MAHARANA PRATAP UNIVERSITY OF AGRICULTURE & TECHNOLOGY

COLLEGE OF TECHNOLOGY & ENGINEERING

UDAIPUR-313001

SYNOPSIS

“Experimental Investigation of Cutting Parameters in CNC

Machining For Controlled Surface Roughness”

 DEPARTMENT OF MECHANICAL ENGINEERING

MAHARANA PRATAP UNIVERSITY OF AGRICULTURE & TECHNOLOGY

COLLEGE OF TECHNOLOGY & ENGINEERING

UDAIPUR-313001

Synopsis of the research work to be carried out in fulfillment of requirement for the
degree of masters in CAD/CAM in Mechanical Department under course work program from
Maharana Pratap University of Agriculture & Technology & Engineering, Udaipur.

1. Name of Scholar : Dheeraj Soni

2. Registration No. : 2012-04-04-67-01

3. Date of Registration : 21/07/2012

4. Title of Thesis : Experimental Investigation of Cutting Parameters in

CNC Machining For Controlled Surface Roughness
5. Department & College : Department of Mechanical Engineering
College of Technology & Engineering

MPUAT, Udaipur

6. Expected Duration of the work : 6 Months

7. Objective:
  To study the effect of cutting parameters on surface roughness in conjunction with
induced vibration in CNC machining process.
 To perform the experiment for full factorial design at different cutting parameters and to
collect the respective response data for each run.
 To establish significant degree of correlation between the parameters and response
 To analyze statistically the significant effect between the response and the cutting
parameters using the Analysis of variance (ANOVA) to obtain best set of cutting
parameters.

8. Importance of Proposed work

A typical operation at automated computer numeric controlled (CNC) cells can produce
precision parts which may require a specified surface roughness. These parts may include
bearing surface on the various components, sealing surfaces on the bores, shafts and pistons etc.
Producing such items using CNC may generate numerous defects due to lack of continuous
operator monitoring.

Although, the surface roughness is highly affected by various factors viz. cutting
parameters, tool wear, work piece material, tool set-up etc. yet in the automated systems tool
wear and cutting parameters play a vital role in surface roughness. In the automated system, the
worn tool will go unnoticed until the operator hears chatter or see the tool condition. When the
problem is noticed, the condition is too late to take preventive or any other corrective action.

But the cutting parameters like depth of cut, feed rate, spindle speed etc. can be
controlled by effective monitoring or controlling the parameters. Until today, the phenomenon of
the surface roughness still not fully understood since many of researches, various study &
investigation shown many contradictory results.

Many research and investigations conducted had proven that feed rate is the most
influential machining parameter that determines the surface roughness and amplitude of
vibration whereas the less studies regarding the effect of cutting speed and depth of cut to tool
wear rate and surface roughness have been made.
 Hence, this work focuses on finding out the parameters which play a crucial role in
affecting the surface roughness using statistical approach. This task will be accomplished by
analyzing all the results and by finding best set of parameters for required response.

It is very important that optimized cutting parameters should be selected in controlling

the quality required for surface finish. Unfortunately, surface roughness does not depend solely
on the feed rate, depth of cut or cutting speed; the surface can also be deteriorated by excessive
tool vibrations and the built-up edge of the materials being machined.

Thus, this work aims to develop a system which includes collecting the data like mean
vibration signal amplitudes and surface roughness generated by machining operation on the
different work piece samples at varying spindle speeds, feed rates, depths of cut etc. and further
analysis using statistical approaches for achieving controlled surface roughness on the work
piece.

Results from the experiments which will be collected in the process will be able to show
that how the various parameters are affecting the surface roughness which will lead to good
performance when implemented in the industry.

9. Literature Review:

From the literature review and on the previous studies and research, we can see that
cutting parameters such as depth of cut, feed rate and cutting speed gives more effect and
influence to the vibration amplitude and surface roughness.

Nowadays, metal cutting is a significant industrial segment in economically developed

countries. The automobile, railway, aircraft manufacture, home appliance, consumer electronics
and construction industries, all these have large machine shops with many thousands of
employees engaged in machining. It is estimated that 15% of the value of all mechanical
components manufactured worldwide is derived from machining operations. All of these
machined components require desired level of surface roughness or surface finishing. These
requirements can only be fulfilled by development of proper tool condition monitoring systems
which can control desired level of accuracies. (Mukherjee I., 2006); (Merchant M., 1998);
(Endres W., 1995)

Various researchers studied for advancement in tool condition monitoring systems using
various techniques like online inspection techniques, experimental approach, modeling
techniques, statistical process control & other mathematical techniques. All of these methods are
still in their developing and implementing stage (Dimla, D. E, 2002).

There are various factors which affect the tool life as well as surface roughness viz. tool
set-up, variation in tool material & various cutting parameters as depth of cut, feed rate, cutting
speed , etc. (Vernon A.,2003).

Researchers are working for effective monitoring system of the tool wear & actual
surface roughness measurement rather than the factors which affect it. It is analyzed that major
emphasis in all the investigations has been on the tool wear and cutting parameters rather than
surface roughness because roughness is directly affected by wearing of tool and its cutting
parameters. If it can be measured in process will be a best idea with high potential but will
require sensitive components to be added.

Although effective techniques for prediction of surface roughness incorporated with tool
wear are under research since 1980’s but yet not in their completion stage (Ulsoy, 1993).
Thomas M. et. al.(1995) and Safeen Y. Kassab (2007) stated that tool vibration also play a vital
role in affecting tool wear as well as surface roughness. The features of vibration like its
frequency & time are correlated with various machining process (Dimla, 2002). Yongjin Kwon
et. al.(2004) investigated that tool condition i.e. wear rate incorporated with cutting parameters
has comprehensive relation with the surface roughness and experimental results also validate the
model that shows 92% accuracy between the predicted surface roughness and the actual
measurements.

In the study for surface roughness prediction by Huang L.H., et. al. (2001) & Risbood
K.A. et. al. (2003) has found that the vibration in single direction as well as various factors like
feed rate, depth of cut, spindle speed etc. affect positively on the surface roughness. But
Armerego et. al.(1969) stated that along with all the cutting parameters the vibration signals in
all the three axes affect the surface roughness thus, it should be considered.

For optimization of the system various investigations are being carried out using
statistical approaches because it is difficult to predict the effect of different parameters on the
vibration signal & the surface roughness (Tobias, S.A.,1969).Hence, Thomas, M. et. al. (2003)
suggested the analysis of variance (ANOVA) technique for prediction of best set of results.

In a recent research on cutting tool condition monitoring system for turning and face
milling operation using vibration analysis has shown that empirical models can be developed
using ANOVA to analyze response of the system. (Chelladurai H., 2008); (Rawangwong, S.,
2012)

10. Proposed plan of Work (Methodology):

It is an attempt to experimentally investigate the effect of various cutting parameters on

the surface roughness along with its vibration signals. A randomized schedule of runs will be
created for all the possible sets of parameter levels being used in the experiment for a number of
samples of work piece having same material.

The material for experimental purpose will be Aluminium Alloy (6061-T6511), which is
most widely being used by the industries. It is widely used due to its strength, comparatively
easy machining and weldability. It is most commonly used for the structures requiring good
corrosion resistance.

The experiment will involve three independent variables (spindle speed, depth of cut &
feed rate) and four dependent variables (Ra and Vx, Vy, Vz etc.). For conducting the experiment
each controlled factor or independent variable will have certain fixed levels as shown below in
Table-1 and this will result in total of 36 runs (i.e. full factorial design) to be conducted to test all
the possible combinations of parameter levels.

Where: Ra: Surface Roughness (µin.)

Vx, Vy, Vz: Vibration Signals in radial, tangential and feed axes respectively
 Table-1: Experimental levels of Cutting Parameters

Cutting Parameters No. of Levels Values For Each Level

SS (rpm) 3 2500 3000 3500

FR (ipr) 6 0.002 0.003 0.004 0.005 0.006 0.007

DC (in.) 2 0.01 0.02

Table-2: Design of Experiment for Full Factorial Data Collection

Spindle Speed
L-1: 2500 L-2: 3000 L-3: 3500
(rpm):
FR DC
L-1: 0.01 L-2: 0.02 L-1: 0.01 L-2: 0.02 L-1: 0.01 L-2: 0.02
(ipr) (in.)

L-1:0.002

L-2:0.003

L-3:0.004

L-4:0.005

L-5:0.006

L-6:0.007

Total nos. of experimental run: 36

Where: SS: Spindle Speed (rpm)

 FR: Feed Rate (ipr)

DC: Depth of Cut (in.)

The necessary data for the response variables will be collected for the individual
experimental run. For collection of the response data an assortment of instruments will be used
like surface roughness tester, vibration measurement device etc.

The surface roughness of the finished work pieces will be measured by a Stylus type
Profilometer set up. This device will be used to measure surface roughness of all the finished
work piece samples. For measuring vibration signals, the vibration data collection system
comprised of accelerometer setup for signal measurement and amplification will be used.

The collected data will be employed for analysis purpose by calculating Pearson
Correlation coefficient between the factors and response to measure significant correlation
between them. It is an attempt to find the most significant cutting parameter which affects the
surface roughness.

After analysing their correlation, the observation will be explored using an analysis of
variance (ANOVA) which will show a statistically significant effect among the response and the
cutting parameters. It will be performed using Statistical Software.

11. Facility Existing:

 The experiment will be performed using a CNC Lathe incorporating standard turning
process. This machine will be used from the available nearby industrial resources.
 For measuring surface roughness, a stylus type surface profilometer will be used from the
nearby available resources.
 For vibration measurement, vibration measuring instrument will be used which is
available in the department of mechanical engineering.
 Final data analysis task will be accomplished in the departmental networking lab.

12. Literature cited:

Armarego, E.J.A., & Brown, R. H. 1969. The Machining of Metals. Englewood Cliffs, NJ:
Prentice-Hall.
Chelladurai, H., Jain, V.K., Vyas, N.S. 2008. Development of a Cutting Tool Condition
Monitoring System for High Speed Turning Operation by Vibration and Strain Analysis.
International Journal of Advance Manufacturing Technology (2008) 37:471–485

Dimla, D. E., Sr. 2002. The Correlation of Vibration Signal Features to Cutting Tool Wear in a
Metal Turning Operation. International Journal of Advanced Manufacturing Technology,
19(10), 705-713.

Endres, W., Devor, R., Kapoor, S. 1995. A Dual-Mechanism Approach to the Prediction of
Machining Forces. I: Model Development. ASME J Eng Ind 1995; 117(4):526–33.

Huang, L. H., & Chen, J. C. 2001. A Multiple Regression Model to Predict In-Process Surface
Roughness in Turning Operation via Accelerometer. Journal of Industrial Technology,
17(2), 1-8.

Merchant, M. 1998. An Interpretive Look at 20th Century Research on Modeling of Machining.

Mach Sci Technol; 2(2):157–63.

Mukherjee, I., Ray, P. K. 2006. A Review of Optimization Techniques in Metal Cutting

Processes. Comput Ind Eng; 50(1–2):15–34.

Rawangwong, S., Chatthong, J., Burapa, R. and Boonchouytan, W. 2012. An Investigation of

Optimum Cutting Conditions for Quality of Surface Roughness in Face Milling Mold
Steel AISI P20 Using Carbide Tool. Proceedings of the Asia Pacific Industrial
Engineering & Management Systems Conference.

Risbood, K. A., Dixit, U. S., & Sahasrabudhe, A. D. 2003. Prediction of Surface Roughness
and Dimensional Deviation by Measuring Cutting Forces and Vibrations in Turning.
Journal of Materials Processing Technology, 132(1-3), 203-214.

Safeen, Y. Kassab, Younis, K. Khoshnaw. 2007. The Effect of Cutting Tool Vibration on
Surface Roughness of Work piece in Dry Turning Operation. Journal of Eng. &
Technology, Vol.25, No.7.
Thomas, M., Beauchamp, Y. 2003. Statistical Investigation of Modal Parameters of Cutting
Tools in Dry Turning. International Journal of Machine Tools & Manufacture 43; 1093–
1106

Thomas M., Beauchamp, Y., Youssef, A. Y., & Masounave, J. 1995. Effect of Tool Vibrations
on Surface Roughness during Lathe Dry Turning Process. Computers and Industrial
Engineering, 31(3/4), 637-644.

Tobias, S.A. 1965. Machine-Tool Vibration, Blackie, London.

Ulsoy, A. G., & Koren, Y. 1993. Control of Machining Processes. ASME Journal of Dynamic
Systems, Measurement, and Control, 115, 301-308.

Vernon, A., & Özel, T. 2003. Factors Affecting Surface Roughness in Finish Hard Turning. 17th
International Conference on Production Research, Blacksburg, Virginia.

Yongjin, K., Yalcin, E., & Tzu-Liang, T. 2004. Characterization of Tool Wear Measurement
with Relation to the Surface Roughness in Turning. Machining Science and Technology
Vol. 8, No. 1, Pp. 39–51.
 MAHARANA PRATAP UNIVERSITY OF AGRICULTURE & TECHNOLOGY

COLLEGE OF TECHNOLOGY & ENGINEERING UDAIPUR-313001

CERTIFICATION

The member of advisory committee of Mr. Dheeraj Soni met on /2014 in which the
candidate submit the synopsis of his research work entitled “Experimental Investigation of
Cutting Parameters in CNC Machining For Controlled Surface Roughness” to be carried
out for M.Tech. in Mechanical Engineering (Specialized in CAD/CAM) after discussion the
committee has recommended synopsis for approval.

SN. Name Adviser Code No. Signature

1 Dr. B.P.Nandwana Major Advisor EML-R04-145
2 Dr. M.A. Saloda Advisor ME-R04-539
3 Dr. S. Jindal Advisor ME-R04-451
4 Dr. Mahesh Kothari DRI Nominee SWE-R04-247

I have examined the above synopsis and recommend that it may be approved

Head, ME

The synopsis is here approved/not approved/to be revised

Dean, C.T.A.E.
 MAHARANA PRATAP UNIVERSITY OF AGRICULTURE & TECHNOLOGY

COLLEGE OF TECHNOLOGY & ENGINEERING UDAIPUR-313001

CERTIFICATION

The members of Advisory Committee of Mr. Dheeraj Soni met on 20/03/2014 at

Department of Mechanical Engineering ,CTAE in which the candidate presented the
synopsis of his research work entitled “Experimental Investigation of Cutting Parameters in
CNC Machining For Controlled Surface Roughness” to be carried out for M.Tech. degree in
the form of a seminar. After discussion, the committee has recommended the synopsis for
approval.

ADVISORY COMMITTEE

S.No. Name & Designation Status P.G. Code No. Signature

1. Dr. B.P.Nandwana Major Advisor EML-R04-145

2. Dr. M.A. Saloda Advisor ME-R04-539
3. Dr. S. Jindal Advisor ME-R04-451
4. Dr. Mahesh Kothari DRI Nominee SWE-R04-247

I have gone though synopsis critically and fully satisfied with the quantum and quality
of proposed research work for M.Tech. and the same is recommended and forwarded for
approval.

Head
Department of Mech. Engg.
CTAE, Udaipur
Forwarded and recommended for approval

Dean
CTAE, Udaipur
The synopsis is hereby approved/not approved/to be revised.

Director, Resident Instructions