, 2009).
The prediction of optimal machining conditions for
good surface finish and dimensional accuracy plays a
very important role in process planning. The present
work deals with the study and development of a surface
roughness prediction model for machining mild steel,
using Response Surface Methodology (RSM) (P.V.S.
Suresh, 2002).
The effects of cutting speed, feed rate, work piece
hardness and depth of cut on surface roughness and
cutting force components in the hard turning were
experimentally investigated. Four-factor (cutting speed,
feed rate, hardness and depth of cut) and three-level
fractional experiment designs completed with a
statistical analysis of variance (ANOVA) were
performed. Mathematical models for surface roughness
and cutting force components were developed using the
response surface methodology (RSM) (HamdiAouici, Figure- 1 Methodology flow chart
2014).The best surface roughness was achieved at the
lower feed rate and the highest cutting speed.
Two independent data sets were obtained on the basis of IV. EXPERIMENTAL DETAILS
measurement: training data set and testing data set. A. WORK PIECE MATERIAL
Spindle speed, feed rate, depth of cut, and vibrations are The alloy 6069 is a new entry to the
used as independent input variables (parameters), while family of 6000 series of heat treatable Mg-Si-Cu
surface roughness as dependent output variable. On the aluminum alloys. The work material used was
basis of training data set, different models for surface aluminium 6069 and its chemical composition and
roughness were developed by genetic programming (M. hardness are tested and hardness value is found to be 48
Brezocnik, 2004). Accuracy of the best model was HRC. The (table 1) below shows the chemical
proved with the testing data. It was established that the composition of aluminium 6069.
surface roughness is most influenced by the feed rate,
whereas the vibrations increase the prediction accuracy. Table 1 chemical composition for Al 6069
In this framework, the present study is focused on
delimiting accurately the working parameters domain Weight (%) 6069
of turning. Also, the effect of process Parameters on the Al Bal
surface roughness for different values has been
Si 0.9
investigated. Moreover, this work treats the effect of
spindle speed, feed rate and depth of cut on surface Cu 0.75
2
 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

Cr 0.2
v 0.2

B.CUTTING TOOL
AK10 Carbide Inserts for Turning Ground and
Polished for Aluminium Uni-tip was used for turning
shown fig.2.

Figure- 3 Surface roughness Tester SJ-210P

Figure- 2 Cutting tool AK10 carbide insert
C.EXPERIMENTAL SET UP AND CUTTING
CONDITIONS
The experimental work was divided into two series:
The main aim of the first experiments series was the
determination of the turning domain and the
quantification of surface roughness evolution. This was
carried out through facing operation with continuously
varying cutting parameters.
The purpose behind the second experiments series was
to investigate the effects of cutting parameters on
surface roughness, then to establish a correlation
between them using the response surface methodology
(RSM).Machining process was carried out in CNC
lathe. The measurements of average surface roughness
(Ra) were taken on surface roughness Tester SJ-
210P.Three measurements of surface roughness were
obtained at different surface of machined work piece
and average value is used in the further analysis
D. SURFACE ROUGHNESS TESTER SJ-210
Roughness plays an important role in determining how a
real object will interact with its environment. Rough
surfaces usually wear more quickly and have
higher friction coefficients than smooth surfaces
Roughness is often a good predictor of the performance
of a quality of the mechanical component, since
irregularities in the surface may form nucleation sites
for cracks or corrosion. On the other hand, roughness
Machining Units Levels
parameter -1 0 1
Spindle Speed () rpm 1000 1500 2000
Feed Rate () mm/min 0.06 0.08 0.1
Depth of Cut () mm 0.4 0.6 0.8
may promote adhesion. The Surface roughness tester
used for measuring surface roughness (Ra) in this
experimental analysis shown in fig.3
E.CNC LATHE
The CNC Lathe is an automated machine used for
machining Purpose and it has greater accuracy and
productivity (Figure 4) shown below along with
specification.
Figure- 4 CNC XL Turning Lathe
Specification:
Control system-Fanuc emulated
Spindle power-1Hp
Spindle speed-100 to 3000 rpm
Max. Turning dia-32mm
Rapid traverse rate-1.2m/min
F.COMBINATION OF PARAMETERS AND
THEIR LEVELS
In order to investigate the influence of machining
parameters on surface roughness, three principal
machining parameters, including the spindle speed (),
feed rate (), depth of cut ()), were specified as
machining parameters. In this study, these machining
parameters were chosen as the independent input
variables.
The desired responses were the surface roughness and
the surface finish which are assumed to be affected by
the above three principal machining
In this experimental analysis the parameters has been
conducted in three levels -1, 0, 1 shown in table 2
Table 2 Combination of Parameters and their levels

G. EXPERIMENTAL VALUES
1) Machining parameters
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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

- spindle speed (rpm)

- Feed rate (mm/min)
- Depth of cut (mm)

2) Responses
Y -surface roughness Ra (m)

Table 3 Experimental machining parameters

Exp.no Machining responses
Parameters
Y
1 1000 0.1 0.6 0.623
2 2000 0.1 0.6 0.687
3 1000 0.08 0.8 0.638
Figure- 5 Analysis of Variance
4 1500 0.06 0.4 0.641
5 1500 0.06 0.8 0.678 I. REGRESSION EQUATIONS
6 1500 0.08 0.6 0.661 The tests for significance of the regression and
7 1500 0.08 0.6 0.663 individual model coefficients were performed to verify
8 1500 0.08 0.6 0.653 the goodness of fit for the obtained model (Khaider
Bouacha, 2007).Regression equations were formed
9 1000 0.06 0.6 0.646 using design- expert 8.0 software for surface roughness
10 1500 0.1 0.4 0.661 Ra (Y) shown in (equation1),
11 2000 0.08 0.4 0.695 The regression equation for Surface Roughness Ra (Y)
is
12 2000 0.06 0.6 0.697 Y=0.50527-1.01500E-005*+1.37625*
13 1000 0.08 0.4 0.638 +0.23025*+3.25000E-004* -1.50000E-005* -
14 1500 0.08 0.6 0.659 2.50000* +1.63000E-008* 2+-3.56250*
15 2000 0.08 0.8 0.689 2+8.12500E-003* 2 equa------1

16 1500 0.08 0.6 0.667

V.RESULTS AND DISCUSSIONS
17 1500 0.1 0.8 0.658
Interaction effect of spindle speed
The interaction and direct effect of spindle speed on
H.ANOVA surface roughness is discussed below.
Analysis of Variance used to test the difference between
3 parameters which has been experimented and also it
shows the significant values and interactions on the
selected machining characteristic, analysis of variance
(ANOVA) was performed. The ANOVA of the raw data
are given in figure 5. From the figure, it is evident that
spindle speed, depth of cut and cutting environment are
significant at 95% confidence level

4
 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

Fig.8, 9 Surface interaction and direct dimensional

views and direct effect views of feed rate and depth
of cut over surface roughness
Fig.8, 9 shows the interaction and direct effect of
feed rate and depth of cut on surface roughness. The
above interaction figure evidenced that the feed rate and
depth of cut on the surface roughness of turning process
has a significant effect. From the Fig.8 it has been
concluded that higher feed rate and depth of cut was
increase the surface roughness whereas lower feed rate
and depth of cut decrease the surface roughness. To
obtain the quality surface of Ra between 0.62 and 0.64
Fig. 6, 7 Surface interaction dimensional views and feed rate less than 0.06 and depth of cut less than 0.70
direct effect views of spindle speed and feed rate should be preferred.
over surface roughness.
Fig.6, 7 shows the interaction
and direct effect of feed rate and spindle speed on Interaction effect of Depth of cut
surface roughness. The above interaction figure The interaction and direct effect of depth of cut on
evidenced that the spindle speed and feed rate on the surface roughness is discussed below.
surface roughness of turning process has a significant
effect. As the spindle speed increases from 1000 rpm to
2000 rpm the surface roughness value is reduced from
0.68 to 0.62 m, where feed rate has the inverse
relationship on surface roughness compared to the
spindle speed. From the result it is concluded that the
change in feed rate (0.06-0.08 mm/min) has a
significant effect on surface roughness (0.64-0.66m) at
higher spindle speed (2000rpm) whereas the change in
feed rate (0.06-0.08 mm/min) has no significant effect
on surface roughness (0.67-0.68m) at lower spindle
speed (1000 rpm). The conclusion can also be verified
from the ANOVA.

Interaction effect of feed rate

The interaction and direct effect of spindle speed on
surface roughness is discussed below.

Fig.10, 11 Surface interaction and direct

dimensional views and direct effect views of spindle
speed and depth of cut over surface roughness
Fig.10, 11 shows the interaction and direct effect of
depth of cut and spindle speed on surface roughness.
The above interaction figure evidenced that the spindle
speed and depth of cut on the surface roughness of
turning process has a significant effect. From the Fig.10
it has been concluded that the lower spindle speed (1000
rpm) with the increase in depth of cut (0.7 to 0.8 mm)
has a significant effect on surface roughness (0.62-
0.67m) at higher spindle speed (2000rpm) whereas the
increase in depth of cut (0.4 to 0.5 mm) has no
significant effect on surface roughness (0.65 to 0.64m)
at lower spindle speed (1000 rpm).The conclusion can
also be verified from the ANOVA

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 International Journal On Engineering Technology and Sciences IJETS
ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016

The change in feed rate (0.06-0.1 mm/min) has

VI. VALIDATION OF THE MODEL a significant effect on surface roughness (0.69-
In order to verify the adequacy of the model developed, 0.66m) at higher spindle speed (2000rpm).
three confirmation run experiments were performed. The change in feed rate (0.06-0.08 mm/min)
The test condition for three confirmation run has no significant effect on surface roughness
experiments were among the cutting conditions that (0.67-0.69m) at lower spindle speed (1000
were performed within the range of the levels defined rpm).
previously. (M.Y. Noordin, 2004) A feed rate less than 0.08 and depth of cut
Table 5 shows the comparison of predicted versus less than 0.60 have been preferred for
experimental value of surface roughness. The obtaining good surface finish.
percentage of error is found to be within 1.5% which
shows the validity of the model. VII.REFERENCES
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and cutting forces using response surface methodology in
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ISSN(P): 2349-3968, ISSN (O): 2349-3976
Volume III, Issue II, February- 2016
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