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Int J Adv Manuf Technol (2009) 40:41–48

DOI 10.1007/s00170-007-1314-3

ORIGINAL ARTICLE

Grey–Taguchi method to optimize the milling parameters


of aluminum alloy
C. C. Tsao

Received: 18 July 2007 / Accepted: 13 November 2007 / Published online: 11 December 2007
# Springer-Verlag London Limited 2007

Abstract The grey–Taguchi method was adopted in this tool condition monitoring technology [1–7]. A couple of
study to optimize the milling parameters of A6061P-T651 investigators have shown that tool wear can be well
aluminum alloy with multiple performance characteristics. correlated to cutting parameters [6, 7]. In fact, tool wear
A grey relational grade obtained from the grey relational has been represented as a function of tangential cutting force
analysis is used as the performance characteristic in the and cutting conditions. However, the tangential cutting force
Taguchi method. Then, the optimal milling parameters are is still correlated with the geometric shape of the tool [8].
determined using the parameter design proposed by the Prickett and Johns presented an overview of approaches to
Taguchi method. Experimental results indicate that the end milling tool monitoring techniques for the detection of
optimal process parameters in milling A6061P-T651 cutting tool wear and breakage during the milling process
aluminum alloy can be determined effectively; the flank [9]. Surface roughness is a measurable characteristic that
wear is decreased from 0.177 mm to 0.067 mm and the could influence the performance of mechanical pieces and
surface roughness is decreased from 0.44 μm to 0.24 μm, the production costs. Achieving the desired surface quality is
leading to a multiple performance characteristics improve- of great importance for the functional behavior of a specific
ment in milling qualities through the grey–Taguchi method. part. Some studies to optimize the cutting conditions to reach
a specific surface roughness have already been carried out
Keywords End mill . Aluminum alloy . Grey-Taguchi [10–12]. Özel et al. investigated machining of AISI D2 steel
method . Grey relational analysis . Analysis of variance using multi-radii wiper mixed alumina ceramic inserts with
TiN coating [13]. It has been shown that using the neural
network models for predicting surface roughness as low as
1 Introduction 0.18–0.20 μm is attainable with wiper tools. A general
overview of the different approaches that are used for
In the automotive and aerospace industries, cutting alumi- predicting surface roughness and certain remarks concerning
num alloys is a major manufacturing process. Milling with each approach can be found in [14]. Furthermore, Yellowley
an end mill is one of the important machining processes for derived an explicit expression of the force and torque with
making profiles, slots, engraving, surface contouring, and multiple straight cutting edges [15]. In the case of end
pockets in precision molds and dies. The machining process milling, the expression was also extended to consider the
is capable of both roughing and finishing operations. It is effect of the helix angle. Medicus et al. assessed the tool
well known that tool wear influences the quality of machined wear rates for high speed machining of aluminum bronze
components. Most published papers deal with the on-line using mean force, flank wear depth, and surface finish [16].
Cakir and Cavdar developed a knowledge-based expert
system to solve metal cutting problems in three main metal
C. C. Tsao (*) cutting areas: turning, milling, and drilling [17].
Department of Automation Engineering,
Tahua Institute of Technology,
Today, there is a worldwide demand for the development
Hsinchu 30740 Taiwan, Republic of China of environmentally friendly and cost effective cutting tech-
e-mail: aetcc@msdb.thit.edu.tw nologies including deposited coatings, high-performance
42 Int J Adv Manuf Technol (2009) 40:41–48

tool geometrics, and material suitable for dry high-speed numerous parameters. As discussed in Sect. 1, many reports
cutting. In dry machining, however, metals of good showed that the tool coating, geometry, and milling
plasticity like aluminum always exhibit high friction and conditions have significant influence on the tool wear and
strong adhesive interaction with tool geometry and surface roughness during milling. In order to observe the
materials, and therefore have a strong tendency of built- degree of influence of control factors (different coatings,
up edge (BUE) formation. BUE has been known to be the helix angle, primary relief angle, cutter diameter, depth of
main reason for high cutting force, poor surface finish, cutting, width of cutting, feed rate, and spindle speed) in
and short tool lifetime. The wear-resistant chemical milling, three levels of eight factors each, are considered,
vapour deposition (CVD) or physical vapour deposition and an L27(313) orthogonal array (OA) was employed. The
(PVD) of surface coatings can protect the heat-spreading OA has 13 columns and 27 rows. Each milling parameter
layer from dissolution and oxidation during cutting. was assigned to a column, according to the standard linear
Diamond-like carbon film coating (DLC) has a low graph [20, 21]. The milling experiment factors and levels
friction coefficient (0.1) against aluminum alloy and an are shown in Table 1. The range of milling parameters is
excellent anti-adhering property. Dai et al. found that the limited by the capability of the machining center. The
wear life of diamond and DLC-coated cutting inserts were spindle speed, feed rate, width of cutting, and depth of
prolonged significantly; the temperature of the cutting cutting are selected according to the pilot experiment. The
insert and cut material has been lowered with an OA follows a random run order. The run order is a
improvement in the processing quality of the workpiece completely random ordering of the experiments that should
[18]. Lahres et al. investigated crystalline hard coating with be followed when running the experiments in order to
“softer” morphological regions (such as WC/C, CrC/C, or reduce experimental error. In this study, the flank wear and
TiN+MoS2), and super-hard diamond coatings have been surface roughness were selected as quality characteristic
recommended in the dry milling of aluminum alloy [19]. factors to get the smaller-the-better characteristics. The S/N
The Taguchi method has been extensively adopted in ratio of the smaller-the-better characteristic can be
manufacturing to solve some confusing problems and to expressed as
improve product/process design optimization with a single
1X 2
j
performance characteristic [20, 21]. In 1982, Deng first S=N ¼ 10 log y ð1Þ
proposed grey relational analysis to fulfill the crucial j i¼1 i
mathematical criteria for dealing with a poor, incomplete,
where j is the number of repetitions of the experiment and
and uncertain system [22]. Grey relational analysis can
yi is the average measured value of experimental data i.
effectively be recommended as a method for optimizing the
The purpose of the analysis of variance (ANOVA) is to
complicated inter-relationships among multiple perfor-
investigate which of the process parameters significantly
mance characteristics [23–26]. Through the grey relational
affect the performance characteristics. This is accomplished
analysis, a grey relational grade is obtained to evaluate the
by separating the total variability of the S/N ratios, which is
multiple performance characteristics. As a result, optimiza-
measured by the sum of the squared deviations from the
tion of the complicated multiple performance characteristics
total mean of the S/N ratio, into contributions by each of
can be converted into the optimization of a single grey
relational grade. The grey–Taguchi method was established
for combining both grey relational analysis and the Taguchi
method. The grey–Taguchi method was successfully ap- Table 1 Factors and levels in milling
plied to optimize the multiple performance characteristics Symbol Factors Level 1 Level 2 Level 3
of complicated problems in manufacturing processes [27–
32]. In this study, the grey–Taguchi method was used to A Coating type TiN+ TiCN+ TiAlN+
optimize the milling process parameter of A6061P-T651 DLC DLC DLC
B Helix angle (deg) 40 45 50
aluminum alloy for end mills. The multiple performance
C Primary relief angle 4 6 8
characteristics included small flank wear and low surface
(deg)
roughness after end milling. D Cutter diameter 10 12 8
(mm)
E Depth of cutting 2 3 2.5
2 Taguchi method (mm)
F Width of cutting 2 3 2.5
A quality analysis to evaluate the results obtained thus far is (mm)
G Feed rate (mm/rev) 0.02 0.03 0.04
desirable. This analysis can be achieved by employing the
H Spindle speed (rpm) 5,000 5,500 6,000
signal-to-noise (S/N) ratio to calculate quality and evaluate
Int J Adv Manuf Technol (2009) 40:41–48 43

the process parameters and the error. The equations of experimental results. The grey relational coefficient ξi(k)
ANOVA and the F-test can be expressed as can be expressed as

P " #2 $ min þζ$ max


b2Ai 1 Xm ξ i ðk Þ ¼ ð6Þ
SSA ¼  b ð2Þ $oi ðk Þ þ ζ$ max
N m i1 Ai
where Δoi is the deviation sequence of the reference
sequence (xo) and the comparability sequence (xi), i.e.
$oi ¼ kxo ðk Þ  xi ðk Þk, and ζ is the distinguishing coeffi-
SSA
VA ¼ ð3Þ cient set between zero and unity; in this study, it was set to
fA
ζ=0.5. $ max ¼ 8max j 2 i8k max kxo ðk Þ  xi ðk Þk is the larg-
est value of Δoi and $ min ¼ 8min j 2 i8k min kxo ðk Þ  xi ðk Þk
VA is the smallest value of Δoi. Next, the grey relational grade
FAO ¼ ð4Þ ξ(xo,xi) is computed by averaging the grey relational
VCE
coefficient corresponding to each performance characteris-
where A represents one of the experimental parameters, m is tic. It is defined as
the number of experiments in the orthogonal array, SSA is
the sum of the squared deviations for parameter A, βA is the 1X n
x ð xo ; xi Þ ¼ x ðk Þ ð7Þ
mean S/N ratio of the ith experiment for parameter A, N is n k¼1 i
the repetition of each level of the parameter A, VA is the
variance of parameter A, fA is the degree of freedom for where n is the number of performance characteristics. The
parameter A, FAo is the F-test for parameter A, o is the grey relational grade shows the correlation between the ref-
number of the process parameters that significantly affect erence sequence and the comparability sequence. The evalu-
the performance characteristic, and VCE is the variance of ated grey relational grade fluctuates from 0 to 1 and equals 1 if
combined error parameters. these two sequences are identically coincident.

3 Grey relational analysis 4 Experimental procedures

In the grey relational analysis, data preprocessing is first In order to investigate the flank wear and surface roughness
performed in order to normalize the raw data for analysis. during milling processes, all end mill material was of
In this study, a linear normalization of the experimental submicron grade tungsten carbide (SANDVIK H10F) with
results is performed in the range between zero and unity, two flutes. The experiments were processed with down
which is also called the grey relational generating [22]. milling because up milling performed poorly in the initial
Usually, there are three categories of performance charac- testing. All end mills were coated by physical vapour
teristics in the analysis of normalized values, i.e. the lower- deposition using a Balzers-1200 machine. The thickness of
the-better, the higher-the-better, and the nominal-the-better. the multilayer coating is about 3 μm. The size of the
In general, the smaller-the-better is the expected value for workpiece was 105 mm×105 mm×76 mm in all tests.
flank wear and surface roughness in milling A6061P-T651
aluminum alloy by end mills. Then, the normalized results 4.1 Milling tests to measure flank wear
can be expressed as
High stresses and temperatures characterize the tool-chip
max hi ðk Þ  hi ðk Þ contact interface, contributing to the wearing action. Flank
xi ð k Þ ¼ ð5Þ
max hi ðk Þ  min hi ðk Þ wear is the main wear mechanism in milling. In general,

where xi(k) is the normalized value of the kth performance


characteristic in the ith experiment, ηi(k) is the kth
experimental result in the ith experiment, and maxηi(k)
and minηi(k) are the maximum and minimum values of
ηi(k), respectively. According to Deng, larger normalized
results correspond to better performance and the best
normalized result should be equal to one [22]. Then, the
grey relational coefficients are calculated to express the
relationship between the ideal (best) and the actual Fig. 1 End and side flank wear on the end mill
44 Int J Adv Manuf Technol (2009) 40:41–48

Table 2 Experimental results for flank wear and surface roughness carried out using a LEADWELL MCV-610AP three-axis
Test A B C D E F G H Flank Surface vertical machining center having a maximum power of
no. wear roughness 5.5 kW and a maximum spindle speed of 6,000 rpm. After
(mm) (μm) removing 6.615 ×105mm3 of A6061P-T651 aluminum
alloy, the end mill was measured with a Mitutoyo TM-
1 1 1 1 1 1 1 1 1 0.515 0.24
101 tool microscope with a precision of 0.005 mm at a
2 1 1 1 1 2 2 2 2 0.588 0.76
magnitude of ×30 to accurately measure the width of the
3 1 1 1 1 3 3 3 3 1.203 0.90
4 1 2 2 2 1 1 1 2 0.337 0.32 end flank wear (WE) and side flank wear (WS) off-line. Dry
5 1 2 2 2 2 2 2 3 0.177 0.44 compressed air 6 kg/cm2 was utilized to directly spurt the
6 1 2 2 2 3 3 3 1 0.296 0.54 cutting zone for the purpose of cooling. The total flank
7 1 3 3 3 1 1 1 3 0.531 0.34 wear (Wi) can be calculated as
8 1 3 3 3 2 2 2 1 0.920 0.75 qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
9 1 3 3 3 3 3 3 2 1.044 0.88 Wi ¼ WS2i þ WE2i i ¼ 1~27 ð8Þ
10 2 1 2 3 1 2 3 1 0.203 1.45
11 2 1 2 3 2 3 1 2 1.151 0.65
12 2 1 2 3 3 1 2 3 1.110 1.35
13 2 2 3 1 1 2 3 2 0.055 1.12 4.2 Milling tests to measure surface roughness
14 2 2 3 1 2 3 1 3 0.068 0.26
15 2 2 3 1 3 1 2 1 0.098 0.66
16 2 3 1 2 1 2 3 3 0.097 0.45 Surface roughness is widely used to assess the quality of
17 2 3 1 2 2 3 1 1 0.191 0.22 mechanical products, especially in contact mechanics. It is
18 2 3 1 2 3 1 2 2 0.326 0.44 affected by the machining process, such as changes in the
19 3 1 3 2 1 3 2 1 0.087 0.96 conditions of the component, tool, or machine. The
20 3 1 3 2 2 1 3 2 0.534 1.06 arithmetic average method is the most widely used
21 3 1 3 2 3 2 1 3 0.190 0.42 averaging method for surface roughness today. In this
22 3 2 1 3 1 3 2 2 0.891 2.00
study, a Hommel Tester T1000 (Hommel-Etamic GmbH,
23 3 2 1 3 2 1 3 3 0.788 1.85
Germany) was used to measure the surface roughness after
24 3 2 1 3 3 2 1 1 0.460 1.25
25 3 3 2 1 1 3 2 3 0.065 0.88 removing a volume of 6.615×105 mm3 from the A6061P-
26 3 3 2 1 2 1 3 1 0.103 0.66 T651 aluminum alloy. Average roughness (Ra) can be
27 3 3 2 1 3 2 1 2 0.067 0.24 obtained by taking the average of 20 different positional
deviations over a 10 mm interval distance in a sampling
length of 2.4 mm with a cut-off at 0.8 mm. The equation of
flank wear occurs on the flank, or relief face, of the tool. It average surface roughness is given as
can be divided into two groups: end flank wear and side
1 X20
flank wear as shown in Fig. 1. As the removal volume Ra ¼ jzi j ð9Þ
increases, the end mill wear increases. Milling tests were 20 i¼1

Table 3 ANOVA for flank wear

Factors Level (S/N) DF SS V F ρ (%)

1 2 3

Coating type 0.552 1.387 1.310 2 3.831 1.915 20.38 18.4


Helix angle 0.684 1.262 1.302 2 2.153 1.076 11.45 10.3
Primary relief angle 0.700 1.264 1.285 2 1.984 0.992 10.56 9.5
Cutter diameter 1.605 1.339 0.304 2 8.500 4.250 45.23 40.8
Depth of cutting 1.400 0.935 0.914 2 1.357 0.679 7.22 6.5
Width of cutting 0.855 1.381 1.012 2 1.314 0.657 6.99 6.3
Feed rate 1.132 1.059 1.057 2 0.032 0.016
Spindle speed 1.257 0.859 1.132 2 0.746 0.373
Error 10 0.940 0.094 4.5
PE (14) (1.718) (0.123) (8.2)
Total 26 20.858 100

DF degree of freedom, SS sum of squares, V variance, P percentage of contribution, PE pooled error


Int J Adv Manuf Technol (2009) 40:41–48 45

Table 4 ANOVA for surface roughness

Factors Level (S/N) DF SS V F ρ (%)

1 2 3

Coating type 0.567 0.438 0.124 2 0.934 0.467 11.01 11.7


Helix angle 0.233 0.260 0.637 2 0.917 0.458 10.81 11.5
Primary relief angle 0.329 0.416 0.385 2 0.035 0.017
Cutter diameter 0.524 0.633 –0.030 2 2.252 1.126 26.56 28.2
Depth of cutting 0.331 0.426 0.372 2 0.041 0.020
Width of cutting 0.417 0.364 0.349 2 0.023 0.011
Feed rate 0.869 0.173 0.087 2 3.311 1.655 39.05 41.5
Spindle speed 0.398 0.324 0.408 2 0.038 0.019
Error 2 0.424 0.042 5.3
PE (18) (0.561) (0.031) (7.0)
Total 26 7.975 100

DF degree of freedom, SS sum of squares, V variance, P percentage of contribution, PE pooled error

where zi is the value of surface roughness in irregular


measurement points.

Table 5 Grey relational coefficient, grey relational grade and rank for 5 Results and discussion
each experiment

Test Grey relational coefficient Grey relational Rank Table 2 shows the experimental data between milling
no. grade parameters and quality character factors (flank wear and
Flank Surface
surface roughness) for end mills in milling A6061P-T651
wear roughness
aluminum alloy. Tables 3 and 4 illustrate the results of the
1 0.5551 0.9781 0.7666 11 analysis of variance (ANOVA) with the flank wear and
2 0.5185 0.6224 0.5704 18
3 0.3333 0.5669 0.4501 24
4 0.6706 0.8990 0.7848 9
5 0.8247 0.8018 0.8132 5 Table 6 Response table for the grey relational grade
6 0.7043 0.7355 0.7199 15
7 0.5467 0.8812 0.7139 16 Symbol Factors Level Level Level ABS Rank
8 0.3989 0.6267 0.5128 21 1 2 3 (max–-
9 0.3672 0.5742 0.4707 23 min)
10 0.7950 0.4198 0.6074 17
11 0.3437 0.6742 0.5090 22 A Coating 0.6447 0.7263 0.6593 0.0816 5
12 0.3524 0.4406 0.3965 25 type
13 1.0000 0.4972 0.7486 12 B Helix 0.5988 0.6805 0.7510 0.1522 3
14 0.9779 0.9569 0.9674 2 angle
15 0.9302 0.6692 0.7997 7 C Primary 0.6207 0.7093 0.7003 0.0886 4
16 0.9318 0.7947 0.8632 4 relief
17 0.8084 1.0000 0.9042 3 angle
18 0.6793 0.8018 0.7405 14 D Cutter 0.7618 0.7684 0.5002 0.2682 1
19 0.9471 0.5460 0.7466 13 diameter
20 0.5451 0.5145 0.5298 19 E Depth of 0.7089 0.6666 0.6549 0.0540 8
21 0.8096 0.8165 0.8130 6 cutting
22 0.4071 0.3333 0.3702 27 F Width of 0.6582 0.7147 0.6574 0.0573 7
23 0.4392 0.3532 0.3962 26 cutting
24 0.5863 0.4635 0.5249 20 G Feed rate 0.7736 0.6365 0.6202 0.1534 2
25 0.9829 0.5742 0.7785 10 H Spindle 0.7087 0.6336 0.6880 0.0751 6
26 0.9228 0.6692 0.7960 8 speed
27 0.9794 0.9781 0.9788 1
Total mean value of the grey relational grade=0.6768
46 Int J Adv Manuf Technol (2009) 40:41–48

Fig. 2 Response graph of grey 0.8

relational grade 0.76

Grey relational grade


0.72

0.68

0.64

0.6

0.56

0.52

0.48
A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3

Milling parameters level

surface roughness in milling A6061P-T651 aluminum multiple performance characteristics among all experi-
alloy. In Table 3, the most important variables affecting ments. Table 6 and Fig. 2 show the response table and
the flank wear are cutter diameter (40.8% contribution), graph of grey relational grade for each milling parameter
followed by coating type (18.4%), helix angle (10.3%), at different levels, respectively. As shown in Table 6, the
primary relief angle (9.5%), depth of cutting (6.5%), and important rank in sequence for various milling parameters
width of cutting (6.3%). Feed rate and spindle speed had in milling A6061P-T651 aluminum alloy is DGBCAHFE.
lesser effects on flank wear. In Table 4, the feed rate (41.5 %) Table 7 illustrates the results of ANOVA for multiple
is the most significant factor, followed by the cutter diameter performance characteristics in milling A6061P-T651 alu-
(28.2 %), the coating type (11.7 %), and helix angle (11.5 %). minum alloy. As shown in Table 7, the main contribution
Primary relief angle, depth of cutting, and width of cutting percentages for cutter diameter (D), feed rate (G), helix
are insignificant on the surface roughness. These results angle (B), and primary relief angle (C) to multiple
conflict with flank wear and surface roughness in milling performance characteristics in milling A6061P-T651 alu-
A6061P-T651 aluminum alloy. In order to investigate minum alloy were 50.3%, 15.3%, 12.5%, and 5.1%,
optimization of milling parameters for flank wear and respectively.
surface roughness, the analysis of multiple performance A confirmative test is the last step for the grey-Taguchi
characteristics is need. Table 5 shows the grey relational method to verify the improvement of multiple performance
coefficient, the grey relational grade, and its rank for each characteristics at the optimal levels of selected milling
experiment. The higher grey relational grade implies that parameters. The optimum combinations for the above milling
the corresponding experimental result is closer to the ideal parameters were set, and two trials were conducted in the
normalized value. In other words, the larger the grey confirmative test. In order to assess the closeness of the
relational grade, the better will be the multiple perfor- observed value of S/N ratio with that of the predicted value,
mance characteristics. Owing to the fact that experiment the confidence interval (CI) value for the optimum factor level
27 has the highest grey relational grades, it has the best combination at a 95% confidence level is determined. The

Table 7 ANOVA for multiple performance characteristics Table 8 Results of milling performance by initial and optimal milling
parameters
Factors DF SS V F ρ (%)
Initial milling Optimal milling parameters
Coating type 2 0.0340 0.0170 parameters
Helix angle 2 0.1043 0.0521 11.39 12.5 Prediction Confirmation
Primary relief angle 2 0.0428 0.0214 4.67 5.1 tests
Cutter diameter 2 0.4212 0.2106 45.97 50.3
Depth of cutting 2 0.0145 0.0007 Setting level A1B2C2D2 A3B3C2D1 A3B3C2D1
Width of cutting 2 0.0194 0.0097 E2F2G2H3 E3F2G1H2 E3F2G1H2
Feed rate 2 0.1278 0.0639 13.95 15.3 Flank wear 0.177 0.067
Spindle speed 2 0.0270 0.0135 Surface 0.44 0.24
Error 10 0.0458 0.0046 5.5 roughness
PE (18) 0.1408 0.0078 16.8 Grey 0.8132 0.9687 0.9788
Total 26 0.8370 100 relational
grade
DF degree of freedom, SS sum of squares, V variance, P percentage of
contribution, PE pooled error Improvement of the grey relational grade=0.1656
Int J Adv Manuf Technol (2009) 40:41–48 47

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