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Experimental Investigation of Material Removal Rate in CNC TC Using Taguchi

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February 2015, Volume 2, Issue 2 JETIR (ISSN-2349-5162)

Experimental Investigation of Material Removal Rate

in CNC TC Using Taguchi Approach
Mihir Thakorbhai Patel
Lecturer, Mechanical Engineering Department, B. & B. Institute of Technology, Vallabh Vidyanagar, India.

Abstract— This paper deals with the optimization of machining parameters in rough turning of E 250 B0 of standard IS:
2062 using carbide insert. During the experiments, controllable parameters like speed, feed and depth of cut are used to
explore the effect on material removal rate. The optimization of material removal rate is done using nine experimental
runs base on L9 orthogonal array by using Taguchi method. After conducting the experiments the material removal rate
was measured and Signal to Noise ratio was calculated. With the help of graphs of raw and SN ratio data, optimum
parameter values were obtained and the confirmation experiments were carried out. These results were compared with
the results of full factorial method. ANOVA analysis also performed to determine which parameters are the most
significant effect on material removal rate.

Index Terms— ANOVA, Design of Experiments, Material Removal Rate, Orthogonal Array, SN Ratio, Taguchi Method.

1. Introduction
The recent developments in science and technology have put tremendous pressure on manufacturing industries. The manufacturing
industries are trying to decrease the cutting costs, increase the quality of the machined parts and machine more difficult materials
[1]. Basically, classical parameter design, developed by Fisher, is complex and not easy to use. Especially, a large number of
experiments have to be carried out when the number of the process parameters increases[6]. Traditional experimental design
methods are very complex, difficult to use and time consuming. Additionally, these methods require a large number of experiments
when the number of process parameters and their levels are increases. In order to minimize the number of experiments required,
Taguchi experimental design method, a powerful tool for designing high-quality system, was developed by Taguchi [11]. Taguchi
method is efficient method for designing process that operates consistently and optimally over a diversity of conditions [4]. One
of the important steps involved in Taguchi’s technique is selection of an orthogonal array (OA). An OA is a small set from all
possibilities which helps to determine least no. of experiments, which will further help to conduct experiments to determine the
optimum level for each process parameters and establish the relative importance of individual process parameters [5].

2. Literature Review
Mihir Patel et. al. [7],[8] have taken input parameters (controllable factors): speed, feed and depth of cut and only few researcher
taken input parameter: nose radius, environment and output parameters: Surface roughness for turning, few researcher taken output
parameter: material removal rate, They also found that for surface roughness the most significant parameters are speed, feed and
nose radius and least significant parameter is DOC and for MRR the most significant parameters are DOC, feed and speed and least
significant parameter is nose radius.

3. Approach for improve quality of product and process

There are various methodologies by which a given process can be optimized. There are different methodologies that are used to
improve the quality of product and process. Some widely used approaches in product/process development are[10].
 Build-Test-Fix
 One Factor at a time
 Design of Experiment (DOE)

Build-Test-Fix
The “Build-test-fix” is the most basic approach which is rather inaccurate as the process is carried out according to the resources
available, instead of trying to optimize it. In this method the process/product is tested and reworked each time till the results are
acceptable.

One factor at a time

The “one factor at a time” approach is aimed at optimizing the process by running an experiment at one particular condition and
repeating the experiment by changing any other one factor till the effect of all factors are recorded and analyzed. Evidently, it is a
very time consuming and expensive approach. In this process, interactions between factors are not taken in to account.

Design of Experiment

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February 2015, Volume 2, Issue 2 JETIR (ISSN-2349-5162)

The Design of Experiments is referred as one of the most comprehensive approach in product/process developments. It is a statistical
approach that attempts to provide a predictive knowledge of a complex, multi-variable process with trials. Following are the major
approaches to DOE:
 Full Factorial Design
 Taguchi Method

Full Factorial Design

A full factorial design contains all possible arrangements of a set of factors. This is the most fool proof design approach, but it is
also the most costly and time consuming in experimental resources. A common experimental design is the one with all input factors
set at two levels each. If there are k factors each at 2 levels; a full factorial design has 2 k runs. Thus for 6 factors at two levels it
would take 26 =64 trial runs. Full factorial designs are the most traditional of all design types. There is little scope for uncertainty
when you are willing to try all combinations of the factor settings. Unfortunately, the sample size grows exponentially in the number
of factors, so full factorial designs are too costly to run for most practical purposes.

Taguchi Method
Taguchi thus, recommends the use of the loss function to measure the performance characteristics that are deviating from the desired
target value. The value of this loss function is further transformed into signal-to-noise (S/N) ratio. This loss function value is further
converted into a signal-to-noise (S/N) ratio. Basically, the performance characteristic has following three categories of the S/N ratio
[3],[9].
The Nominal-the-Better characteristics
S/N ratio = − 10 log10 [Square of mean/Variance] ---------------------------(1)
The Larger-the-Better characteristics
S
ratio = −10 log10 [mean of sum squares of reciprocal of measured data] -- ------------------------(2)
N
The Lower-the-Better characteristics
S/N ratio = − 10 log10 [mean of sum of square of measured data] -----------------------------(3)
Steps involved in Taguchi Method:

• Determine the Quality/Performance Characteristic to be Optimized.

1
• Identify the testing condition and determine the number of levels and possible
2 intereaction between the process

• Select appropriate Orthogonal Array and assign OA to process parameters.

3

• Conduct the experimental according to OA matrix

4

• Analysed the results.

5
• Select the optimal level of process parameters.
6

• Verify the optimal process parameters through conformation experiments.

7

4. Taguchi Experimental Procedure

Taguchi is systemic approach to achieve optimal level of process parameters for given performance characteristics. Here material
removal rate is taken as performance characteristics for given case study and experiments are carried out on CNC TC for rough
turning. The procedure is given below.

4.1 Determine the Quality/Performance characteristic to be optimized

For a given case study the quality/performance characteristics is material removal rate. The material removal rate has been
calculated from the difference of weight of work before and after machining by using following formula.
W -W
MRR= i f
ρt
Where,
Wi = weight of work before machining
Wf = weight of work after machining
ρ = density of E250 B0 grade material
t = machining time in sec
For given case study the objective function taken larger the better and

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 n  2 

1 1
S/N ratio for given function = -10 log10    
 n i 1  yi  
 
4.2 Identify the testing condition and ddetermine the number of levels and possible interaction between the process
The experimental setup and testing condition as below:
Work piece material : E 250 B0 of standard IS: 2062
Machine Tool : Sprint 20 TC made by Batliboi
The chemical composition of : E 250 B0 material:

Table 1 Chemical composition of E 250 B0 of standard IS: 2062[2]

Grade Quality C% Mn % S% P% Si C. E. %

Max. Max. Max. Max. Max. Max.

E 250 B0 0.22 1.5 0.045 0.045 0.4 0.41

Cutting Tool : Sandvik CNMG 12 04 08-PR 4225

Testing Equipment: Digital weight scale and stop watch
The controllable factors and their levels were decided for conducting the experiment, based on a “brain storming” that was held
with a group of people and also considering the guide lines given in the operator’s manual provided by the manufacturer of the lathe
machine and tool inserts company. The factors and their levels are shown in table 2

Table 2 Cutting Parameters and their levels

Levels
Parameters/ Factors
1 2 3

Speed (rpm) 800 1000 1200

Feed (mm/rev) 0.1 0.15 0.2

Depth of cut (mm) 0.5 1 1.5

4.3 Select appropriate Orthogonal Array and assign OA to process parameters

The selection of orthogonal array based on number of factors to be studied, number of levels for each factor and Number of
interactions to be estimated.
For above mentioned parameters/factors and their levels for single interaction
Degree of freedom (DOF) for Speed = (3-1) = 2
Degree of freedom (DOF) for Feed = (3-1) = 2
Degree of freedom (DOF) for Depth of cut = (3-1) = 2
The total degree of freedom = 2 + 2+ 2 = 6
Therefore Minimum number of experiment = Total DOF for parameters +1 = 6 + 1
Minimum number of experiment =7
L9 orthogonal array of Taguchi is selected. L9 orthogonal array designed as shown in below table 3.

Table 3 L9 Orthogonal Array Design

A (Speed) B (Feed) C (DOC)
in rpm in mm/rev in mm
1 1 1
1 2 2
1 3 3
2 1 2
2 2 3
2 3 1
3 1 3
3 2 1
3 3 2

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4.4 Conduct the experimental according to OA matrix

According to above OA, experiments were conducted with their factors and their levels as mentioned in table 2. The experimental
matrix with the selected values of the factors is shown in Table 3. Each of the above 9 experiments were conducted 2 times to
account for the variations that may occur due to the noise factors. The material removal rate (MRR) was measured using the Digital
scale weight and stop watch. The table 4 shows the values of material removal rate obtained from different experiments with their
SN ratio value.

Table 4 Experimental Result of Material Removal Rate for Rough Turning

Exp. A (Speed) B (Feed) C (DOC) MRR SN Ratio for
No. in rpm in mm/rev in mm In mm3/sec MRR

1 800 0.10 0.5 119.81 41.5695

2 800 0.15 1.0 529.90 54.4838
3 800 0.20 1.5 910.56 59.1862
4 1000 0.10 1.0 417.52 52.4134
5 1000 0.15 1.5 819.95 58.2758
6 1000 0.20 0.5 270.24 48.6349
7 1200 0.10 1.5 661.25 56.4073
8 1200 0.15 0.5 260.03 48.3670
9 1200 0.20 1.0 1032.27 60.2758

4.5 Analysed the result

Figures 1show that there is significance interaction between the processes parameters in affecting the material removal rate, since
the responses at different levels of process parameters for a given level of parameter value are almost interact with each other.

Interaction Plot for MRR

Data Means
1 2 3
1000 A (Speed)
1
2
500 A (Speed) 3

0
1000 B (Feed)
1
2
B (Feed) 500 3

0
1000 C (DOC)
1
2
500 C (DO C) 3

0
1 2 3 1 2 3

Figure 1 Interaction Plot for MRR

4.6 Select the optimal level of process parameters

The average values of material removal rate (MRR) for rough turning for each process parameter at levels (1, 2 & 3) for raw data
and S/N ratio data are plotted in Figures 2 and 3 respectively. Figures 1 & 2 told that the material removal rate maximum at for
speed at level 3, feed at level 3 and depth of cut at level 3. Then, optimal sequence for the material removal rate for rough turning
is A3B3C3.

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Main Effects Plot for Means for MRR

Data Means
A (Speed) B (Feed)
800

600

400
Mean of Means

200
1 2 3 1 2 3
C (DOC)
800

600

400

200
1 2 3

Figure 2 Main effects plot for means for MRR

Main Effects Plot for SN ratios for MRR

Data Means
A (Speed) B (Feed)
57
54
51
Mean of SN ratios

48
45
1 2 3 1 2 3
C (DOC)
57
54
51
48
45
1 2 3
Signal-to-noise: Larger is better
Figure 3 Main Effects Plot for SN Ratio for MRR

4.7 Verify the optimal process parameters through conformation experiments

Estimation of means
The optimal setting of selected process parameters is: A3B3C3
The estimated mean of the response characteristic Ra (Turning) can be computed as:
𝜇𝐴4𝐵1 𝐶3 𝐷1 = T ̅3 − T
̅ + (A ̅) + (B
̅3 − T ̅3 − T
̅) + (C ̅)
=A̅3 + B ̅ 3 + −3(T
̅3 + C ̅)
= 651.8 + 737.7 + 793.3 + −3(518.17)
= 632.29 mm3/sec

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The 95 % confidence interval of the predicted optimum means is:

= (𝜇𝐴3 𝐵3𝐶3 − 𝐶𝐼) < 𝜇𝐴3𝐵3𝐶3 < (𝜇𝐴3𝐵3 𝐶3 + 𝐶𝐼)
= −36.48 < 𝜇𝐴3 𝐵3𝐶3 < 1301.06
Four confirmation experiments were thus conducted at the optimal settings for turning process parameters recommended by the
investigation. The average value of material removal rate (Rough Turning) while turning E 250 B0 of standard IS: 2062 material
with CVD -coated carbide inserts was found to 1155.8 mm3/sec. This result was within the 95% confidence interval of the predicted
optimal value of the selected responding characteristic Ra (Turning). Hence the optimal settings of the process parameters, as
predicted in the analysis, can be implemented.

5. Full Factorial Design

A full factorial design contains all possible arrangements of a set of factors. As far as the following experiments are concerned the
3 factors i.e.; speed, feed, and depth of cut were considered at 3 different levels as shown in Table 2. These were compared with
the results of the fractional factorial that was conducted using Taguchi method. The full factorial design matrix as shown in below.

Table 5 Full Factorial Design Matrix

Exp. A (Speed) B (Feed) C (DOC) MRR
No. in rpm in mm/rev in mm In mm3/sec
1 800 0.1 0.5 119.81
2 800 0.1 1 349.38
3 800 0.1 1.5 460.52
4 800 0.15 0.5 179.41
5 800 0.15 1 529.90
6 800 0.15 1.5 709.24
7 800 0.2 0.5 234.40
8 800 0.2 1 690.42
9 800 0.2 1.5 910.56
10 1000 0.1 0.5 141.87
11 1000 0.1 1 417.52
12 1000 0.1 1.5 547.53
13 1000 0.15 0.5 210.80
14 1000 0.15 1 620.97
15 1000 0.15 1.5 819.95
16 1000 0.2 0.5 270.24
17 1000 0.2 1 795.84
18 1000 0.2 1.5 1059.84
19 1200 0.1 0.5 170.47
20 1200 0.1 1 501.88
21 1200 0.1 1.5 661.25
22 1200 0.15 0.5 262.03
23 1200 0.15 1 774.51
24 1200 0.15 1.5 1007.74
25 1200 0.2 0.5 302.88
26 1200 0.2 1 1032.27
27 1200 0.2 1.5 1143.47

6. Comparisons of Full factorial design with Taguchi parameter design

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From above full factorial matrix the maximum material removal rate ware obtained at 1200 rpm, 0.2 mm/rev and 1.5 mm of depth
of cut. From Taguchi parameter design the optimum parameter levels obtained were also the same. Thus, it can be noted that
Taguchi parameter design will also give same and accurate results with lesser number of experiments.

7. ANOVA
Analysis of variance is important analysis to find out which parameters are most significant effect on the performance characteristics
and also help to determine to % contribution of each parameters. In the analysis, the sum of squares and variance are calculated. F-
test value at 95 % confidence level is used to decide the significant factors affecting the process and percentage contribution is
calculated [19]. The ANOVA analysis for percentage calibration is shown in Table 6. It is clear from the table that depth of cut,
feed and speed are the most significant factors for material removal rate and their percentage contribution 67.26, 20.51 and 6.11
respectively.

Table 6 Analysis of Variance for MRR

Source DF Seq SS Adj SS Adj MS F P % Contribution

A (Speed) 2 156829 156829 78414.50 9.96 0.010

6.11
B (Feed) 2 526751 526751 263375.50 33.45 0.000
20.51
C (DOC) 2 1727678 1727678 863839.00 109.72 0.000
67.26
Error 20 157459 157459 7872.95

Total 26 2568717

8. Conclusion
The present study was carried out to study the effect of input parameters on the material removal rate. The following conclusions
have been drawn from the study:
 The parameters considered in the experiments are optimized to attain maximum material removal rate. The best combination
setting of controllable process parameters for rough turning within the selected range is as follows:
 Speed i.e. 1200 rpm (A3).
 Feed rate i.e. 0.2 mm/rev (B3).
 Depth of cut should be 1.5 mm (C3).
 From ANOVA analysis, Depth of cut, feed and speed are the most significant factors for material removal rate and its
percentage contribution are 67.26, 20.51 and 6.11 respectively.
 The Taguchi’s robust orthogonal array design is suitable to analyze the material removal rate problem as described in this
paper.
 Taguchi parameter design can be show the same result as full factorial design experiments.
 Taguchi’s approach can be analyzed any kind of problem.

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