‘OPTIMIZATION OF INTERNAL

TURNING PROGESS USING GENETIC

ALGORITHM FOR ALUMINIUM, CAST
IRON AND MILD STEEL’

Dissertation submitted to
ShriRamdeobaba College of Engineering & Management, Nagpur
in partial fulfillment of requirement for the award of
degree of

Bachelor of Engineering
In

MECHANICAL ENGINEERING

By
HarshvardhanRaiHarshitAgrawal

Faizan Khan PrateekShivhare

Guide
Prof. Pranjali.S.Deole

Department of Mechanical Engineering

ShriRamdeobaba College of Engineering & Management, Nagpur 440 013
(An Autonomous Institute affiliated to RashtrasantTukdojiMaharaj Nagpur University Nagpur)

April 2017
 SHRI RAMDEOBABA COLLEGE OF ENGINEERING & MANAGEMENT, NAGPUR
(An Autonomous Institute affiliated to RashtrasantTukadojiMaharaj Nagpur University Nagpur)

Department of Electronics Engineering

CERTIFICATE

This is to certify that the Thesis on “OPTIMIZATION OF INTERNAL TURNING PROGESS

USING GENETIC ALGORITHM FOR ALUMINIUM, CAST IRON AND MILD STEEL” is
a bonafide work of HasrhvardhanRai, PrateekShivhare, HarshitAgrawal, Faizan Khan submitted to
the RashtrasantTukadojiMaharaj Nagpur University, Nagpur in partial fulfillment of the award of
Bachelor of Engineering, in Mechanical Engineering and has been carried out at the Department of
Mechanical Engineering, ShriRamdeobaba College of Engineering and Management, Nagpur during the
academic year 2016-17.

.
Date :

Place:Nagpur

Prof. P.S.Deole Dr.K.N.Agrawal

Project guide H.O.D
Department of Department of Mechanical Engineering
Mechanical Engineering

Dr. R. S. Pande
Principal
 DECLARATION

We , hereby declare that the thesis titled “OPTIMIZATION OF INTERNAL TURNING

PROGESS USING GENETIC ALGORITHM FOR ALUMINIUM, CAST IRON AND MILD
STEEL” submitted herein , has been carried out in the Department of Mechanical Engineering of
ShriRamdeobaba College of Engineering & Management, Nagpur. The work is original and has not
been submitted earlier as a whole or part for the award of any degree / diploma at this or any other
institution /University.

Date:

Place: Nagpur

________________ ________________

(HarshvardhanRai) (HarshitAgrawal)
(Roll no.36) (Roll no.35)

________________ ________________

(PrateekShivhare) (Faizan Khan)

(Roll no.53) (Roll no.80)

 Approval Sheet

This thesis/dissertation/report entitled ‘’OPTIMIZATION OF

INTERNAL TURNING PROGESS USING GENETIC
ALGORITHM FOR ALUMINIUM, CAST IRON AND MILD
STEEL’’ by HasrhvardhanRai, PrateekShivhare, HarshitAgrawal,
Faizan Khan is approved for the degree of Bachelor of Engineering
in Mechanical Engineering.

Name & Signature ofSupervisor Examiner Name & signature of External

Examiner

---------------------------- ----------------------------
---------------------------- ----------------------------

+
Name & signature RRC Members Name & signature of HOD

---------------------------- ----------------------------
---------------------------- ----------------------------

Date:

Place: Nagpur

1
 ACKNOWLEDGEMENT

With a profound feeling of immense gratitude and affection, we would like to thank our
Project guide Prof. PranjaliDeole for their continuous support, motivation, enthusiasm
& guidance. Their encouragement, supervision with constructive criticism and
confidence enabled us to complete this project.

We also wish to extend our reverences to Dr. K. N. Agrawal, Head of Mechanical

Engineering Department, for motivating me to put my best efforts in this project work.

We express our deep gratitude towards Dr. R.S. Pande, Principal for constant
motivation and providing necessary infrastructure.

We express our admirations for Dr. A.K. Jha (B.E. Project Coordinator) for his valuable
advice and support throughout this venture.

We would express our heartfelt gratitude to Mr. Vijay Tayade, Workshop Assistant for
always getting us out of the difficulties which we faced in the workshop.

We would express our special gratitude to Prof. Dr.Gajendra R Potey, Workshop

Superintendent for helping us at those moments when we were stuck up in our work
and were heading no way.

We feel indebted to Mr.Jamdar, M/s Kinetic Gears, Nagpur for providing us access to
their equipment to enable us to execute very important parts of our project.
The guidance and support received from all the faculty members of Mechanical
Department and Workshop of SRCOEM who contributed to this project was vital for
the success of the report. We are grateful for their constant support and help.

We also express our deepest gratitude to all the Suppliers who provided us with all the
material which we required to carry out our project work.

Finally, graceful thanks to family, friends, colleagues and everyone who has directly or
indirectly contributed to make this project a success.

HarshitAgrawal
HarshvardhanRai
Pratik Shivhare
Fizan Khan

2
 ABSTRACT

Internal turning is a basic machining operation, yet it presents its own set of
complexities. Internal turning operation is one of the most common operations done in
any manufacturing industry. Internal turning is the process of enlarging a hole that has
already been drilled (or cast), by means of a single-point cutting tool. Internal turning is
used to achieve greater accuracy of the diameter of a hole.

In our Research Project, we are analysing and studying the various process parameters
involved in the boring operation performed on CNC machine. The various parameters
are spindle speed, feed, depth of cut and work piece material. The main aim of our
research is to find out which process parameters contribute the highest towards surface
roughness of the work piece and the material removal rate of the insert on the turning
bar. We are following Taguchi method for varying each parameter for each
experimental run. We have used L9 orthogonal array for the four process parameter.
We have used Aluminium, Cast Iron and Mild Steel material for our experiment
because of their wide applications. In this project, determination of optimal machining
parameters to obtained minimum surface roughness and maximum material removal
rate by using GA which is a most widely used optimization method.

3
 TABLES OF CONTENTS

DESCRIPTON PAGE
NO
List of Figures
List of Tables
List of Figures
1.Introduction 1
1.1Machining Process 2
1.2 Internal Operations 3
1.3 Introduction to Internal Turning 4
Process
1.3.1 Types of Internal Turning 5
Operation
1.4 Factors Characterizing Internal 5
Turning Process
1.4.1 Machine Tool 6
1.4.2 Cuttimg Tool 6
1.4.3 Tool Geometry 6
1.4.4 Cutting Parameters 6
1.5 Control of Internal Turning Process 7
1.6 Summary 8
2. Literature Review 9
2.1 Study of Parametric Evaluation of 10
Cutting Parameters
2.2 Study of Genetic Algorithm for 12
Parameter
2.3 Findings from Literature 13
3. Aim and Objective 15
4. Methodology 17
4.1 Design of Experiments 19
4.1.1 Trial and Error Approach 19
4.1.2 Taguchi Approach 20
4.2 Advantages of DOE using Taguchi 20
Aproach
4.3 Steps in Taguchi Methodology 21
4.4 Selection of an Orthogonal Array 23
4.4.1 Selection of Input and Output 23
Factors
4.4.2 Selection of Levels of Factors 24
4.5 Genetic Algorithm 25
4.5.1 Introduction 25
4.5.2 Selection of Genetic Algorithm 26
structure
4.5.3 Selection of Control Parameters 27
4.5.4 Effect of Crossover Probability 28
and Mutation rate

4
5. Experimental Setup 29
5.1 Workpiece 30
5.2 CNC Machine 31
5.3 Tools used in CNC Machine 32
5.4 CNC Programming
5.5 ANOVA terms, Notations and 33
Development
5.6 Advantage of S/N ratio over average 36
6. Calculations 38
6.1 ANOVA calculations for Surface 39
Roughness
6.2 ANOVA calculations For MRR 43
6.3 GA calculations 55
7.Results,Conclusion and Future 58
Scope
7.1 Results 59
7.2 Conclusion 59
7.3 Future Scope 60
List of References 61
ANNEXURE
1. Project Group Members
2. Project Group Photo

5
 LIST OF FIGURES:

Figure Description

Figure4.1 Steps to be followed

Figure5.1 Work piece

Figure5.2 CNC experimental setup

Figure5.3 Experimental tool and turret setup

Figure6.1 Crossover(0.5)

Figure6.2 Crossover(0.3)

Figure6.3 Using bit string

Figure6.4 Mutation(0.8)

Figure6.5 Crossover(0.8)

LIST OF TABLES:

Table Description

Table 3.1 Taguchi L9 sequence

Table 4.1 Cutting parameter and levels

Table 4.2 Control parameters

Table 5.1 ANOVA calculations for surface

roughness 1
Table 5.2 ANOVA calculations for surface
roughness 2
Table 5.3 ANOVA calculations for MRR1

Table 5.4 ANOVA calculations forMRR2

LIST OF GRAPH:

Graph Description

Graph5.1 Residual plot for Ra

6
Graph5.2 Interaction plot for Ra

Graph5.3 Main effect plot for Ra

Graph5.4 Residual plot for MRR

Graph5.5 Interaction plot for MRR

Graph5.6 Main effect plot for MRR

Graph5.7 Main effect plot for SN ratio

Graph5.8 Residual plot for SN ratio

Graph5.9 Overall desirability

Graph5.10 Surface plot of speed VsRa,MRR

Graph5.11 Surface plotof feed VsRa,MRR

Graph5.12 Surface plot of DOC Vs Ra, MRR

Graph5.13 Contour plot of speed VS Ra, MRR

Graph5.14 Contour plot feed VsRa,MRR

7
CHAPTER 1
INTRODUCTION

8
CHAPTER 1: INTRODUCTION

Material removal processes are a group of manufacturing process in which excess

material is removed from the starting work piece so that the resulting shape is the
desired geometry. The excess material is removed in the form of small fragments
called chips and the process is referred to as machining. The body which removes the
excess material through direct mechanical contact is called cutting tool and the
machine which provides the necessary motions between the work piece and the tool is
called machine tool. Since material is removed in the form of chips, therefore the
machining of a finite area requires a continuous movement of the uncut portion
towards the cutting at a suitable rate.

1.1 MACHINING PROCESSES

Some of the major machining processes are as follows:

Drilling: This is used to make a hole in a solid body. The tool usually has two
cuttingedges, and the cutting motion is obtained by the rotation of the tool and
feeding motion is obtained by linear motion of the tool along its axis. The surface
generated is an internal cylindrical surface. Operations similar to drilling include
reaming (finishing an existing hole), boring (enlarging an existing hole) and hole
milling (improving hole geometry).

Shaping and planning: This is used to generate a plane surface. A single

pointcutting tool reciprocates to give cutting motion, and thus is is an intermittent
cutting operation. In shaping, the work piece is small and is thus advanced
perpendicular to cutting direction after every tool reciprocation to give feed motion.
In planning, the work piece is much larger and hence feed motion is given to the
tool.

Milling: This is a very versatile process and uses a rotary tool with multiple
cuttingedges to remove material. It can produce plane, contoured, axisymmetric or
complex surfaces based on the feed motion imparted to the cutting tool and the form
of the cutting tool itself. Various kinds of milling processes exist such as slab
milling, end milling, face milling, form milling, slot milling and thread milling.

Turning: This is widely used for producing external and internal

axisymmetricsurfaces. This requires a special machine called a lathe in which the
work piece is held and rotated to give cutting motion and a single point cutting tool
is moved against the work piece to provide feed motion. Turning generally refers to
machining of external surfaces and includes many operations such as straight
turning, taper turning, step turning, form turning, thread turning, facing, grooving
and parting off. The internal surfaces machining counterpart to turning is called
boring and includes straight boring, taper boring, counter boring, thread boring

9
Facing: - A single-point turning tool moves radially, along the end of the work
piece,removing a thin layer of material to provide a smooth flat surface. The depth
of the face, typically very small, may be machined in a single pass or may be
reached by machining at a smaller axial depth of cut and making multiple passes.

Grooving: - A single-point turning tool moves radially, into the side of the
workpiece, cutting a groove equal in width to the cutting tool. Multiple cuts can be
made to form grooves larger than the tool width and special form tools can be used
to create grooves of varying geometries.

1.2 INTERNAL OPERATIONS

Internal turning: - A Internal turning tool enters the work piece axially and
cutsalong an internal surface to form different features, such as steps, tapers,
chamfers, and contours. The Internal turning tool is a single-point cutting tool,
which can be set to cut the desired diameter by using an adjustable Internal
turning head. Internal turning is commonly performed after drilling a hole in order
to enlarge the diameter or obtain more precise dimensions.
Reaming: - A reamer enters the work piece axially through the end and enlargesan
existing hole to the diameter of the tool. Reaming removes a minimal amount of
material and is often performed after drilling to obtain both a more accurate
diameter and a smoother internal finish.
Tapping: - A tap enters the work piece axially through the end and cuts
internalthreads into an existing hole. The existing hole is typically drilled by the
required tap drill size that will accommodate the desired tap.
The family of turning operations seems most fascinating as it gives a wide variety
of products by using only a single point cutting tool. Today, various techniques are
being used in machining to improve the dimensional and geometrical accuracy of
products. For instance, tool balancing reduces chatter and improves surface finish
and dimensional accuracy considerably. But in case of turning, it is the work piece
which needs balancing and this increases the complexity of machining even
further. Another point to note is the significance of boring operation. Boring is said
to be the internal machining counterpart to turning as it is almost similar to turning
as both employ same machine, same fixtures and same tool movements. However,
in boring, the cutting tool is surrounded by the work piece, and thus it is much
more challenging than turning. Therefore, control of boring operation would be
more complicated as compared to other machining operations.

10
1.3 INTRODUCTION TO INTERNAL TURNING PROCESS

Internal turning is one of the most important machining operations. In this, a pre-
drilled, cast or pierced hole is enlarged to required size by using a single point cutting
tool. Internal turning operation serves the following purposes:

1. A hole of any size can be obtained by an internal turning tool (such as micro-
adjustable internal turning tool).On the other hand, drills and reamers have standard
and fixed diameters.
2. A hole of any required surface finish can be obtained by an internal turning tool by
adjusting machining parameters. In contrast, a reamer is required to finish a drilled
hole.
3. During drilling of comparatively long holes, the tool tends to deviate and „walk-
off‟from a straight line. Internal turning can straighten such holes.
4. In lathe, internal turning can make the hole at the work piece center concentric with
the outside diameter.
5. As much as the internal turning operation is beneficial, it suffers from certain
limitations too. Following are challenges faced during internal turning:
6. Maximum bore depth depends on the length of the internal turning tool.
7. Slender tooling‟s are susceptible to cantilever deflection.
8 .Tool clearance angle needs to be increased so that the tool flank may clear the
machined surface, but this reduces tool rigidity.
9. Less cutting speed/spindle speed has to be used compared to other machining
processes.
10. Evacuating chips from the machined bore is very difficult.
11.Surface of machined bore gets deteriorated due to rubbing of accumulated chips.
12.Inspection of machined surface is very difficult.

With its own tips, tricks, challenges and body of expertise, internal turning in lathes is
considered as an area of machining practice in its own right separate from turning.
Internal turning process will thus be seen in more detail.

11
1.3.1 TYPES OF INTERNAL TURNING OPERATION:

Internal turning operations are divided into following types:

 Single-edge cuts
 Multi-edge cuts
 Step-Internal turning

Single-edge Internal turning is usually applied for finishing operations and for roughing
and finishing in materials where chip control is demanding. A single-edge Internal
turning tool may also be a solution when machine power is a limiting factor.

Multi-edge Internal turning, involving two or three cutting edges, is employed for
roughing operations where metal removal rate is the first priority. High productivity
levels can be maintained by allowing two or three inserts, set at the same axial height,
each to machine at the recommended feed per tooth. This results in a high feed per
revolution through the hole.

Step-Internal turning is performed in roughing by a Internal turning tool having the

inserts set at different axial heights and diameters. This also improves chip control in
demanding materials with the different depths of cut of up to 1.0 or 1.5 times the
cutting edge length. Depths of cut of 0.5 times the cutting edge length can be divided
into smaller cuts, providing smaller chips. Reaming is a light finishing operation
performed with a multi edge tool giving high-precision holes. Very good surface finish
and close dimensional tolerance are achieved at high penetration rates. The pre-
machined hole needs to be within close limits and the radial depth of cut is small.

1.4 FACTORS CHARACTERIZING INTERNAL TURNING

PROCESS

Various factors characterize an internal turning process and control its outcome.
Following are some of the factors that characterize an internal turning process.

1.4.1. MACHINE TOOL

Internal turning can be carried out in machines such as horizontal boring machines,
vertical boring machines, jig borers and lathes. In lathes, jig borers and vertical boring
machines, a cylindrical work piece is rotated to enlarge a pre existing hole at the
center of the work piece. In other machines, a rotating internal turning tool is fed into
a clamped work piece to enlarge the pre-existing hole.

1.4.2. CUTTING TOOL

12
Boring bars of various designs are used for internal turning. Some of these are solid
bars, boring bars with fixed insert pockets and boring bars with adjustable insert
holders (or insert cartridges). The boring bar material may be steel, alloy steel or solid
carbide. The tool body may have an internal duct for supplying coolant to the cutting
edge. The boring bar slenderness (or length to diameter ratio) must be kept preferably
below 4 so that material removal rate does not get significantly impaired while trying
to reduce tool deflection. The bar diameter must be carefully selected to balance tool
deflection and ease of chip evacuation.

1.4.3. TOOL GEOMETRY:

A large clearance angle is used in internal turning to prevent the tool flank from
rubbing on the machined surface. Increasing rake angle reduces tangential cutting
forces, and also reduces support material below the cutting edge thereby reducing
tool strength. A small lead angle results in smaller cutting force in radial direction and
larger cutting force in axial direction. Thus, more force gets directed along the boring
bar, but then cutting forces get distributed over a shorter section of the cutting edge
leading to abrupt loading when tool engages with work piece. Chip breakers on the
tool are required in internal turning, otherwise long chips would get jammed in the
bore. However, this requires more power and can increase tool vibration. Chip
breaking is dependent on lead angle, nose radius, cutting speed, speed and depth of
cut.

1.4.4 CUTTING PARAMETERS:

The cutting speed, speed and depth of cut directly influence material removal rate.
Generally reduced feed and increased cutting speed increase chip length. Also, since
the tool edge has less base material for support, cutting speeds have to be reduced in
order to reduce cutting forces and prevent tool breakage. Increased cutting speeds will
also lead to increase in .tangential cutting forces, tool shank torsion and uneven
cutting depth, thereby deteriorating the bore form and geometry. However, at too low
cutting speeds, the shearing of work material does not progress without fracturing the
sheared portion, thus causing intermittent ruptures leading to discontinuous chips and
rough surface. Increased feed and depth of cut can lead to buckling and deflection of
the tool and increase the surface roughness. However, at too low depths of cut, the
tool edge is not able to shear the material. It digs into the material, thereby crushing
and hardening it. At too high depths of cut, the sheared material tends to have higher
temperature and stick to the tool causing a built up edge. The built up edge changes
the tool geometry and when enough material has stuck to the tool, it breaks off and
gets embedded in the work material leading to a very rough work surface. Low feeds
improve surface finish and tool life, but reduce material removal rate significantly.

1.5 CONTROL OF INTERNAL TURNING PROCESS

13
The outcome of an internal turning process is a bore satisfying the required
dimensional and geometrical accuracy at the least cost. The measurable responses in
an internal turning process include

1. Bore diameter
2. Bore surface finish
3. Bore roundness
4. Bore straightness
5. Bore taper
6. Tool wear
7. Tool vibration
8. Tool temperature
9. Power consumption
10. Acoustic emission

Several process parameters need to be controlled in order to improve the responses.

These factors include:
1. Work piece material
2. Work piece physical properties
3. Work piece metallurgical properties
4. Tool cutting speed
5. Tool feed
6. Depth of cut
7. Tool geometry
8. Tool slenderness
9. Tool material
10. Coolant type
11. Coolant concentration
12. Coolant pressure

1.6 SUMMARY

A process improvement project would consist of selecting and adjusting a number of

process parameters for improving one response. In this project work, three
parameters or factors are considered for controlling internal turning process:

1. Spindle speed
2. Feed rate
3. Depth of cut
4. Material used

14
CHAPTER 2
LITERATURE
REVIEW

15
CHAPTER 2: LITERATURE REVIEW

Any endeavour to improve a process involves referring to available literature in order to

understand the recent work done in that domain and find gaps in existing research. This
provides the opportunity and motivation to take up a project work.

REVIEW OF PUBLISHED LITERATURE

2.1 STUDY OF PARAMETRIC EVALUATION OF CUTTING PARAMETERS USING ANOVA -

Satish Chinchanikar present work performance of coated carbide tool was investigated
considering the effect of work material hardness and cutting parameters during turning
of hardened AISI 4340 steel at different levels of hardness. The correlations between the
cutting parameters and performance measures like cutting forces, surface roughness
and tool tip temperature, were established by multiple linear regression models. The
correlation coefficients found close to 0.9, showed that the developed models are
reliable and could be used effectively for predicting the responses within the domain of
the cutting parameters. Highly significant and optimized parameters were determined
by performing an Analysis of Variance (ANOVA).

S.R.Das used optimization methods in turning process, considered being a vital role for
continual improvement of output quality in product and process include modeling of
input-output and in process parameters relationship and determination of optimal
cutting conditions. This paper presents an optimal method of the cutting parameters
(cutting speed, depth of cut and feed rate) in dry turning of AISI D2 steel to achieve
minimum tool wear and low work price surface temperature. The experimental layout
was designed based on Taguchi L9 orthogonal array technique and analysis of variance
(ANOVA) was performed to identify the effect of cutting parameters on the response
variable. The results show that depth of cut and cutting speed is the most important
parameter influencing the tool wear. Similarly low work piece surface temperature was
obtained. The relationship between factors and performance measure were developed
by using multiple regression analysis.

Achyut K. Panda In this study, Taguchi method is used to identify the factors and their
interactions that may affect the thermo-catalytic degradation of waste polypropylene to
liquid fuel in a batch reactor. The yield of liquid fuel in this process was greatly
influenced by factors such as temperature, catalyst concentration and acidity of catalyst.
By using orthogonal experimental design and analysis technique, the performance of
this process can be analyzed with more objective conclusion through only a small
number of simulation experiments. Analysis of variance (ANOVA) was carried out to
identify the significant factors affecting the response and the best possible factor level
combination was determined through. Finally, a regression model for yield of liquid fuel
from catalytic degradation of waste polypropylene has been developed, as a function of
process parameters. It was found that yield of liquid fuel in this process were highly
dependent on temperature followed by acidity of catalyst and catalyst concentration.

16
Ramanuj Kumaret al, This paper works deals with the cutting forces and cutting
temperature during turning of titanium alloy Ti-6Al-4Vwith PVD Tin coated tungsten
carbide insert under dry environment. The first order mathematical models are
developed using multiple regression analysis and optimized the process parameters
using counter plots. The model present high determination coefficient (R2=0.964 and
0.989 explaining 96.4% and 98.9% of the variability in the cutting forces and cutting
temperature, which indicates the goodness of fit for the model and the high significance
of the model. The developed mathematical model correlates the relationship of the
cutting force and temperature with the process parameters with good degree of
approximation. Cutting speed is found to be the most significant parameter on cutting
forces followed by feed. Similarly, for cutting temperature, feed is found to be the most
influencing parameter followed by cutting speed.

Milenko Sekulicet al, Determination of optimal machining parameters is continuous

engineering task which goals are to reduce the production costs and to achieve the
desired product quality. This paper discusses the use of Taguchi‟s method for optimizing
the cutting parameters in turning for minimizing the tool-chip interface temperature.
The cutting temperature is a key factor which directly affects cutting tool wear,
workpiece surface integrity and machining precision. In this research work the tool-chip
interface temperature is measured experimentally during turning of Č1730 (EN C60)
steel with cemented carbide inserts using a tool-work thermocouple technique. The
study shows that the Taguchi method is suitable for optimizing the cutting parameters
with the minimum number of experiments. From the analysis using

Taguchi’s method, results indicate that among the all-significant parameters, cutting
speed is the most significant parameter. Results obtained from Taguchi method closely
match with ANOVA.

Rahul Bhatti et al,Hard Turning is a technique can be used in machining the steel with
hardness greater than 45 HRC (hardness on the Rockwell test c-scale). We consider AISI
H11 as work piece and Multi-coated carbide TH1500 (CVD) as cutting tool. For this
experiment, the L9 Taguchi method is used. The Taguchi method is an Experimental
design technique, which is useful in reducing the number of experiments dramatically by
using an orthogonal array and also tries to minimize effects out of control. During an
investigation the cutting conditions for an experiment are Speed = 100, 120 & 140
m/min, Feed = 0.1, O.2 & O.3 rev/min , D.O.C = 0.2, 0.4, & 0.6 mm . It is observed that
the tool wear (flank wear) is mainly effected by the cutting speed is found to be the
most contributing factor with percentage contribution of 89.83% while in case of surface
roughness also the cutting speed is found to be the most contribution factor with
67.11%. The optimized machining condition for minimizing tool wear from Taguchi
Method are: cutting speed 100 m/min, feed 0.20 mm/rev, depth of cut 0.60 mm with an
estimated flank wear 130 μm. The optimized machining condition for minimizing tool
wear from Taguchi Method is: cutting speed 120 m/min, feed 0.20 mm/rev, D.O.C
0.25mm with an estimated surface roughness of 0.86 μm. Also, CVD

Multi-coated carbide cutting tool inserts employed in current investigation have been
observed to be an economical alternative to costly CBN, PCBN, Ceramic tools, for

17
continuous hard turning application over the range of parameters selected for this
study. In future, the effect of varying in work piece hardness may also be investigated.
The Chips forms using the same material with CVD Multi-coated Carbide cutting tool
inserts may be carried out to improve machining performance.

K. Someswara Raoet al, Niobium based super alloys are an unusual class of metallic
materials with an exceptional combination of high temperature strength, toughness,
and resistance to degradation in corrosive or oxidizing environments. The focus of
present work was to study the effect of cutting parameters – speed, feed and depth of
cut on the machinability of Niobium C-103 under dry machining condition using
response surface methodology (RSM)1. In present study various machinability models
were developed. This machinability models defined a functional relationship between
cutting variables and response (Cutting Temperature). Cutting levels for
experimentation was selected based on the cutting insert manufacturer
recommendations. The analysis shows that Cutting speed is the most evident factor for
cutting temperature.

2.2 STUDY OF GENETIC ALGORITHM FOR PARAMETER

OPTIMIZATION
Jabriet al, In this paper present a multi-optimization technique based on genetic
algorithms to search optimal cuttings parameters such as cutting depth, feed rate and
cutting speed of multi-pass turning processes. This paper presents a multi-objective
optimization of turning process. Multi-pass turning operation is considered in this study
and the objective was to select cutting parameters of turning operation (cutting speed,
feed rate and depth of cut) which minimizes simultaneously cutting cost and used tool
life subject to practical constraints.

Mir Asif Iquebal, Genetic Algorithm (GA) is a calculus free optimization technique based
on principles of natural selection for reproduction and various evolutionary operations
such as crossover, and mutation. Various steps involved in carrying out optimization
through GA are described. Three applications, viz. finding maximum of a mathematical
function, obtaining estimates for a multiple linear regression model, and fitting a
nonlinear statistical model through GA procedure, are discussed. Finally, results are
compared to those obtained from standard (calculus based) solution techniques.

M.Sanjeevkumar, (IJMER) In this paper an attempt is made to use of genetic algorithm

to minimize the surface roughness by optimizing the depth of cut, feed rate and cutting
speeds. Obtained a optimum values of cutting parameters to achieve a minimum surface
roughness of tool.

Dusan Petkovicet al, Optimization methods of machining processes are tools for
improving product quality and reducing cost and production time. Modern optimization
methods, among which genetic algorithms (GA) have been, used a lot during last two
decades. This paper describes the optimization of machining processes by using genetic

18
algorithms. Optimal parameters of machining (cutting speed and feed) were
determined. Also, minimal cost for the turning process was achieved.

2.3 FINDINGS FROM LITERATURE

After reviewing the literature of recent work done, the following observations were
made:

1. The most common control factors in case of internal turning process are cutting
speed, feed and depth of cut. However, the effect of tool slenderness was not
studied.

2. The most common response variable was surface roughness, and this response
was not limited to internal turning process only.

3. The use of multi-objective function was becoming very much common, which is a
reflection of the challenges faced in the real world.

4. In some cases, multi-objective optimization was done by taking mainly those

responses which affected quality. For productivity improvement, the control
variables move in a direction opposite to that for quality improvement. Thus
practicality must be considered while opting for multiple objectives.

5. One approach for multi-objective optimization is to give weights to the responses

and combine them to form a composite response. The most common methods
used were desirability function.

6. In all publications, only one set of weights was taken for combining responses. A
more real world consideration would involve analyzing the process by taking not
one, but different combinations of relative weights.

7. Direct multi-objective optimization gives a set of non-dominated solutions in

which further improving one objective at a solution point would worsen all other
objectives. The use of this technique was uncommon in machining processes.

19
CHAPTER 3:
AIM AND
OBJECTIVE

20
CHAPTER 3: AIM AND OBJECTIVE

The following objectives would have to be realized in order to fulfill the aim of the
project work:

 To design a suitable combination of experimental runs using Taguchi L9

methodology.

 To conduct experiments on aluminium, cast iron, mild steel work piece in CNC
turning centre.

 To optimize internal turning process parameters using Genetic Algorithm (GA).

21
CHAPTER 4
METHODOLOGY

22
CHAPTER 4: METHODOLOGY

Steps to be followed.

Figure 4.1

4.1 DESIGN OF EXPERIMENTS

An experiment can be defined as a test or series of runs in which purposeful changes are
made to the input variables (or treatments) of a system or process so that changes in the
output response variable (or experimental units) may be observed and the reasons for the
same may be identified. Some process variables x1, x2, …xp are controllable, whereas other
variables z1, z2, … zq may be uncontrollable. An experiment serves the following purposes:

23
  Determine which variables x1, x2, …xp are most influential on response y.

 Determine where to set the influential x’s so that y is always near to the desired
nominal value.

 Determine where to set the influential x’s so that variability in y is minimum.

 Determine where to set the influential x’s so that effects of uncontrolled variables is
minimum.

Design of Experiments refers to the process of planning, designing and analyzing the
experiment so that valid and objective conclusions can be drawn effectively and efficiently.
In order to draw statistically sound conclusions from the experiment, it is necessary to
integrate simple and powerful statistical methods into the experimental design
methodology. The success of any industrially designed experiment depends on sound
planning, appropriate choice of design, statistical analysis of data and teamwork skills. Some
important contributors to the field of experimental designs are R. A. Fisher, C. R. Rao, R. C.
Bose, D. R. Cox,G. E. P. Box and G. Taguchi.
Every experimenter has to plan and conduct experiments to obtain enough and relevant
data so that he can infer the science behind the observed phenomenon. The various
methods available are:

4.1.1. TRIAL-AND-ERROR APPROACH

Performing a series of experiments each of which gives some understanding requires

making measurements after every experiment so that analysis of observed data will allow
him to decide what to do next - "Which parameters should be varied and by how much".
Many a times such series does not progress much as negative results may discourage or will
not allow a selection of parameters which ought to be changed in the next experiment.
Therefore, such experimentation usually ends well before the number of experimental runs
reaches a double digit. The data is insufficient to draw any significant conclusions and the
main problem (of understanding the science) still remains unsolved.

4.1.2 TAGUCHI APPROACH

Dr. Taguchi of Nippon Telephones and Telegraph Company, Japan has developed a method
based on “ORTHOGONAL ARRAY” experiments which gives much reduced “variance” for the
experiment with “optimum settings “of control parameters. Thus the marriage of Design of
Experiment with optimization of control parameters to obtain best results is achieved in the
Taguchi Method. "Orthogonal Arrays" (OA) provide a set of well balanced (minimum)
experiments and Dr. Taguchi's Signal-to-Noise ratios (S/N), which are log functions of
desired output, serve as objective functions for optimization, help in data analysis and
prediction of optimum results.

4.2 ADVANTAGES OF DOE USING TAGUCHI APPROACH

24
The application of DOE requires careful planning, prudent layout of the experiment, and
expert analysis of results. Thus, DoE using the Taguchi approach has become a much more
attractive tool to practicing engineers and scientists. Based on years of research and
applications Dr. Genechi Taguchi has standardized the methods for each of these DoE
application steps described below.

Experiment planning and problem formulation - Experiment planning guidelines are

consistent with modern work disciplines of working as teams. Consensus decisions about
experimental objectives and factors make the projects more successful.

Experiment layout -High emphasis is put on cost and size of experiments. Size of the
experiment for a given number of factors and levels is standardized. Approach and priority
for column assignments are established. Clear guidelines are available to deal with factors
and interactions (interaction tables). Uncontrollable factors are formally treated to reduce
variation. Discrete prescriptions for setting up test conditions under uncontrollable factors
are described. Guidelines for carrying out the experiments and number of samples to be
tested are defined. Data analysis -Steps for analysis are standardized. Standard practice for
determination of the optimum is recommended. Guidelines for test of significance and
pooling are defined.

Interpretation of results - Clear guidelines about meaning of error term. Discrete indicator
about confirmation of results (Confidence interval).

Overall advantage - DoE using Taguchi approach attempts to improve quality which is
defined as the consistency of performance. Consistency is achieved when variation is
reduced. The prime motivation behind the Taguchi experiment design technique is to
achieve reduced variation (also known as ROBUST DESIGN). This technique, therefore, is
focused to attain the desired quality objectives in all steps. The classical DoE does not
specifically address quality.

4.3 Steps in Taguchi Methodology

Taguchi method is a scientifically disciplined mechanism for evaluating and implementing

improvements in products, processes, materials, equipment, and facilities. These
improvements are aimed at improving the desired characteristics and simultaneously
reducing the number of defects by studying the key variables controlling the process and
optimizing the procedures or design to yield the best results.

The method is applicable over a wide range of engineering fields that include processes that
manufacture raw materials, sub systems, products for professional and consumer markets.
In fact, the method can be applied to any process be it engineering fabrication, computer-
aided-design, banking and service sectors etc. Taguchi method is useful for 'tuning' a given
process for 'best' results.

Taguchi proposed a standard 8-step procedure for applying his method for optimizing any
process,

25
8-STEPS IN TAGUCHI METHODOLOGY:

STEP-1: Identify the main function, side effects, and failure mode

STEP-2: Identify the noise factors, testing conditions, and quality characteristics

STEP-3: Identify the objective function to be optimized

STEP-4: Identify the control factors and their levels

STEP-5: Select the orthogonal array matrix experiment

STEP-6: Conduct the matrix experiment

STEP-7: Analyze the data; predict the optimum levels and performance

STEP-8: Perform the verification experiment and plan the future action

In this Experimentation, we are using L9 (34) orthogonal array. An array's name, for example,
L9 (34) indicates 9 number of rows, 4 columns and 3 number of levels in each column. The
number of columns of an array indicates the maximum number of factors or parameters,
which can be considered using that array. Number of rows represents the number of
experiments to be carried out. In order that an array is a viable choice, the number of rows
must be at least equal to the degree of freedom required for the case study. The degree of
freedom of a factor is equal to the number of levels of a factor minus one and for an
interaction among factors; it is equal to multiplication of degree of freedom of individual
factors. Usually, the smallest possible orthogonal array that meets the requirement of the
case study is selected for the experiment i.e. L9.

4.4 SELECTION OF AN ORTHOGONAL ARRAY

Selection of an orthogonal array depends on the selection of the number of factors, their
operating levels and their interactions. These aspects may be discussed before selecting an
array.

4.4.1 Selection of Input and Output Factors

The input factors set for the boring operation are as follows:

1. Spindle speed - The rotational speed of the spindle and the work piece in revolutions per
minute (RPM). The spindle speed is equal to the cutting speed divided by the circumference
of the work piece where the cut is being made. In order to maintain a constant cutting

26
speed, the spindle speed must vary based on the diameter of the cut. If the spindle speed is
held constant, then the cutting speed will vary.

2. Feed rate - The speed of the cutting tool's movement relative to the work piece as the
tool makes a cut. The feed rate is measured in mm per revolution.

3. Depth of cut - The depth of the tool along the radius of the work piece as it makes a cut,
as in a turning or boring operation. A large depth of cut will require a low feed rate, or else it
will result in a high load on the tool and reduce the tool life. Therefore, a feature is often
machined in several steps as the tool moves over at the depth of cut.

4. Work piece material – The work piece material used for the boring operation were
Aluminium, Cast iron and mild steel.

The output factors set for the internal turning operation are as follows:

Surface Roughness – The surface roughness of the work piece was obtained after the
machining was measured. The unit of the surface roughness is Ra.

Material Removal Rate – The formula for material removal is

MRR= Cross section removed * Bore length

Bore length / Feed rate per min

4.4.2 Selection of Levels of Factors

The nature of variation of response with respect to a particular factor helps in deciding the
level of the factor. If the variation is linear, a factor with two levels is chosen. However, the
levels shall be decided carefully if the variation is non-linear in nature. The nature of
variation, linear or non-linear, is judged by the previous machining experience. In the
present case of boring experiments, the levels of the factors are decided to be THREE for all
the four factors.

Cutting parameters and levels

SR.NO. Spindle Speed Depth of cut Feed rate Material used

M
(RPM) (mm) (mm/rev)

1 200 0.3 0.10 Aluminum

27
 2 300 0.5 0.12 Cast Iron

3 400 0.7 0.15 Mild Steel

Table4.1

Orthogonal Array Plan for experiments

The array depicted by L9 (34) from Taguchi's Standard Orthogonal Array has been chosen for
boring process. The reasons for the choice of the array are listed in the following:
The array gives minimum number of experiments to be performed with factor level chosen
as per the requirement.
It does not have any mixed levels.
It considers the necessary interaction effects.

4.5 GENETIC ALGORITHM

4.5.1. INTRODUCTION

The mathematical model is optimized using Genetic Algorithm to determine optimum

values of input parameters to achieve minimum surface roughness and maximum Material
removal rate. Genetic algorithms (GAs) have been found to be robust in finding the
optimum solutions for various engineering optimization problems.

In brief, genetic algorithms (GA’s) iterate on a set of solutions “population” that are
randomly initialized. Each solution consists of all variables that are assigned a value within
its lower and upper bounds. Then the process of generating new solutions commences after
assigning fitness values for each solution (chromosome) accomplished by main operators.
These main operators are known as: selection, recombination (crossover), and mutation. In
addition, to ensure the solution does not become totally random the best solution will
remain in the new generation. This process is known as “replacement”.

The problem variables are combined together in a term known as a “chromosome” and part
of it is named as “gene”. Practically, the chromosome(s) is encoded in a concatenated string
of binary numbers (binary encoding), or a vector of real values (real encoding). In the case of
the binary encoding, a gene is represented by a single bit in the binary string (the value of a
problem variable being represented by several bits). In contrast, real encoded GAs operate
directly on the real value of the problem variable.

4.5.2. SELECTION OF GENETIC ALGORITHM STRUCTURE

Genetic algorithm structure incorporates the five main operations in iteration to create the
new chromosome. In contrast to a real vector chromosome, a binary encoding has

28
potentially greater exploratory power than a real vector chromosome, and naturally lends
itself operating with both discrete and continuous variables.

i. Binary encoding

Both continuous and discrete variables can be encoded in a binary chromosome through
controlling the number of bits assigned to a given variable (a three bit encoding will result in
8 discrete values for the variable). The inherent encoding of mixed-integer problems and the
associated control of variable precision, make a binary encoding very useful in the solution
of optimization problems.

ii. Fitness assignment

In this study, we seek to minimize the surface roughness and therefore, the lower the
surface roughness, the higher the fitness of an individual selection. Then, solutions will be
ranked-ordered (stochastic ranking) based on the surface roughness obtained from
objective function. Hence the stochastic ranking will simply rank all solutions based on their
objective function values alone. It sorts the solutions in order of the “best” to the “worst”.

iii. Selection

The selection operator is used to select solutions from the current population that will be
used to form the next population of solutions (this being the basis for the next iteration of
the algorithm).

iv. Crossover

The recombination operator controls the mixing of “genetic information” selected from
paired individuals through a process known as “crossover” (each individual in the pair
resulting from a separate tournament selection). It takes place by swapping bit values
between the two individuals. In the “uniform crossover” operator used in this research,
each pair of bits is swapped with a 50% probability (an average of 50% of the bits will be
swapped). The effect of chromosome crossover probability on the performance of the
search is examined here by application , apart from this taking 30% and 80% probabilty also
the solutions were optained.

v. Mutation

A probabilistic bit-wise mutation, in which a given gene value if flipped from 0 to 1, or vice
versa, was adopted in this study. The effect of mutation probability on the performance of
the search is examined here through applications ,the default value was kept at 0.01 and
the experimentation was also performed for the value 0.8.

4.5.3. SELECTION OF CONTROL PARAMETERS

29
Naturally, GAs have many parameters that need to be tuned in order to find the best
performance for any optimization problem. The main control parameters are the population
size, selection operator, the crossover probability pc; and the mutation probability pm. In
order to identify suitable control parameter values for solving the performance of the GA
will be evaluated for several different sets of these parameters.
see Table 4.2
From the combination of these control parameters, different sets of GA control parameters
will be tested. It is known that GAs are a probabilistic optimizer, repeated runs are required
(10 different runs) to eliminate the effects of the initial random selected solution.

Control parameter Values

Population size (_) 200

Probability of Crossover [0.3, 0.7, 0.8]

Probability of Mutation [0.01, 0.8]

Table 4.2

4.5.4. EFFECT OF CROSSOVER PROBABILITY AND MUTATION RATE

The results show that GA performance is not-sensitive to most control parameter values,
such as crossover probability and mutation rate, since there was no statistically significant
difference between the optimum solutions. the smallest population sizes showed a greater
reduction rate for a smaller number of simulation calls (less than 350) compared with the
other population sizes. Although the crossover probability and mutation rate showed less
sensitivity on the GA performance, there are some evidences that suggested that they are
performing better with the higher crossover probability (0.7) and lower mutation rate
(0.01). Ultimately, a general conclusion that was possibly drawn at the end of this study is
that the small population size, high crossover probability, and low mutation rate are the
most appropriate control parameter sets for the optimization problem.

30
 CHAPTER 5
EXPERIMENTAL
SET UP

31
CHAPTER 5. EXPERIMENTATION

In the previous chapter, the factor levels of control factors were selected and a sequence of
experiments was determined. However, in order to carry out a machining experiment
successfully, various entities have to come together. These include the workpiece, machine
and tooling.

5.1. WORKPIECE

The material chosen for experimentation was Aluminium, Cast Iron, Mild Steel. The
workpiece dimensions were fixed at mm diameter and 80mm length. Boring experiments
would be carried out at both ends of the workpieces.

Figure 4.1

5.2 CNC MACHINE

The specifications of the CNC lathe machine which was used for the experimentation
purpose is given below:
2 axis slant bed lathe
Max. Turning diameter = 165mm
Max turning length =235 mm

32
 Distance between the centers = 380 mm
Dimensions of machine : L=2300mm, H= 1900mm, W=1600mm
8 Station CNC Turret - 4 Rectangular and 4 Circular
The CNC lathe machine can be used for turning, facing, drilling, boring, threading and other
operations.

Figure 4.2

5.3 TOOLS USED IN CNC LATHE MACHINE

a) Turning tool

Turning is a machining process in which a cutting tool, typically a non-rotary tool bit,
describes a helical tool path by moving more or less linearly while the work piece rotates.
The tool's axes of movement may be literally a straight line, or they may be along some set
of curves or angles, but they are essentially linear (in the nonmathematical sense). Usually
the term "turning" is reserved for the generation of external surfaces by this cutting action,
whereas this same essential cutting action when applied to internal surfaces (that is, holes,
of one kind or another) is called "boring". Thus the phrase "turning and boring" categorizes
the larger family of (essentially similar) processes. The cutting of faces on the work piece

33
(that is, surfaces perpendicular to its rotating axis), whether with a turning or boring tool, is
called "facing", and may be lumped into either category as a subset.

Figure 4.3

5.4 ANOVA TERMS, NOTATIONS AND DEVELOPMENT

In the analysis of variance many quantities such as degrees of freedom, sums of square,
mean square etc. are computed and organized in a standard tabular format. These
quantities and their interrelationships are defined below and their mathematical
development is presented.

Total number of trials [n] : - It is the addition of all the experimental trials performed at
different levels to determine the effect of different factors on the response.
n  n1 n2... nt

Degrees of freedom [DOF, f] :- It is a measure of the amount of information that can

beuniquely determined from a given set of data. DOF for data concerning a factor equals
one less than the number of levels. Thus a 3 level factor has 2 DOF. The concept of DOF can
be extended to the experiment. An experiment with n trial and r repetitions of each trial has
n X r trial runs. The total DOF becomes:
ft n  r 1
Similarly, the DOF for a sum of squares term is equal to the number of terms used to
compute the sum of squares and the DOF of the error term is given by
fe ft f A f B fC

34
Sum of Squares [St]: - The sum of squares is a measure of the deviation of theexperimental
data from the mean value of the data. Summing each squared deviationemphasizes the
total deviation. Thus
n
St(Yi Y )2
i 1

Variance [V]:- Variance measures the distribution of the data about the mean of the
data.Since the data is representative of only a part of all possible data. DOF rather than the
number of observations is used in the calculation. It is the ratio of sum of squares to the
degrees of freedom
V = St / F

5. Variance Ratio [F]:- The variance ratio commonly called the F statistic, is the ratio
ofvariance due to the effect of a factor and variance due to the error term. It is named after
Sir Ronald A. Fisher. This ratio is used to measure the significance of the factor under
investigation with respect to the variance of all the factors included in the error term. The F
value obtained in the analysis is compared with a value from standard F-tables for a given
statistical level of significance. The tables for various significance levels and different
degrees of freedom are available in most handbooks of statistics. To use the tables enter
the DOF of the numerator to determine the column and the DOF of the denominator for the
row. The intersection is the F value. When the computed F value is less than the value
determined from the F tables at the selected level of significance, the factor does not
contribute to the sum of the squares within the confidence level.
F = V / Vt
Pure sum of squares:- When the product of error variance and degrees of freedom
issubtracted from the sum of squares expression, the remainder is called the pure sum of
squares.

Percent Contribution [P]:- The percent contribution for any factor is obtained bydividing the
pure sum of squares for that factor by St and multiplying the result by 100.

Confidence Intervals (C.I.): - The calculations shown in the ANOVA table are only estimates
of the population parameters. These statistics are dependent upon the size of the sample
being investigated. In statistics, it is therefore customary to represent the values of a
statistical parameter as a range within which it is likely to fall, for a given level of
confidence. This range is termed as the confidence interval (C.I.). If the estimate of the
mean value of a set of observations is denoted by E(m), then the CI for the mean is given by:

f1 = DOF of mean (which always equals 1)

f2 = DOF of error term.
Ve = Variance of error term.
ne = number of equivalent replications and is given by:

ne = (Number of trials)

35
 [DOF of mean (always 1) + DOF of the factors used in the estimate]

Pooling: When the contribution of a factor is small, the sum of squares for that factor is
combined with the error Se. This process of disregarding the contribution of a selected
factor and subsequently adjusting the contributions of the other factor is known as Pooling.
Pooling is usually accomplished by starting with the smallest sum of squares and continuing
with the ones having successively larger effects. Pooling is recommended when a factor is
determined to be insignificant by performing test of significance against the error term at a
desired confidence level. A general guideline for when to pool is obtained by comparing
error DOF with the total factor DOF. No matter the effect on the results, insignificant factors
should always be pooled. The larger DOF for the error term as a result of pooling increases
the confidence level of the significant factors.

S/N Ratio: The change in the quality characteristics of a process under investigation,
inresponse to a factor introduced in the experiment design is the “signal” of the desired
effect. However, when an experiment is conducted, there are numerous external factors
not designed into the experiment which influence the outcome. These external factors are
called the noise factors and their effect on the outcome of the quality characteristic under
test is termed “the noise”. The signal to noise ratio (S/N ratio) measures the sensitivity of
the quality characteristic being investigated in a controlled manner, to those external
influencing factors (noise factors) not under control. The aim of any experiment is always to
determine the highest possible S/N ratio for the result. A high value of S/N implies that the
signal is much higher than the random effects of the noise factors. Process operation
consistent with highest S/N , always yields the optimum quality with minimum variance.
The S/N analysis is designed to measure quality characteristics. From the quality point of
view, there are three possible categories of quality characteristics. They are:
 Smaller is better.
 Nominal is best.
 Bigger is better.
 Smaller-the-better

This is expressed as
n= - 10Log10 [mean of sum of squares of measured data]
This is usually the chosen S/N ratio for all the undesirable characteristics like “defects” for
which the ideal value is zero. When an ideal value is finite and its maximum or minimum
value is defined then the difference between the measured data and the ideal value is
expected to be as small as possible. Thus, the generic form of S/N ratio becomes,
n= - 10Log10 [mean of sum of squares of (measured – ideal)]

 Larger-the-better
This is expressed as
n= - 10Log10 [mean of sum of squares of reciprocal of measured data]
This is often converted to smaller-the-better by taking the reciprocal of the measured data
and next, taking the S/N ratio as in the smaller-the-better case.

 Nominal-the-best
36
This is expressed as
n= - 10Log10 [Square of mean/Variance]
This case arises when a specified value is the most desired, meaning that neither a smaller
nor a larger value is desired.

5.6 Advantages of S/N ratio over average

To analyze the results of experiments involving multiple runs, use of the S/N ratio over
standard analysis (use average of results) is preferred. Analysis using the S/N ratio will offer
the following two main advantages:

It provides guidance to a selection of the optimum level based on least variation around the
target and also on the average value closest to the target.

It offers objective comparison of two sets of experimental data with respect to variation
around the target and the deviation of the average from the target value.

Use of the S/N ratio of the results, instead of the average values, introduces some minor
changes in the analysis. Whenever an experiment involves repeated observations at each of
the trial conditions, the S/N ratio has been found to provide a practical way to measure and
control the combined influence of deviation of the population mean from the target and the
variation around the mean.

11. R-square
R-squared is a statistical measure of how close the data are to the fitted regression line. It is
also known as the coefficient of determination, or the coefficient of multiple determinations
for multiple regressions.
The definition of R-squared is fairly straight-forward; it is the percentage of the response
variable variation that is explained by a linear model. Or:

R-squared = Explained variation / Total variation

R-squared is always between 0 and 100%.0% indicates that the model explains none of the
variability of the response data around its mean.

100% indicates that the model explains all the variability of the response data around its
mean.

In general, the higher the R-squared, the better the model provides a decent fit to the data.

12. Residuals
Residuals of a observed value is the difference between the observed value and estimated
function value.
Residual=Observed value – Fitted value

13. Regression Equation

37
Linear regression calculates an equation that minimizes the distance between the fitted line
and all of the data points. Technically, ordinary least squares (OLS) regression minimizes the
sum of the squared residuals.
In general, a model fits the data well if the differences between the observed values and the
model's predicted values are small and unbiased.

38
 CHAPTER 6:
CALCULATIONS

39
CHAPTER 6: CALCULATIONS

ANOVA TERMS
DOF – Degree of freedom
SS- Sum of Squares
MS- Mean Square
F, P- Statistical Parameters of ANOVA

6.1 ANOVA CALCULATIONS FOR SURFACE ROUGHNESS

SOURCE DF ADJ SS ADJ MS F- VALUE P-VALUE

SPEED 2 1.5022 0.7511 0.65 0.607
FEED 2 2.7818 1.3909 1.20 0.455
DOC 2 0.2454 0.1227 0.11 0.904
ERROR 2 2.3288 1.1614
TOTAL 8 6.852
Table6.1
S R-SQ R-SQ(ADJ) R-SQ(PRED)
1.0769 66.1% 0% 0%
Table6.2
Regression Equation:-
Ra = 2.211 + 0.489 Speed_200 + 0.022 Speed_300 - 0.511 Speed_400 - 0.421 Feed_0.10
+ 0.786 Feed_0.12 - 0.364 Feed_0.15 -0.154 DOC_0.3 + 0.229 DOC_0.5 - 0.074 DOC_0.7

Column 1 represents variable sources such as spindle speed, feed, and depth of cut. In next
columns degree of freedom (DF), adjusted sum of square (Adj SS), adjusted mean of square
(Adj MS), distribution (F) and probability (P) are calculated respectively. The standard
deviation of errors in modelling, S= 2.3288, R2 =66.1% which indicates that model is not
capable of predicting response with higher accuracy.

40
 Graph6.1

There are three assumptions in ANOVA analysis: normality, constant variance, and
independence. The normality plot of the residuals is used to check the normality of the
treatment data. If the distribution of residuals is normal, the plot will resemble a straight
line. Here, since the distribution of residuals is about the straight line, it confirms the
normality of treatment data. The constant variance assumption is checked by the plot of
residuals versus fitted values. If the plot of residual vs. fitted values (treatment) does not
show any pattern, the constant variance assumption is satisfied. The residuals v/s fitted
value plot confirms the second assumption of constant variance as there is no specific
pattern can be detected. If the plot of residual vs. run order (time order of data collection)
does not reveal any pattern, the independence assumption is satisfied. Here as there is no
specific pattern detected, the assumption of independence is satisfied.

41
 Gaph6.2

When the effect of one factor depends on the level of the other factor, one can use an
interaction plot to visualize possible interactions. Parallel lines in an interaction plot indicate
no interaction. The greater is the difference in slope between the lines, the higher the
degree of interaction. However, the interaction plot doesn't alert you if the interaction is
statistically significant.

Since the factors are more than two, the matrix for interaction plot is shown in the graph. In
this graph, the first row shows the interaction plot between spindle speed vs feed, spindle
speed vs depth of cut, spindle speed vs workpiece material. From this we can conclude that
there is interaction between spindle speed, feed, depth of cut and workpiece material for
different levels.

The second row shows the interaction plot between feed vs depth of cut and feed vs
workpiece material. As different lines have steep slope and intersecting each other, there is
significant interaction. The third plot is between depth of cut vs workpiece material. Since
all the lines are intersecting, there is interaction between depth of cut and workpiece
material.

42
 Graph6.3

When the line is horizontal (parallel to the x-axis), then there is no main effect. Each level of
the factor affects the response in the same way, and the response mean is the same across
all factor levels. When the line is not horizontal, then there is a main effect. Different levels
of the factor affect the response differently. The steeper is the slope of the line, the greater
the magnitude of the main effect.

This plot is plotted against the data means for surface roughness and spindle speed, feed,
depth of cut, workpiece material. From spindle speed 150 rpm to 200 rpm the surface
roughness decreases but From 200 rpm to 250 rpm the surface roughness increases. For the
feed rate of 0.08mm/rev the surface roughness is low but it increases for feed rate 0.09
mm/rev and again decreases for a feed rate 0.10 mm/rev. The mean values increases as
depth of cut increases from 0.2 to 0.3 and decreases again for 0.4mm.The MS_1 workpiece
has the highest value for surface roughness and CI_2 has the lowest surface roughness. This
means that, the MS material gives the good surface finish as compared to EN 8 grade CI for
defined levels of parameters

6.2 ANOVA CALCULATIONS FOR MRR

SOURCE DF ADJ SS ADJ MS F VALUE P VALUE
SPEED 2 11655345 5827672 9.11 0.099
FEED 2 2875732 1437866 2.25 0.308
DOC 2 16782369 8391185 13.12 0.071

43
ERROR 2 1279116 639558
TOTAL 8 32592563
Table6.3
S R-SQ R-SQ(ADJ) R-Q(PRED)
799.724 96.08% 84.3% 20.53%
Table6.4

Regression Equation:-
MRR = 4579 - 1335 Speed_200 - 111 Speed_300 + 1446 Speed_400 -504 Feed_0.10 -
285 Feed_0.12+ 789 Feed_0.15 - 1749 DOC_0.3 + 167 DOC_0.5 + 1583 DOC_0.7

In Table7.1.2, column 1 represents variable sources such as spindle speed, feed, and depth
of cut. In next columns degree of freedom (DF), adjusted sum of square (Adj SS), adjusted
mean of square (Adj MS), distribution (F) and probability (P) are calculated respectively. The
standard deviation of errors in modelling, S= 799.724, R2 =96.08% which indicates that
model is capable of predicting response with higher accuracy.

Graph6.4

There are three assumptions in ANOVA analysis: normality, constant variance, and
independence. The normality plot of the residuals is used to check the normality of the
treatment data. If the distribution of residuals is normal, the plot will resemble a straight
line. Here, since the distribution of residuals is about the straight line, it confirms the
normality of treatment data. The constant variance assumption is checked by the plot of

44
residuals versus fitted values. If the plot of residual vs. fitted values (treatment) does not
show any pattern, the constant variance assumption is satisfied. The residuals v/s fitted
value plot confirms the second assumption of constant variance as there is no specific
pattern can be detected. If the plot of residual vs. run order (time order of data collection)
does not reveal any pattern, the independence assumption is satisfied. Here as there is no
specific pattern detected, the assumption of independence is satisfied.

Graph 6.5

When the effect of one factor depends on the level of the other factor, one can use an
interaction plot to visualize possible interactions. Parallel lines in an interaction plot indicate
no interaction. The greater is the difference in slope between the lines, the higher the
degree of interaction. However, the interaction plot doesn't alert you if the interaction is
statistically significant.

Since the factors are more than two, the matrix for interaction plot is shown in the graph. In
this graph, the first row shows the interaction plot between spindle speed vs feed, spindle
speed vs depth of cut, spindle speed vs workpiece material. From this we can conclude that
there is interaction between spindle speed, feed, depth of cut and workpiece material for
different levels.

The second row shows the interaction plot between feed vs depth of cut and feed vs
workpiece material. As different lines have steep slope and intersecting each other, there is
significant interaction. The third plot is between depth of cut vs workpiece material. Since
all the lines are intersecting, there is interaction between depth of cut and workpiece
material.

45
 Graph6.6

When the line is horizontal (parallel to the x-axis), then there is no main effect. Each level of
the factor affects the response in the same way, and the response mean is the same across
all factor levels. When the line is not horizontal, then there is a main effect. Different levels
of the factor affect the response differently. The steeper is the slope of the line, the greater
the magnitude of the main effect.

This plot is plotted against the data means for surface roughness and spindle speed, feed,
depth of cut, workpiece material. From spindle speed 150 rpm to 200 rpm the surface
roughness decreases but From 200 rpm to 250 rpm the surface roughness increases. For the
feed rate of 0.08mm/rev the surface roughness is low but it increases for feed rate 0.09
mm/rev and again decreases for a feed rate 0.10 mm/rev. The mean values increases as
depth of cut increases from 0.2 to 0.3 and decreases again for 0.4mm.The Al_3 workpiece
has the highest value for material removal rate and Al_1 has the lowest material removal
rate.

46
Graph6.7
Graph6.8

47
 Graph6.9

Surface Plot of Speed vs Ra, MRR

400

S peed 300

3
200
Ra
2
2000
4000
6000 1
MRR 8000

48
 Graph6.10

Surface Plot of Speed vs Ra, MRR

From the graph it can be seen that higher MRR in the range of 3000-4000 and lower surface
roughness from 1.0-1.75 is obtained with the depth of cut of 300-350mm

Surface Plot of Feed vs Ra, MRR

0 .1 4

Feed
0.12
4

3
0.10
Ra
2
2000
4000
6000 1
MRR 8000

Graph6.11

Surface Plot Of Feed vs Ra, MRR

From the graph it can be seen that higher MRR in the range of 5000-5500 and lower surface
roughness from 1.0-1.75 is obtained with the depth of cut of 0.14-0.15mm

49
 Surface Plot of DOC vs Ra, MRR

0.75

0 .6 0
DO C

0.45 4

3
0 .3 0
Ra
2
2000
4000
6000 1
MRR 8000

Graph6.12

Surface Plot of DOC vs Ra, MRR

From the graph it can be seen that higher MRR in the range of 5000-7000 and lower surface
roughness from 1.0-1.75 is obtained with the depth of cut of 0.5-0.6mm

Contour Plot of Speed vs Ra, MRR

Speed
< 200
200 – 250
3.5
250 – 300
300 – 350
350 – 400
> 400
3.0
Ra

2.5

2.0

1.5

2000 3000 4000 5000 6000 7000

MRR

50
 Graph6.13

Contour Plolt of Speed vs Ra, MRR

From the graph it can be seen that higher MRR in the range of 3000-4000 and lower surface
roughness from 1.0-1.75 is obtained with the depth of cut of 300-350mm

Contour Plot of Feed vs Ra, MRR

Feed
< 0.10
0.10 – 0.11
3.5
0.11 – 0.12
0.12 – 0.13
0.13 – 0.14
0.14 – 0.15
3.0
> 0.15
Ra

2.5

2.0

1.5

2000 3000 4000 5000 6000 7000

MRR

Graph6.14

Contour Plot of Feed vs RA, MRR

From the graph it can be seen that higher MRR in the range of 5000-5500 and lower surface
roughness from 1.0-1.75 is obtained with the depth of cut of 0.14-0.15mm

51
 Contour Plot of DOC vs Ra, MRR
DOC
< 0.3
0.3 – 0.4
3.5
0.4 – 0.5
0.5 – 0.6
0.6 – 0.7
> 0.7
3.0
Ra

2.5

2.0

1.5

2000 3000 4000 5000 6000 7000

MRR

Graph6.15

Contour plot DOC vs RA, MRR

From the graph it can be seen that higher MRR in the range of 5000-7000 and lower surface
roughness from 1.0-1.75 is obtained with the depth of cut of 0.5-0.6mm

52
 Figure 6.1 : Crossover 0.5

From the figure, keeping the value of crossover 0.5 we observed that the optimized value of
speed came out to be 390 rpm and value of feed 0.101 mm/min and depth of cut as
0.311mm.

53
 Figure 6.2 : Crossover 0.3
From the figure, keeping the value of crossover 0.5 we observed that the optimized value of
speed came out to be 371 rpm and value of feed as 0.101 mm/min and depth of cut as 0.3
mm.

54
 Figure 6.3 : Crossover 0.8
From the figure, keeping the value of crossover 0.5 we observed that the optimized value of
speed came out to be 277 rpm and value of feed as 0.1 mm/min and depth of cut as 0.3
mm.

55
 CHAPTER 7
RESULTS
CONCLUSION AND
FUTURE SCOPE

56
CHAPTER 7: CONCLUSIONS AND FUTURE SCOPE

7.1. RESULT
By performing ANOVA we found the regression equation and using these equations we
performed Genetic Algorithm keeping the value of crossover 0.5 we observed that the
optimized value of speed came out to be 277 rpm and value of feed as 0.1 mm/min and
depth of cut as 0.3 mm.

7.2. CONCLUSIONS

The following concluding remarks can be drawn from the activities conducted in the project:
1. Design of experiments is a very structured methodology for planning and designing a
sequence of experiments.
2. Desirability function approach is a very robust method for converting multiple responses
into a single response. Observations having the most undesirable response get overall
desirability also as zero thereby simplifying calculations.
3. The main effect and interaction plots developed under DOE give a quick overview of the
optimum inputs.
4. Contour plots are extremely helpful for visualizing the trend of responses.
5. Multi-objective optimization gives a Pareto front, but the feasible solution space
determination can be done only when ideal objective vector, found by calculating best value
of each response individually, is available.
6. Thus, finally it can be observed that we must select the cutting parameters, which are
cutting speed, feed rate, and depth of cut, in such a way so as to have minimum surface
roughness and maximum material removal rate, and thus we could have the longest tool life
and better machining economy.

7.3. FUTURE SCOPE

A scientific study is always a work in progress, and experimentations have scope for
incorporating more and more of real world complexity. However time and resource
constraints restrict the pursuit of ambitious goals for attaining more real world objectives.
The project, though concluded, can be extended further in the following ways:
1. Further study could consider more factors such as coolant concentration, clamping force,
tool geometry, insert coating, workpiece material
2. Other experimental design methods such as Latin hypercube design can applied.
3. Other nature inspired algorithms either alone or in combination with artificial intelligence
techniques, can be explored for optimization

57
 LIST OF REFERENCES

[1]. Satish Chinchanikar, “Effect of work material hardness and cutting parameters on
performance of coated carbide tool when turning hardened steel: An optimization
approach”, ELSEVIER, 2013, pp.1572-1584.

[2]. S.R.Das, S.P.Nayak, “Optimization of cutting parameters on tool wear and workpiece
surface temp. in turning of AISI D2 steel”, International journal of lean thinking, 2012,
volume 3, issue 2, pp.141-156.

[3]. Achyut K. Panda, “Optimization of process parameters by Taguchi method: Catalytic

degradation of polypropylene to liquid fuel”, International Journal of Multidisciplinary and
Current, 20132, pp.2321-3124.

[4]. Ramanuj Kumar et al, “Some Studies on Cutting Forces and Temperature in Machining
Ti-6Al-4V Alloy using Regression Analysis and ANOVA”, 2013, International Journal of
Industrial Engineering Computations, pp.427-436.

[5]. Milenko Sekulic, “Optimization Of Cutting Parameters Based On Tool chip Interface
Temperature In Turning Process UsingTaguchi‟s Method”, 15th International
Research/Expert Conference, Trends in the Development of Machinery and Associated
Technology, 2011, pp.69-72.

[6]. Rahul Bhatti, “Optimization of Cutting Parameters on AISI H11 Steel using Multi-Coated
Carbide Tool by Taguchi Method”, International Journal of Current Engineering and
Technology, 2015, Vol.5, pp.2418-2424.

[7]. K. Someswara Rao et al, “Optimization of Machining Parameters for cutting

temperature on turning of Niobium alloy C-103by using RSM”, 2015, Vol.4, pp.13-17.

[8]. S.H. Rathod, Mohd. Razik, “finite element analysis of single point cutting tool“,
International journal of modern engineering research, 2014, Vol.4, pp.2249-664. [9]. Sana J.
Yaseen, “Theoretical study of temperature distribution and heat flux variation in aturning
process”, Al-Qadisiya journal for engineering science, 2012, Vol., No.3, pp.299-313.

[10]. Satish Chinchanikar, ”Evaluation of tool-chip interface temperature: Effect of coating

and cutting parameters during turning hardened AISI4340 steel”, ELSEVIER, 2014, pp.996-
1005.

[11]. J.E. Jam, V.N. Fard, ”A noval method is to determine tool-chip interface thermal
contact conductance in machining”, IJEST, 2011, pp.0975-5462.

58
ANNEXURES

59
ANNEXURE 1: PROJECT GROUP MEMBERS
HARSHIT AGRAWAL
7507775777
PGM Layout,Narendra Nagar,Nagpur
harshitagrawal@hotmail.com

HARSHVARDHAN RAI
305 Himalaya Prestige, South Ambazari
road, Nagpur
7722033232
harshvardhanrai11@gmail.com
PRATEEK SHIVHARE
G-6 Poonam apartment, Nagpur
8483020634
prateekshivhare26@gmail.com

FAIZAN KHAN
95-A, Gandhi Layout, Jafar Nagar
Nagpur
7304247304
faizankhan2208@gmail.com

60
 ANNEXURE 2: PROJECT GROUP PHOTO

Standing from left Pratik Shivhare, Harshvardhan Rai, Prof. Pranjali Deole, Harshit Agrawal,
Faizan Khan with the CNC machine.

61