Measurement 46 (2013) 1849–1864

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Measurement
journal homepage: www.elsevier.com/locate/measurement

Multi-objective optimization using Taguchi based grey

relational analysis for micro-milling of Al 7075 material with
ball nose end mill
Emel Kuram ⇑, Babur Ozcelik
Department of Mechanical Engineering, Gebze Institute of Technology, Gebze, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: This study was carried out to understand micro-milling of aluminum material with ball
Received 18 August 2012 nose end mill and consisted of four stages: experimental work, modelling, mono and multi
Received in revised form 25 December 2012 objective optimization. In the first stage (experimental work), micro-milling experiments
Accepted 7 February 2013
were carried out using Taguchi method. The effects of spindle speed, feed per tooth and
Available online 24 February 2013
depth of cut on tool wear, force and surface roughness were investigated. Cutting tools
and workpiece surfaces were also inspected via scanning electron microscope. Adhesion
Keywords:
and abrasion wear mechanisms during micro-milling of aluminum were observed. Work-
Micro-milling
Grey relational analysis
piece surfaces had the accumulations of plastically deformed workpiece material due to
Tool wear the high ductility of aluminum. In the second stage (modelling), all data gathered in the
Cutting force experimental works were utilized to formulate first-order models with interaction. These
Surface roughness first-order models with interaction could be used to predict responses in micro-milling
Multi objective optimization of aluminum with a minor error. In the third stage (mono-objective optimization),
responses were used alone in optimization study as an objective function. To minimize
all responses, Taguchi’s signal to noise ratio was used. The effect of control factors on
responses was determined by analysis of variance. In the fourth stage (multi objective opti-
mization), responses were optimized simultaneously using grey relational analysis.
Ó 2013 Elsevier Ltd. All rights reserved.

1. Introduction of producing two dimensional structures with a third

Nowadays, there have been increasing demands for mi-
cro-components in many industries such as electronics,
optics, aerospace, medicine and biotechnology. Non-tradi-
tional fabrication methods such as laser machining, fo-
cused ion beam machining, electrochemical machining
and electrodischarge machining (EDM) are used to produce
micro-components, but these methods have limited poten-
tial due to the limited workpiece material selection, poor
productivity and high cost [1]. Apart from these non-tradi-
tional methods, micro-mechanical machining (micro-mill-
ing, micro-drilling, micro-turning, and micro-grinding) has
gained increasing interest in recent years since it is capable
⇑ Corresponding author. Tel.: +90 262 6052788.
E-mail address: kuram@gyte.edu.tr (E. Kuram).
dimension (2½D) [2] and real three dimensional (3D)
microstructures [2,3], but some drawbacks such as unpre-
dictable tool life [4], burr formation [5–7], chatter [8–10],
tool alignment error [11], high friction due to rubbing at
the workpiece–tool interfaces [12], poor surface quality
[13] restrict its performance.
One of the micro-mechanical machining processes is
micro-milling. Micro-milling uses miniature cutting tools
which have been adopted from macro-tools and many
works have been conducted to design and fabricate mi-
cro-milling tools [14–24]. In order to fabricate micro-mill-
ing tools, focused ion beam process was used [14,15]. Fang
et al. [16] reported finite element analysis results of the
various types of tool geometry, namely, commercial type
two-flute end-mills, triangle-based end-mills and semi cir-
cle-based end-mills. Uhlmann and Schauer [17] developed

0263-2241/$ - see front matter Ó 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2013.02.002
1850 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864
a parametric tool design for micro-end mills. Ali and Ong
[18] used wire electrodischarge grinding and focused ion
beam sputtering for the fabrication of micro-tools. Suzuki
et al. [19] developed micro-milling tools made of polycrys-
tal diamond. Chern et al. [20] fabricated micro-tools with a
minimum of 31 lm in diameter using the wire electro-
discharge grinding method. Fleischer et al. [21] used
electro discharge machining in order to manufacture the
micro-tools. Cheng et al. [22] fabricated a polycrystalline
diamond micro-hexagonal end mill using wire electrical
discharge machining. Egashira et al. [23] developed
cemented tungsten carbide micro-tools with a diameter
of 3 lm by electrical discharge machining. Friedrich [24]
developed micro-tools with a diameter of 22 lm. Since
the size of the cutting tool is downscaled in micro-milling,
cutting process changes as compared to conventional
(macro) size machining and some ignored parameters in
macro-milling become significant for micro-milling. In mi-
cro-milling, the ratio of feed per tooth to tool radius is
much higher than macro-milling. The assumption of the
cutting tool is sharp and generates chip in macro-milling
are not valid anymore for micro-milling. This is due to
the highly negative rake angle. The chip does not always
formed in micro-milling and its formation depends on
minimum chip thickness. The tool run-out even being
within microns affects extensively the micro-milling pro-
cess. The tool deflection and tool edge radius greatly affect
the micro-milling performance as compared to macro-
milling. Although shearing cutting is dominant in macro-
milling, shearing and ploughing cutting are observed in
micro-milling.
Manufacturing of complex 2D and 3D shapes is possible
with micro-milling and micro-components made from a
great variety of engineering materials such as polymer
[24], aluminum [25–36], steel [34–45], copper [46–49], sil-
icon [50–52], brass [53–55], tungsten carbide [19,56], glass
[57], composite [58] and NiTi [59] were machined success-
fully with micro-milling. However, micro-milling of hard-
ened steels is a challenging task [60,61] due to the
unpredictable tool life [61]. The output responses during
micro-milling of above engineering materials were exten-
sively investigated; these responses included cutting force
[25–31,33,34,37–41,46,48,50–54,58], surface roughness
[32,33,41–44,49,52,56–58], burr formation [33,35,43,44],
temperature [36] and tool wear [43,44,49,52,54,55,58].
Tansel et al. [25] proposed genetic tool monitor in order
to identify the problems by using an analytical model
and genetic algorithm for micro-milling process. Chae
and Park [26] used Kalman filter approach to measure
the micro-milling forces accurately. Cutting force models
were also developed for micro-milling in the literature
[27–29,31,34,37–39]. In the literature, diamond coated mi-
cro-milling tools were used in order to improve tool life
[30,33]. Lekkale et al. [35] investigated the effect of speed,
feed rate, depth of cut, tool diameter and number of flutes
on the formation of burr in micro-milling. Wissmiller and
Pfefferkorn [36] characterized the heat transfer in micro-
end mill tools and measured tool temperatures using an
infrared camera. Li et al. [40] studied the challenges in mi-
cro-milling of thin ribs with high aspect ratios and ma-
chined thin ribs about 15 lm wide and with an aspect
ratio of more than 50. Vogler et al. [41] developed a mech-
anistic force model for heterogeneous materials. In another
study they investigated the surface generation in the mi-
cro-milling of both single-phase and multiphase workpiece
materials [42]. Aramcharoen et al. [43] studied the effect of
physical vapor deposition coatings on tool wear and ma-
chined surface. Li and Chou [44] investigated the perfor-
mance of the minimum quantity of lubrication technique
in micro-milling by evaluating tool wear, surface rough-
ness and burr formation. Kumar et al. [45] presented a
new method based on monitoring changes in the power
spectral characteristic of the spindle vibration signal to de-
tect tool–workpiece contact in micro-milling process.
Although the monitoring of tool wear is difficult task in mi-
cro-milling, some attempts have been seen in the literature
[62–65].
Although a lot of researches have been conducted about
micro-milling process, there is very few study about opti-
mization of machining parameters in micro-milling. The
optimization of surface roughness in micro-milling has
been reported by Cardoso and Davim [66]. In some mi-
cro-milling studies, different design of experiment meth-
ods such as response surface, full factorial and Taguchi
were used. Wang et al. [67] used response surface method
in order to investigate the effect of spindle speed, feed rate,
depth of cut and tool diameter on surface roughness of
brass material in micro-milling. Vázquez et al. [68] de-
signed micro-channel milling experiments using full facto-
rial with five variable factors (spindle speed, depth of cut
per pass, channel depth, feed per tooth and coolant) and
two levels per variable factor. Surface roughness, micro-
channel width dimension and micro-channel shape were
taken as response variables in micro-milling of aluminum
and copper. Mian et al. [69] investigated the effects of cut-
ting variables (cutting velocity, ratio of undeformed chip
thickness to cutting edge radius, axial depth of cut and tool
coating) on the size effect of Inconel 718 material using
Taguchi orthogonal array. Analysis of variance (ANOVA)
was used to determine the dominant cutting factors and
results showed that in addition to chip thickness, the cut-
ting velocity was also a dominant factor.
In macro-machining Taguchi method [70,71] and grey
relational analysis [72,73] were used to optimize machining
performance. To the best our knowledge, there is no pub-
lished study about the optimization of multi performance
characteristics in micro-milling by using grey relational
analysis. There are many parameters affecting tool wear,
cutting force and surface roughness in micro-milling, such
as spindle speed, feed per tooth, axial depth of cut, radial
depth of cut (width of cut and step over), tool diameter,
workpiece material, etc. In current study spindle speed, feed
per tooth and axial depth of cut were chosen as machining
factors in order to investigate their effects on tool wear, cut-
ting force and surface roughness. So the important point of
measurement used in this study was to investigate a rela-
tionship between the micro-milling parameters and
machinability performance, including tool wear, forces
and surface roughness. This study presented the optimiza-
tion of micro-milling for aluminum alloy so as to minimize
the tool wear, force and surface roughness simultaneously
using Taguchi based grey relational analysis.
 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864
2. Experimental
2.1. Materials
The micro-milling tests were conducted at DECKEL
MAHO DMU 60 P CNC milling machine. In the micro-
milling experiments, Al 7075 material with a Vickers hard-
ness of 139 was used as a workpiece material, which had a
dimension of 15 mm  10 mm  20 mm (Fig. 1). The
chemical compositions of aluminum material were deter-
mined by a spectrometer (SpectroMAXx, Germany) and re-
sults were given in Table 1. Before micro-milling
experiments, the workpiece was finished by milling to en-
sure flatness. 800 lm diameter two-flute ball end mill (Un-
ion Tool, CB3A 20080-040) was used in the micro-milling
experiments. The total length and shaft diameter of tool
were 38 mm and 3 mm, respectively. Before experiment
all cutting tools were inspected visually via scanning elec-
tron microscope (SEM) so that guarantee the absence of
any defects on tools surface (Fig. 2). For each experiment,
new cutting tools were utilized. The static runout of tool
shaft was measured via dial gauge before each experiment
and the values were found to be smaller than 5 lm.
Distance between the cutting tool tip and end of tool
holder (overhang length) was fixed about 20 mm for each
experiment. The workpiece materials and cutting tools
from the same production batch were used in the micro-
milling experiments in order to avoid differences in the
machining performances. All micro-milling experiments
were conducted as down milling method and dry condi-
tions. For each experiment, the tests were carried out on
15 mm  10 mm blocks of workpiece and surfaces were
machined at two times.
2.2. Measurements
In this study, tool wear, force and surface roughness
were measured during micro-milling of aluminum alloy.
The wear of cutting tools was measured by a SEM (Philips,
JEOL JSM-840 SEM) at 500 magnifications. In current
study, any difference between a new and used tool such
as build up edge was considered as ‘‘wear’’ [74].
Fig. 1. Aluminum workpiece material.
1851
Machining forces give important information about cut-
ting process, such as determining power consumption and
productivity, and can affect the quality of machined sur-
faces. In micro-milling, it is very difficult to detect broken
cutting edges and shafts during machining process because
micro-cutting tools are very small. Measurement of force is
the most effective methodology for detecting tool condi-
tions during machining process. For these reasons, mea-
surement of forces during micro-milling is mandatory.
Therefore, in this study forces (Fx and Fy) during micro-
milling were measured on-line with a dynamometer in-
stalled in the machine table. Workpiece was clamped in
the vise and the vise was mounted on the dynamometer.
Force data was acquired via a DAQ card and an amplifier,
and was processed with Dynoware software. Using this
force setup, three force components (Fx, Fy and Fz) can
be measured simultaneously and can be saved on a per-
sonal computer. In this study, two force components (Fx
and Fy) were taken into consideration during micro-mill-
ing experiments because the Z-axis force component had
little information in milling and data for the forces were
measured along the workpiece material continuously.
Surface roughness is one of the most important factors
that affects the quality of a machined product. Surface
roughness is usually measured off-line after the product
is machined. After the micro-milling experiments, the sur-
face roughness of machined surfaces was measured in feed
direction by the Mitutoyo Surf Test 301 profilometer. Prior
to the surface roughness measurements, the profilometer
was calibrated with a standard calibration block. In this
study, average surface roughness (Ra) was selected as a
roughness parameter. The measurement of Ra was re-
peated ten times and average values of these measure-
ments were taken into consideration to make further
analysis. The experimental setup was shown in Fig. 3.
2.3. Design with Taguchi method
Taguchi method uses specially constructed tables
named as ‘‘orthogonal array’’ to design the experiments
and using of these orthogonal arrays diminishes the num-
ber of experiments. As a result, experimental cost, effort
and time will reduce. Taguchi’s L9 orthogonal array was
used for the experimental design in order to achieve the
aims of how the controlled factors affect the output factors
and what the optimal micro-milling controlled parameters
to obtain lower tool wear, force and surface roughness.
Spindle speed, feed per tooth and depth of cut were consid-
ered as controlled factors and tool wear, force and surface
roughness were selected as output factors. The control fac-
tors and their levels were given in Table 2. The experimen-
tal plan for three micro-milling parameters (spindle speed,
feed per tooth and depth of cut) with three levels (33) was
organized by the Taguchi method (L9 orthogonal array, Ta-
ble 3). Width of cut was constant during experiments be-
cause it was demonstrated in the literature that the
width of cut had a negligible effect on the surface rough-
ness [75] and width of cut was fixed at 200 lm for all
experiments.
1852 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864

Table 1
Chemical composition of Al 7075 aluminum alloy (wt%).

Li Si Mn P Sr Cr Ni Na Al
<0.0002 0.92 0.348 <0.001 <0.0001 0.093 0.057 0.003 89.0
Cu Co Ti Be V Fe Pb Mg B
1.71 <0.001 0.048 0.0003 0.009 0.55 0.018 2.00 0.0017
Sn Zn Ag Bi Ca Cd Zr
0.008 5.22 0.0022 0.0018 0.0027 0.0031 0.0078

Fig. 2. 800 lm diameter two-flute ball end mill (new tool).

Fig. 3. Experimental setup.

 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864 1853

Table 2
Control variables and their levels.

Code Control parameters Unit Level 1 Level 2 Level 3

A Spindle speed rpm 10,000 11,000 12,000
B Feed per tooth lm/tooth 0.5 1.0 1.5
C Depth of cut lm 50 75 100

Table 3
Taguchi L9 (33) orthogonal array.

Experiment Spindle Feed per Depth of

number speed
1 1
2 1
3 1
4 2
5 2
6 2
7 3
8 3
9 3
tooth cut
1 1
2 2
3 3
1 2
2 3
3 1
1 3
2 1
3 2

3. Results and discussion

The tool wear diminishes the quality of the product in

the machining process [76], for that reason measurement
of tool wear is mandatory to detect any deterioration be- Fig. 4. Example tool wear SEM results in micro-milling experiments. (a)
fore breakage of cutting tool. For this reason, we measured Experiment 5, spindle speed of 11,000 rpm, feed per tooth of 1 lm/tooth
tool wear during micro-milling. As mentioned above any and depth of cut of 100 lm. (b) Experiment 8, spindle speed of
12,000 rpm, feed per tooth of 1 lm/tooth and depth of cut of 50 lm.
difference between a new and used tool was measured as
‘‘wear’’. Some examples of the used cutting tools were
shown in Fig. 4. It was seen in this figure that some mate-
rials adhered to the cutting tool and this build up edge was
due to the ductile nature of workpiece material. It can be
said that the dominant wear mechanisms during micro-
milling of aluminum were abrasion and adhesion. For all
experiments, the cutting tools were in good condition
and could be used for further machining.
Cutting forces affect the specific cutting pressure, power
consumption, tool wear and heat generation in machining
[77] so measurement of cutting forces during machining
process gives to us valuable information. Example of cut-
ting forces measured from dynamometer was depicted in
Fig. 5 as a function of time. In current study the average
of peak-to-valley (P-to-V) forces were taken into consider-
ation. In micro-milling, the force components were very
small, only about 1–2 N.
Workpiece surfaces were also analyzed by SEM and Fig. 5. Sample force–time graph.

some examples of surfaces were depicted in Fig. 6. In this

figure, ‘‘ii.’’ and ‘‘iii.’’ were close-up views of ‘‘i.’’. Views of
the main ridges was also observed in the micro-milling
surfaces for ‘‘i.’’, ‘‘ii.’’ and ‘‘iii.’’ were taken by SEM at 50,
with a ball nose end mill in the literature [78].
250 and 1000 magnifications, respectively. From sur-
face texture, it was clearly seen the defined step over traces
(Fig. 6a, ‘‘i.’’ and Fig. 6b, ‘‘i.’’). When we enlarged ‘‘i.’’ in 3.1. Regression analysis
Fig. 6a and b, it was seen that workpiece surfaces had the
accumulations of plastically deformed workpiece material The relationship between independent and dependent
due to the high ductility of aluminum material (Fig. 6a, variables is determined by regression analysis. Regression
‘‘ii.’’ and ‘‘iii.’’). The accumulation of smeared material on analysis is used to predict dependent variables as a func-
1854 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864

Fig. 6. Workpiece surfaces. (a) Experiment 2, spindle speed of 10,000 rpm, feed per tooth of 1 lm/tooth and depth of cut of 75 lm. (b) Experiment 9, spindle
speed of 12,000 rpm, feed per tooth of 1.5 lm/tooth and depth of cut of 75 lm.

tion of independent variables. The general form of the first- R2 ¼ 99:3% R2 ðadjÞ ¼ 98:2%
order model and the model with first-order predictors and
interaction are given in Eqs. (1a) and (1b), respectively. Fy ¼ 3:22 þ 0:000373n þ 0:4f z  0:00013ap ð6Þ
X
k
y ¼ b0 þ bi xi þ e ð1aÞ R2 ¼ 94:2% R2 ðadjÞ ¼ 90:8%
i¼1

Ra ¼ 1:26  0:00012n  0:431f z þ 0:00275ap

X
k X
k X
k
y ¼ b0 þ bi xi þ bi;j xi xj þ e ð1bÞ þ 0:000068nfz ð7Þ
i¼1 i< j¼2

where b is a coefficient of each term, k is a number of inde- R2 ¼ 96:2% R2 ðadjÞ ¼ 92:5%

pendent variables and e is an error.
To justify the validity of developed first-order model, R2 where n, fz and ap were spindle speed, feed per tooth and
(R-squared, correlation coefficient) value is used. R2 can be axial depth of cut, respectively.
defined as: To estimate R2 values for responses, SSE and SST values
were used. SSE values for tool wear, Fx, Fy and Ra were
Sum squared residual ðSSRÞ found to be 0.00726, 0.00000, 0.06596 and 0.02847,
R2 ¼ ð2Þ
Sum squared total ðSSTÞ respectively. SST values for tool wear, Fx, Fy and Ra were
obtained as 0.19260, 1241.79000, 1.14229 and 4.13700,
Sum squared error ðSSEÞ respectively. R2 values were calculated using Eq. (3). In
R2 ¼ 1  ð3Þ
Sum squared total ðSSTÞ multiple regression analysis, R2 should be between 0.8
and 1. In this study, regression equations were found to
In current study, tool wear, forces and surface rough-
be consistent with experimental values (R2 > 90%) and
ness were taken as responses (output) while spindle speed,
these first-order models with interaction could be used
feed per tooth and depth of cut were determined as inde-
to predict tool wear, force and surface roughness in mi-
pendent (input) variables. The first-order equations with
cro-milling of aluminum alloy.
interaction were as follows:
The predicted values obtained from first-order models
Tool wear ¼ 140 þ 0:0117n  19:7f z þ 1:15ap with interaction were compared with experimental results
þ 0:00269nfz  0:000054nap and the relationship between these values was plotted as
shown in Fig. 7. It was found from this figure that the vari-
 0:215f z ap ð4Þ ations between experimental and predicted values were
minimal.
R2 ¼ 100% R2 ðadjÞ ¼ 100%
3.2. S/N analysis
Fx ¼ 3:34 þ 0:00051n  1:64f z  0:0148ap
þ 0:000170nfz þ 0:0110f z ap ð5Þ The term ‘‘signal’’ represents the desirable effect for the
output characteristic and the term ‘‘noise’’ stands for the
 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864
Fig. 7. Comparison of measured-predicted values for (a) tool wear; (b) Fx; (c) Fy; and (d) surface roughness results.
undesirable effect for the output characteristic. S/N ratio
measures the quality characteristics deviating from the de-
sired values and higher S/N ratio means the optimal level of
the process parameters. Since lower tool wear, force and
surface roughness were desirable, the smaller-the-better
S/N quality characteristic was used in this study. Quality
characteristic of the smaller-the-better is calculated in
the following equation:
" !#
1 X n
S=N ¼ 10log10 y2i
n i¼1
yi is the ith measured experimental results in a run/row
and n explains the number of measurements in each test
trial/row.
The experimental results and the S/N ratio values calcu-
lated by taking Eq. (8) into consideration were given in
Table 4.
The level of a parameter with the highest S/N ratio gives
the optimal level. All the optimal machining parameters
were highlighted in circles in Figs. 8–11. So the optimal
process parameter setting for the tool wear was A1B1C1
(Fig. 8). Thus, the best combination values for minimizing
tool wear were spindle speed of 10,000 rpm, feed per tooth
of 0.5 lm/tooth and depth of cut of 50 lm.
1855
The analysis of the results showed that the optimum
combination of micro-milling parameters for Fx was
A1B1C3, namely, spindle speed of 10,000 rpm, feed per
tooth of 0.5 lm/tooth and depth of cut of 100 lm (Fig. 9).
The optimum combination of process parameters for Fy
was A1B1C2, namely, spindle speed of 10,000 rpm, feed per
tooth of 0.5 lm/tooth and depth of cut of 75 lm (Fig. 10).
A3B1C1 was the optimum combination of process
parameters for low Ra (Fig. 11). For Ra, the optimum
parameters were as follows: spindle speed of 12,000 rpm,
ð8Þ feed per tooth of 0.5 lm/tooth and depth of cut of 50 lm.
From the main effects plot it can be concluded that
spindle speed was more significant factor for all responses
except for Ra, because the slope gradient was very big and
this result was similar to those obtained with variance
analysis. For Ra, feed per tooth was more significant factor
in micro-milling and this result was in consistent with
macro-machining [77,79,80].
3.3. Effect of cutting parameters on responses
In order to evaluate the effects of micro-milling param-
eters on tool wear, forces and surface roughness, 3D sur-
face plots were drawn changing two parameters while
the other parameter was kept constant. 3D surface plots
1856 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864

Table 4
Experimental and S/N results.

Experiment number Tool wear Fx Fy Ra

Result (lm) S/N (dB) Result (N) S/N (dB) Result (N) S/N (dB) Result (lm) S/N (dB)
1 5.41 14.664 1.33 2.477 0.71 2.975 0.33 9.630
2 13.51 22.613 1.63 4.244 0.86 1.310 0.47 6.558
3 16.22 24.201 2.02 6.107 1.02 0.172 0.71 2.975
4 27.02 28.634 1.62 4.190 1.08 0.668 0.32 9.897
5 32.43 30.219 2.03 6.150 1.49 3.464 0.59 4.583
6 14.86 23.440 2.65 8.465 1.52 3.637 0.58 4.731
7 45.95 33.246 2.10 6.444 1.36 2.671 0.27 11.373
8 27.03 28.637 2.99 9.513 1.66 4.402 0.35 9.119
9 32.43 30.219 3.55 11.005 1.81 5.154 0.58 4.731

Fig. 8. Main effects plot of S/N ratios for tool wear.

Fig. 9. Main effects plot of S/N ratios for Fx.

for tool wear, Fx, Fy and surface roughness were depicted
in Figs. 12–15. The tool wear of aluminum alloy during mi-
cro-milling increased with spindle speed (Fig. 12a) and
depth of cut (Fig. 12b). The increment of tool wear with
increasing spindle speed was observed in the literature
[81]. When spindle speed is increased, the temperature
at the tool–workpiece contact area increases and this leads
to an increment of tool wear. The increment of the feed per
tooth initially increased the tool wear; however, as this
parameter was further increased, tool wear eventually de-
creased (Fig. 12c). In the literature, it was observed that
when milling at a low feed per tooth, the wear of micro-
 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864 1857

Fig. 10. Main effects plot of S/N ratios for Fy.

Fig. 11. Main effects plot of S/N ratios for Ra.

tools were smaller [82]. Consequently, the lowest tool
wear value was obtained at the lowest spindle speed, feed
per tooth and depth of cut combination.
Fx increased with an increment of spindle speed
(Fig. 13a and b) and feed per tooth (Fig. 13a). Increasing
Fx with feed per tooth was in consistent with conventional
macro-milling. Fx decreased with an increment of depth of
cut. The lowest Fx was obtained at the lowest spindle
speed, feed per tooth and depth of cut combination.
Fy increased with an increment of spindle speed
(Fig. 14a and b) and feed per tooth (Fig. 14a) as observed
in Fx. The increment of the depth of cut initially increased
Fy; however, as this parameter was further increased, Fy
eventually decreased (Fig. 14b and c). In the literature, it
was found that the forces (Fx and Fy) increased with spin-
dle speed [58], feed per tooth [47,58,82,83] and depth of
cut [47]. Increasing Fx and Fy with feed per tooth can be
explained by the increment in chip cross-sectional area
with increasing feed per tooth [83]. From 3D surface plots
for Fy, it was concluded that, Fy can be minimized by using
lower values of spindle speed, feed per tooth and depth of
cut.
The increment of the spindle speed decreased Ra
(Fig. 15a). Uhlmann et al. [58] found similar result with
our study and the decreasing Ra with the increasing spin-
dle speed was explained by the built up edge on the flank
surface of the cutting tool and by the tool deflection
orthogonal to the feed direction. On the contrary, it was
found that Ra increased with an increment of spindle
speed in the literature [67]. In this study, Ra increased with
an increment of feed per tooth (Fig. 15a) and depth of cut
(Fig. 15c). Yun et al. [48] observed that Ra decreased from
26 to 13 nm when feed per tooth decreased from 4 to
0.8 lm. However, when the feed per tooth was diminished
to less than 0.8 lm, Ra increased again [48] due to the
ploughing effect. Li et al. [49] found that Ra decreased lar-
gely as feed per tooth increased from 0.6 to 0.8 lm, and
after that an increment was observed when feed per tooth
increased from 1.0 to 3.0 lm. As was our study, Ra in-
creased slightly with axial depth of cut in the literature
[84]. Thus, using a larger axial depth of cut is an effective
way in order to increase the machining efficiency without
affecting tool breakage and tool life. From 3D surface plots
for Ra, it was clear that, Ra can be minimized by utilizing
1858 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864
Fig. 12. 3D surface plots for effects of (a) spindle speed and feed per
tooth; (b) spindle speed and depth of cut; and (c) feed per tooth and
depth of cut on tool wear.
lower values of feed per tooth and depth of cut with higher
spindle speed.
3.4. ANOVA
Analysis of variance (ANOVA) was utilized to determine
the statistically significant factors influencing the tool wear,
force and surface roughness during micro-milling of alumi-
num alloy and to determine the percentage contribution of
each control factor on responses. ANOVA results were given
in Tables 5–8. The analyses were made for the level of con-
fidence 95% (the level significance is 5%). Spindle speed, feed
per tooth and depth of cut influenced the tool wear values
by 66.565%, 3.041% and 30.100%, respectively (Table 5).
From the analysis of this table, it could be observed that
spindle speed and depth of cut had statistical and physical
significance on the tool wear because P value was lower
than 0.05. It was also known that spindle speed had the
highest influence on tool wear in macro-milling [70].
Fig. 13. 3D surface plots for effects of (a) spindle speed and feed per
tooth; (b) spindle speed and depth of cut; and (c) feed per tooth and
depth of cut on Fx.
For Fx, the most significant factor was the spindle speed
with a percentage contribution of 55.364% (Table 6). The
second most influential factor was feed per tooth
(40.485% contribution). The spindle speed and feed per
tooth had statistical and physical significance on Fx.
The most influential factor for Fy was spindle speed
with a percentage contribution of 76.020% and followed
by feed per tooth (Table 7). Other factor, depth of cut con-
tributed 0.334% to Fy, which can be neglected. Only the
spindle speed had statistical and physical significance on
Fy. In the literature, it was found that the effect of the axial
depth of cut on the forces (Fx and Fy) was insignificant [82]
as we observed.
The spindle speed, feed per tooth and depth of cut af-
fected Ra values by 10.419%, 78.124%, and 8.550%, respec-
tively (Table 8). The feed per tooth had statistical and
physical significance on Ra. In the literature same result
(Ra was mainly influenced by feed per tooth) was observed
[68,84]. It was also found that depth of cut did not influ-
 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864 1859

Fig. 14. 3D surface plots for effects of (a) spindle speed and feed per
tooth; (b) spindle speed and depth of cut; and (c) feed per tooth and
depth of cut on Fy.
Fig. 15. 3D surface plots for effects of (a) spindle speed and feed per
tooth; (b) spindle speed and depth of cut; and (c) feed per tooth and
depth of cut on Ra.

ence Ra and this result was consistent with other studies

[69,84]. according to the type of performance response [85]. If the
target value of the original sequence is infinite, it has a
‘‘the-larger-the-better’’ characteristic and the original se-
3.5. Multi-objective optimization using grey relational quence can be normalized as follows:
analysis
xki ðkÞ  minðx0i ðkÞÞ
xi ðkÞ ¼ ð9Þ
Grey relational grade is used to convert optimization maxðx0i ðkÞÞ  minðx0i ðkÞÞ
problem from a multi-objective to a single-objective. The
If a defined target value, OB, exists, the original se-
aim of this study was to determine the optimal combina-
quence can be normalized as follows:
tion of micro-milling parameters that simultaneously min-  0 
imize tool wear, force and surface roughness. To do so, grey x ðkÞ  OB
i
relational analysis was used in this study. Steps of grey
xi ðkÞ ¼1     
max max x0i ðkÞ  OB; OB  min x0i ðkÞ
relational analysis are as follow:
ð10Þ
Step 1: Grey relational generation In the present study, as tool wear, force and surface
roughness were to be minimized (‘‘the-smaller-the-better’’
The first step of grey relational analysis is to normalize is a characteristic of the original sequence), the original se-
(in the range between 0 and 1) the experimental data quence should be normalized as follows:
1860 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864

Table 5
ANOVA for tool wear.

Factors Degree of freedom, DF Sum of squares, SS Mean squares, MS F ratio a = 5% P Contribution (%)
Spindle speed 2 826.60 413.30 226.78 0.004 66.565
Feed per tooth 2 37.76 18.88 10.36 0.088 3.041
Depth of cut 2 373.78 186.89 102.55 0.010 30.100
Error 2 3.65 1.82 0.294
Total 8 1241.79 100

Table 6
ANOVA for Fx.

Factors Degree of freedom, DF Sum of squares, SS Mean squares, MS F ratio a = 5% P Contribution (%)
Spindle speed 2 2.29040 1.1452 48.87 0.020 55.364
Feed per tooth 2 1.67487 0.8374 35.74 0.027 40.485
Depth of cut 2 0.12487 0.0624 2.66 0.273 3.018
Error 2 0.04687 0.0234 1.133
Total 8 4.13700 100

Table 7
ANOVA for Fy.

Factors Degree of freedom, DF Sum of squares, SS Mean squares, MS F ratio a = 5% P Contribution (%)
Spindle speed 2 0.86836 0.43418 57.55 0.017 76.020
Feed per tooth 2 0.25502 0.12751 16.90 0.056 22.325
Depth of cut 2 0.00382 0.00191 0.25 0.798 0.334
Error 2 0.01509 0.00754 1.321
Total 8 1.14229 100

Table 8
ANOVA for Ra.

Factors Degree of freedom, DF Sum of squares, SS Mean squares, MS F ratio a = 5% P Contribution (%)
Spindle speed 2 0.020067 0.010033 3.58 0.218 10.419
Feed per tooth 2 0.150467 0.075233 26.87 0.036 78.124
Depth of cut 2 0.016467 0.008233 2.94 0.254 8.550
Error 2 0.005600 0.002800 2.907
Total 8 0.192600 100

 
max x0i ðkÞ  x0i ðkÞ
xi ðkÞ ¼  0    ð11Þ Table 9
max xi ðkÞ  min x0i ðkÞ
Normalized experimental results.
where xi ðkÞ is the value after grey relational generation Experiment number Tool wear Fx Fy Ra
(normalized value), maxðx0i ðkÞÞ and minðx0i ðkÞÞ are the larg-
Ideal value 1.000 1.000 1.000 1.000
est and smallest values of x0i ðkÞ for the kth response, 1 1.000 1.000 1.000 0.864
respectively, k being 1 for tool wear, 2 for Fx, 3 for Fy 2 0.800 0.865 0.864 0.545
and 4 for surface roughness. 3 0.733 0.689 0.718 0.000
4 0.467 0.869 0.664 0.886
The processed data after grey relational generation was
5 0.333 0.685 0.291 0.273
given in Table 9. The normalized values are ranged be- 6 0.767 0.405 0.264 0.295
tween zero and one. Larger normalized results mean to 7 0.000 0.653 0.409 1.000
the better performance and the best normalized result 8 0.467 0.252 0.136 0.818
should be equal to 1. 9 0.333 0.000 0.000 0.295

Step 2: Grey relational coefficient 0 < ni ðkÞ 6 1 ð13Þ

Grey relational coefficients denote the relationship be- where D0i(k) is the deviation sequence of reference se-
tween the ideal and the actual experimental results. Grey quence x0 ðkÞ and comparability sequence xi ðkÞ,
 
relational coefficient (ni(k)) can be calculated as: D0i ðkÞ ¼ x0 ðkÞ  xi ðkÞ ð14Þ
Dmin þ fDmax  
ni ðkÞ ¼ ð12Þ  
D0i ðkÞ þ fDmax Dmin ¼ minminx0 ðkÞ  xj ðkÞ ð15Þ
8j2i 8k
 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864 1861

 
Table 10  
Dmax ¼ maxmaxx0 ðkÞ  xj ðkÞ ð16Þ
Grey relational coefficients. 8j2i 8k

Experiment number Tool wear Fx Fy Ra f is the distinguishing coefficient (f e [0, 1]) and is used
1 1.000 1.000 1.000 0.786 to adjust the difference of the relational coefficient. In this
2 0.714 0.787 0.786 0.524 study f was taken as 0.5 and the grey relational coefficient
3 0.652 0.617 0.640 0.333
calculated using Eq. (12) was given in Table 10.
4 0.484 0.793 0.598 0.815
5 0.429 0.613 0.414 0.407
6 0.682 0.457 0.404 0.415 Step 3: Grey relational grade
7 0.333 0.590 0.458 1.000
8 0.484 0.401 0.367 0.733 Grey relational grade shows the relationship among the
9 0.429 0.333 0.333 0.415
series and is calculated as follows:

1X n

Table 11 ai ¼ n ðkÞ ð17Þ

n k¼1 i
Grey relational grade and its order.

Experiment number Grade
1 0.946
2 0.703
3 0.560
4 0.672
5 0.466
6 0.490
7 0.596
8 0.496
9 0.378
Order where n is the number of performance characteristics (in
1 this study n is 4). Higher grade relational grade corre-
2 sponds to the closer experimental value to the ideal nor-
5 malized value. Thus, higher grey relational grade shows
3
8
that the corresponding parameter combination is closer
7 to the optimal.
4 Step 4: Grey relational ordering
6 The highest grey relational grade is assigned an order of
9
1. Grey relational grade computed using Eq. (17) and grey
relational order was given in Table 11. According to Ta-
ble 11 and Fig. 16, the control parameters’ setting of 1
(experiment 1) had the highest grey relational grade and
this meant that experiment 1 was the optimal micro-mill-
ing factors’ setting for minimum tool wear, force and sur-
face roughness simultaneously among the other
experiments.
Since higher multiple performance characteristics was
desirable, the larger-the-better S/N quality characteristic
was adopted for grey relational grade. Quality characteris-
tic of the larger-the-better is calculated in the following
equation:
" !#
1 X n
1
S=N ¼ 10log10 ð18Þ
n i¼1 y2i

yi is the ith measured experimental results in a run/row

and n explains the number of measurements in each test
Fig. 16. Grey relational grade. trial/row.

Fig. 17. Main effects plot of S/N ratios for grey relational grade (multiple performance characteristics).
1862 E. Kuram, B. Ozcelik / Measurement 46 (2013) 1849–1864
Table 12
ANOVA for grey relational grade (multiple performance characteristics).
Factors Degree of freedom, DF Sum of squares, SS
Spindle speed 2 0.100961
Feed per tooth 2 0.108374
Depth of cut 2 0.016145
Error 2 0.000841
Total 8 0.226320
The level of a parameter with the highest S/N ratio gives
the optimal level and optimal level was highlighted in cir-
cles in Fig. 17. So the optimal process parameter setting for
the multiple performance characteristic was A1B1C1
(Fig. 17). Thus, the best combination values for maximizing
the multiple performance characteristic were spindle
speed of 10,000 rpm, feed per tooth of 0.5 lm/tooth and
depth of cut of 50 lm.
ANOVA result of the multiple performance characteris-
tics was given in Table 12. The analyses were made for the
level of confidence 95% (the level significance is 5%). Spin-
dle speed, feed per tooth and depth of cut influenced the
multiple performance characteristics by 44.61%, 47.89%
and 7.13%, respectively (Table 12). From the analysis of this
table, it could be concluded that spindle speed and feed per
tooth were two dominant parameters that affect grey rela-
tional grade.
4. Conclusions
In this study, the effects of spindle speed, feed per tooth
and depth of cut on tool wear, force components (Fx and
Fy) and surface roughness during micro-milling of alumi-
num were investigated using Taguchi experimental design
method. All data gathered in the experimental studies
were used to formulate first-order models with interac-
tion. Responses were used alone in optimization study as
an objective function. Taguchi’s signal to noise ratio was
utilized to minimize all responses. The effect of factors
on responses was determined by ANOVA. Responses were
optimized simultaneously using grey relational analysis.
Cutting tools and workpiece surfaces were also examined
via scanning electron microscope (SEM) so that understand
micro-milling process. Adhesion and abrasion wear mech-
anisms were observed in micro-milling of aluminum mate-
rial. Accumulations of plastically deformed workpiece
material were observed on the workpiece surfaces owing
to the high ductility of aluminum material. First-order
models with interaction were developed and it was found
that these models could be used to predict tool wear, force
and surface roughness with a minor error. From mono-
objective results it was concluded that the optimal values
for minimizing tool wear were spindle speed of
10,000 rpm, feed per tooth of 0.5 lm/tooth and depth of
cut of 50 lm. Tool wear increased with spindle speed
and depth of cut. Initially an increment of tool wear with
increasing of feed per tooth was observed; however as feed
per tooth was further increased, tool wear eventually de-
creased. The optimum combination for Fx was spindle
speed of 10,000 rpm, feed per tooth of 0.5 lm/tooth and
depth of cut of 100 lm. Fx increased with an increment
Mean squares, MS F ratio a = 5% P Contribution (%)
0.050480 120.10 0.008 44.61
0.054187 128.91 0.008 47.89
0.008072 19.20 0.049 7.13
0.000420 0.37
100
of spindle speed and feed per tooth but decreased with
depth of cut. The optimum combination for Fy was spindle
speed of 10,000 rpm, feed per tooth of 0.5 lm/tooth and
depth of cut of 75 lm. Fy increased with an increment of
spindle speed and feed per tooth. The increment of the
depth of cut initially increased Fy; however, as this param-
eter was further increased, Fy eventually decreased. For Ra,
optimum parameters were found to be as spindle speed of
12,000 rpm, feed per tooth of 0.5 lm/tooth and depth of
cut of 50 lm. Ra decreased with spindle speed and in-
creased with feed per tooth and depth of cut. From ANOVA
results, it was concluded that spindle speed was more sig-
nificant factor for all responses except for Ra. For Ra, feed
per tooth was more significant factor. From multi-objective
optimization results it was found that the best combina-
tion values for minimizing the tool wear, Fx, Fy and surface
roughness were spindle speed of 10,000 rpm, feed per
tooth of 0.5 lm/tooth and depth of cut of 50 lm. The ap-
proach used in this study can be utilized in simultaneously
optimizing the micro-milling of other materials and
responses.
Acknowledgements
First author, Emel Kuram was awarded Ph.D. scholar-
ship by TUBITAK (BIDEB) and thanks to TUBITAK (BIDEB).
The authors thank to Gebze Institute of Technology for
supporting this project (Project No: BAP 2012-A19).
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