EXPERIMENTAL SETUP

Process Parameters

The experiment was conducted for face milling operation. The input parameters and
responses that were considered are:

Input Parameters:

1. Speed (m/min).
2. Feed (mm/min).
3. Depth of Cut (DOC) (mm).

Responses:

1. Cutting Force (kg).

2. Thrust Force (kg).
3. Surface Roughness (Ra).

The experiment was carried out for two different material, Alloy steel and Mild steel.
Carbide cutting tool was selected for both the material.

Experimental Data Collection

The experiment was designed using Design of Experiments (DOE). Two level full
factorial design was adopted. Two replicates were considered for each combination of input
variables and the experiment was randomized.

The cutting force and the thrust force were measured using a milling dynamometer
and the surface roughness was measured using talysurf.

Levels of the Input Parameters

The experiment was carried out at only two levels based on two level full factorial
design. The maximum and the minimum level were fixed based upon the available speed and
feed on the machine and after carrying out a number of trial cuts.
 Sl. No. Parameters Factor levels
Minimum Maximum
1 Speed (m/min) 54.28 104.55
2 Feed (mm/min) 33.33 66.67
3 Depth of cut (mm) 0.5 1.25
Table. Levels of input parameters

Same levels were fixed for both the materials, Alloy steel and Mild steel.

Design Matrix

The design matrix was obtained using the software, Minitab v14, based on two level
full factorial design with two replicates. The experiment was randomized.

Input Parameters Response

Cutting Surface
Speed Feed DOC force Thrust force Roughness
StdOrder RunOrder (m/mm) (mm/min) (mm) (kg) (kg) (Ra)
11 1 54.28 66.67 0.5
4 2 104.55 66.67 0.5
2 3 104.55 33.33 0.5
7 4 54.28 66.67 1.25
10 5 104.55 33.33 0.5
14 6 104.55 33.33 1.25
13 7 54.28 33.33 1.25
9 8 54.28 33.33 0.5
5 9 54.28 33.33 1.25
12 10 104.55 66.67 0.5
1 11 54.28 33.33 0.5
16 12 104.55 66.67 1.25
6 13 104.55 33.33 1.25
8 14 104.55 66.67 1.25
3 15 54.28 66.67 0.5
15 16 54.28 66.67 1.25

Experimental Data and Analysis

The experiments were performed separately for Alloy steel and Mild steel.

ALLOY STEEL

Input Parameters Response

StdOrder RunOrdr Speed Feed DOC Cutting Thrust Surface
 force force roughness
(m/min) (mm/min) (mm) (kg) (kg) (Ra)
11 1 54.28 66.67 0.5 8 5 2.52
4 2 104.55 66.67 0.5 6 4 1.66
2 3 104.55 33.33 0.5 3 3 0.59
7 4 54.28 66.67 1.25 20 5 3.02
10 5 104.55 33.33 0.5 3 4 0.83
14 6 104.55 33.33 1.25 7 5 1.16
13 7 54.28 33.33 1.25 11 3 2.56
9 8 54.28 33.33 0.5 5 4 3.04
5 9 54.28 33.33 1.25 11 4 2.7
12 10 104.55 66.67 0.5 5 4 1.14
1 11 54.28 33.33 0.5 6 4 3.53
16 12 104.55 66.67 1.25 15 6 1.91
6 13 104.55 33.33 1.25 6 4 2.62
8 14 104.55 66.67 1.25 15 7 2.42
3 15 54.28 66.67 0.5 8 5 3.695
15 16 54.28 66.67 1.25 22 5 2.46
Table. Experimental data for Alloy steel

The table shows the data experimental obtained for alloy steel. This data was analysed
using Minitab software. The linear regression model was developed and the analysis was
performed through the significance test and ANOVA test.

The input-output relations were studied with the help of main effect plots ant
interaction plots for the responses – cutting force, thrust force and surface roughness.

Cutting Force

Significance Test

Significance test was carried out to study the effects, contribution and significance of
the input parameters and their interaction terms on the response.

Term Effect Coef SE Coef T P

Constant 9.43 0.1654 57.07 0.000
8
Speed -3.875 -1.937 0.1654 -11.72 0.000
Feed 5.875 2.937 0.1654 17.76 0.000
DOC 7.875 3.938 0.1654 23.81 0.000
Speed*Feed -0.375 -0.187 0.1654 -1.13 0.290
 Speed*DOC -1.375 -0.687 0.1654 -4.16 0.003
Feed*DOC 3.375 1.688 0.1654 10.21 0.000
Speed*Feed*DO -0.375 -0.188 0.1654 -1.13 0.290
C
Table.Estimated Effects and Coefficients for Cutting force (coded units)

The significance test results are shown in the table. A confidence level of 95% was
considered to test the significance of the various factors and their interactions. A confidence
level of 95% implies a P value (values in the last column) less than 0.05. From the table it can
be seen that speed, feed, depth of cut (DOC) are significant. Moreover the P value for the
interaction terms speed*DOC and feed*DOC are also less than 0.05, hence these interactions
are significant. Other terms do not have significant contribution on the cutting force. Three
way interaction (speed*feed*DOC) do not take place. The coefficient of determination (R^2)
is 99.31%.

Main Effect Plot

Main Effects Plot (data means) for Cutting force

Speed Feed
14

12

10
Mean of Cutting force

54.28 104.55 33.33 66.67

DOC
14

12

10

0.50 1.25

Main effect plot-cutting force

 It can be seen from the graph that speed has a negative effect on the cutting force i.e.
the cutting force decreases as the speed increases. Feed and depth of cut have a positive effect
on the cutting force i.e. it increases with the increase in feed and depth of cut.

From the effect table it can be seen that depth of cut has maximum positive effect
whereas speed has the maximum negative effect on the cutting force.

Interaction Plot

Interaction Plot (data means) for Cutting force

33.33 66.67 0.50 1.25

Speed
15 54.28
104.55
Speed 10

Feed
15 33.33
66.67
Feed 10

DO C

Interaction plot-cutting force

Interaction is said to take place when the interaction plot lines are inclined to each
other i.e. they are intersecting. It can be seen from the graph that interaction takes place
between speed and depth of cut and also between feed and depth of cut. This can also be
verified from the P value. For both of these interactions the P value is less than 0.05.

Linear Regression Equation

 The coefficients for the mathematical model are obtained from the coefficient table.
The table gives the coefficients in coded units. These coded units are converted to un-coded
units using the relation

X’ = [X-(Xmax+Xmin)/2]÷[(Xmax-Xmin)/2] ......( )

Where, X’ is coded

X is any value of the parameter

Xmax and Xmin are the maximum and the minimum level of the input parameters.

The equation for cutting force (CF), only taking the significant terms, in coded form can be
written as,

CF= 9.438-1.937×S’+2.937×F’+3.938×D’-0.687×S’×D’+1.688×F’×D’ ... ( )

Converting to un-coded,

CF= 9.438-1.973×[S-(104.55+54.28)/2]÷[(104.55-54.28)/2]

+2.937×[F-(66.67+33.33)/2]÷[(66.67-33.33)/2]+3.938×[D-(1.25+0.5)/2]÷[(1.25-0.5)/2]

-0.687×[S-(104.55+54.28)/2]÷[(104.55-54.28)/2]× [D-(1.25+0.5)/2]÷[(1.25-0.5)/2]

+1.688×[F-(66.67+33.33)/2]÷[(66.67-33.33)/2]×[D-(1.25+0.5)/2]÷[(1.25-0.5)/2] ... ( )

On simplifying,

CF=

Random Test Cases

 Two random experiments were conducted to test the validity of the mathematical
model. The input parameters were selected within the maximum and minimum levels of the
input parameters.

SPEED FEED DOC MEASURED CALCULATED % ERROR

(m/min) (mm/min) (mm) FORCE (kg) FORCE (kg)

67.6 42.85 0.75 9 7.90 12.22

97.51 60 1 11 11.29 2.63

Average error 7.425

Table.Results of random tests-cutting force

Thrust Force

Significance Test

Term Effect Coef SE Coef T P

Constant 4.5000 0.1250 36.00 0.000
0
Speed 0.2500 0.12500 0.1250 1.00 0.347
0
Feed 1.2500 0.62500 0.1250 5.00 0.001
0
DOC 0.7500 0.37500 0.1250 3.00 0.017
0
Speed*Feed -0.00000 -0.00000 0.1250 -0.00 1.000
Speed*DOC 1.0000 0.50000 0.1250 4.00 0.004
0
Feed*DOC 0.5000 0.25000 0.1250 2.00 0.081
0
Speed*Feed*DO 0.2500 0.12500 0.1250 1.00 0.347
C 0
Table. Estimated Effects and Coefficients for Thrust force (coded units)

The above table shows the effects, coefficients and the P value of the various terms.
The P value for feed, depth of cut and the interaction between speed and depth of cut are less
than 0.05 (i.e. confidence level of 95%). So, these terms have significant contribution on the
thrust force. Three way interaction is not present. The coefficient of determination (R^2) is
87.50%.

Main Effect Plot

Main Effects Plot (data means) for Thrust force

Speed Feed

5.00
4.75
4.50
Mean of Thrust force

4.25
4.00

54.28 104.55 33.33 66.67

DOC

5.00
4.75
4.50
4.25
4.00

0.50 1.25

Main effect plot-thrust force

From the main effect plot of thrust force it can be seen that all the input parameters,
speed, feed and depth of cut have a positive effect on the thrust force i.e. the thrust force
increases with the increase in these input parameters. The feed has the maximum positive
effect as shown in the effect table.

Interaction Plot
 Interaction Plot (data means) for Thrust force
33.33 66.67 0.50 1.25
6
Speed
54.28
104.55
5
Speed

4
6
F eed
33.33
66.67
5
Feed

DO C

Interaction plot-thrust force

From the above graph it can be seen that the interaction plot of speed and feed are
parallel lines, therefore no interaction takes place between them. The interaction plots of
speed and depth of cut and that of feed and depth of cut are intersecting; therefore there exists
interaction between them. But as the P value for the interaction between feed and depth of cut
is more than 0.05 it is not significant.

Linear Regression Equation

The linear mathematical equation for thrust force (TF) in terms of input parameters in
coded form may be written, using the coefficients from the coefficient table, only considering
the significant terms can be written as,

TF= 4.5 +0.625×F’+0.375×D’+0.5×S’×D’ ..... ( )

Converting to un-coded and simplifying,

TF= .... ( )

Random Test Cases

 Two random experiments were conducted to test the validity of the mathematical
model. The input parameters were selected within the maximum and minimum levels of the
input parameters.

SPEED FEED DOC MEASURED CALCULATED % ERROR

(m/min) (mm/min) (mm) FORCE (kg) FORCE (kg)

67.6 42.85 0.75 5 4.18 16.4

97.51 60 1 5 5.119 2.38

Average error 9.39

Table.Results of random tests-thrust force

Surface Finish

Significance Test

Term Effect Coef SE Coef T P

Constant 2.2409 0.1351 16.59 0.000
Speed -1.3994 -0.6997 0.1351 -5.18 0.001
Feed 0.2244 0.1122 0.1351 0.83 0.430
DOC 0.2306 0.1153 0.1351 0.85 0.418
Speed*Feed 0.2581 0.1291 0.1351 0.96 0.367
Speed*DOC 0.7419 0.3709 0.1351 2.75 0.025
Feed*DOC -0.0319 -0.0159 0.1351 -0.12 0.909
Speed*Feed*DO -0.1756 -0.0878 0.1351 -0.65 0.534
C
Table.Estimated Effects and Coefficients for Surface Roughness (coded units)

The table shows the effect, coefficient and P value for the surface finish. The factors
speed and interaction between speed and depth of cut, have a significant contribution on the
surface finish (P≤0.05). Three way interaction do not take place. Coefficient of determination
(R^2) is 82.27%.

Main Effect Plot

 Main Effects Plot (data means) for Surface roughness
Speed Feed
3.0

2.5
Mean of Surface roughness

2.0

1.5
54.28 104.55 33.33 66.67
DOC
3.0

2.5

2.0

1.5
0.50 1.25

Main effect plot-surface roughness

From the graph it can be seen that speed has a negative effect on surface roughness
whereas feed and depth of cut has a positive effect. In other words, to have a better surface
finish the cutting speed should be high, feed rate should be low and depth of cut should be
small.

Interaction Plot

Interaction Plot (data means) for Surface roughness

33.33 66.67 0.50 1.25

Speed
3
54.28
104.55
Speed 2

1
3 Feed
33.33
66.67
Feed 2

DO C

Interaction plot-surface roughness

 The interaction between speed and depth of cut is significant as P value is less than
0.05. Very little interaction takes place between feed and depth of cut as the lines are almost
parallel. Interaction takes place between speed and feed but it is not significant (P≥0.05).

Linear Regression Equation

The linear regression equation for the surface roughness (SR), taking only the
significant terms, in coded form can be written as,

SR= 2.2409-0.6997×S’+0.3709×S’×D’ ..... ( )

Converting to un-coded and simplifying,

SR= ....... ( )

Random Test Cases

Two random experiments were conducted to test the validity of the mathematical
model. The input parameters were selected within the maximum and minimum levels of the
input parameters.

SPEED FEED DOC MEASURED CALCULATE %

(m/min) (mm/min) (mm) D ERROR
(Ra)
(Ra)

67.6 42.85 0.75 2.34 2.62 11.96

97.51 60 1 1.88 1.826 2.87

Average error 6.893

Table.Results of random tests-surface roughness

MILD STEEL

Input Parameters Response

Cutting Thrust Surface
Speed Feed DOC force force Roughness
StdOrder RunOrder (m/min) (mm/min) (mm) (kg) (kg) (Ra)
11 1 54.28 66.67 0.5 7 4 3.77
4 2 104.55 66.67 0.5 6 4 1.92
2 3 104.55 33.33 0.5 2 3 0.83
7 4 54.28 66.67 1.25 18 4 3.54
10 5 104.55 33.33 0.5 2 3 0.9
14 6 104.55 33.33 1.25 7 4 2.84
13 7 54.28 33.33 1.25 9 2 3.41
9 8 54.28 33.33 0.5 4 4 3.43
5 9 54.28 33.33 1.25 11 1 3.5
12 10 104.55 66.67 0.5 5 4 1.9
1 11 54.28 33.33 0.5 4 3 3.32
16 12 104.55 66.67 1.25 14 3 1.39
6 13 104.55 33.33 1.25 8 4 1.53
8 14 104.55 66.67 1.25 15 3 1.84
3 15 54.28 66.67 0.5 8 2 2.54
15 16 54.28 66.67 1.25 20 4 3.5
Table. Experimental data for Mild Steel
The table shows the data experimental obtained for mild steel. This data was analysed using
Minitab software. The linear regression model was developed and the analysis was performed
through the significance test and ANOVA test.

The input-output relations were studied with the help of main effect plots ant
interaction plots for the responses – cutting force, thrust force and surface roughness.

Cutting Force

Significance Test

Significance test was carried out to study the effects, contribution and significance of
the input parameters and their interaction terms on the response.

Term Effect Coef SE T P

Coef
Constant 8.750 0.2165 40.41 0.000
Speed -2.750 -1.375 0.2165 -6.35 0.000
Feed 5.750 2.875 0.2165 13.28 0.000
DOC 8.000 4.000 0.2165 18.48 0.000
Speed*Feed -0.500 -0.250 0.2165 -1.15 0.282
Speed*DOC -0.750 -0.375 0.2165 -1.73 0.122
Feed*DOC 2.250 1.125 0.2165 5.20 0.001
Speed*Feed*DO -0.500 -0.250 0.2165 -1.15 0.282
C
Table.Estimated Effects and Coefficients for Cutting force (coded units)

The significance test results are shown in the table. A confidence level of 95% was
considered to test the significance of the various factors and their interactions. A confidence
level of 95% implies a P value (values in the last column) less than 0.05. From the table it can
be seen that speed, feed, depth of cut (DOC) are significant. Moreover the P value for the
interaction term feed*DOC are also less than 0.05, hence this interactions is significant. Other
terms do not have significant contribution on the cutting force. Three way interaction
(speed*feed*DOC) do not take place. The coefficient of determination (R^2) is 98.66%.

Main Effect Plot

 Main Effects Plot (data means) for Cutting force
Speed Feed

12

10

8
Mean of Cutting force

4
54.28 104.55 33.33 66.67
DOC
12

10

4
0.50 1.25

Main effect plot-cutting force

It can be seen from the graph that speed has a negative effect on the cutting force i.e.
the cutting force decreases as the speed increases. Feed and depth of cut have a positive effect
on the cutting force i.e. it increases with the increase in feed and depth of cut.

From the effect table it can be seen that depth of cut has maximum positive effect
whereas speed has the maximum negative effect on the cutting force.

Interaction Plot

Interaction Plot (data means) for Cutting force

33.33 66.67 0.50 1.25

Speed
15
54.28
104.55
10
Speed

Feed
15
33.33
66.67
10
Feed

DO C
 Interaction plot-cutting force

Interaction is said to take place when the interaction plot lines are inclined to each
other i.e. they are intersecting. It can be seen from the graph that interaction takes place
between feed and depth of cut. Other interactions are not significant as the interaction graphs
are almost parallel, which is confirmed by the P value which is less more than 0.05.

Linear Regression Equation

The coefficients for the mathematical model are obtained from the coefficient
table. The table gives the coefficients in coded units. The equation for cutting force (CF) in
coded form, only considering the significant terms can be written as,

CF= 8.75-1.375×S’+2.875×F’+4×D’+1.125×F’×D’ .... ( )

Converting to un-coded and simplifying,

CF= ...... ( )

Random Test Cases

Two random experiments were conducted to test the validity of the mathematical
model. The input parameters were selected within the maximum and minimum levels of the
input parameters.

SPEED FEED DOC MEASURED CALCULATED %

(m/min) (mm/min) (mm) FORCE (kg) FORCE (kg) ERROR

67.6 42.85 0.75 7 6.99 0.142

97.51 60 1 10 11.04 10.4

Average error 5.271

Table.Results of random tests-cutting force

Thrust Force

Significance Test
 Term Effect Coef SE Coef T P
Constant 3.2500 0.1531 21.23 0.000
Speed 0.5000 0.2500 0.1531 1.63 0.141
Feed 0.5000 0.2500 0.1531 1.63 0.141
DOC -0.2500 -0.1250 0.1531 -0.82 0.438
Speed*Feed -0.5000 -0.2500 0.1531 -1.63 0.141
Speed*DOC 0.2500 0.1250 0.1531 0.82 0.438
Feed*DOC 0.2500 0.1250 0.1531 0.82 0.438
Speed*Feed*DO -1.2500 -0.6250 0.1531 -4.08 0.004
C
Table.Estimated Effects and Coefficients for Thrust force (coded units)

The above table shows the effects, coefficients and the P value of the various terms.
Only the three way interaction i.e. Speed*Feed*DOC is significant (P≤0.05). The coefficient
of determination (R^2) is 76.92%.

Main Effect Plot

Main Effects Plot (data means) for Thrust force

Speed Feed
3.48

3.36

3.24
Mean of Thrust force

3.12

3.00
54.28 104.55 33.33 66.67
DOC
3.48

3.36

3.24

3.12

3.00
0.50 1.25

Main effect plot-thrust force

From the main effect plot of thrust force it can be seen that the input parameters,
speed and feed have a positive effect on the thrust force i.e. the thrust force increases with the
increase in these input parameters. Depth of cut has a negative effect on the thrust force.
Speed and feed has the same maximum positive effect as shown in the effect table.

Interaction Plot
 Interaction Plot (data means) for Thrust force
33.33 66.67 0.50 1.25
3.5 Speed
54.28
104.55
3.0
Speed

2.5
3.5
Feed
33.33
66.67
3.0
Feed

2.5

DO C

Interaction plot-thrust force

Interaction takes place between all the factors but none of them are significant as P
value is more than 0.05. Only three way interaction is significant.

Linear Regression Equation

The linear mathematical equation for thrust force (TF) in terms of input parameters in
coded form may be written, using the coefficients from the coefficient table, only considering
the significant terms can be written as,

TF= 3.25-0.625×S’×F’×D’ ...... ( )

Converting to un-coded and simplifying,

TF= .... ( )

Random Test Cases

Two random experiments were conducted to test the validity of the mathematical
model. The input parameters were selected within the maximum and minimum levels of the
input parameters.
SPEED FEED DOC MEASURED CALCULATED %
(m/min) (mm/min) (mm) FORCE (kg) FORCE (kg) ERROR

67.6 42.85 0.75 4 3.29 17.75

97.51 60 1 4 3.16 21

Average error 19.37

Table.Results of random tests-thrust force

Surface Finish

Significance Test

Term Effect Coef SE Coef T P

Constant 2.5100 0.1162 21.5 0.000
9
Speed -1.7325 -0.8663 0.1162 -7.45 0.000
Feed 0.0800 0.0400 0.1162 0.34 0.740
DOC 0.3675 0.1838 0.1162 1.58 0.153
Speed*Feed 0.1575 0.0788 0.1162 0.68 0.517
Speed*DOC 0.1450 0.0725 0.1162 0.62 0.550
Feed*DOC -0.3325 -0.1663 0.1162 -1.43 0.191
Speed*Feed*DO -0.4750 -0.2375 0.1162 -2.04 0.075
C
Table.Estimated Effects and Coefficients for Surface Roughness (coded units)

The table shows the effect, coefficient and P value for the surface finish. Only speed
is the significant term (P≤0.05). Coefficient of determination (R^2) is 89.08%.

Main Effect Plot

 Main Effects Plot (data means) for Surface Roughness
Speed Feed
3.5

3.0
Mean of Surface Roughness

2.5

2.0

1.5
54.28 104.55 33.33 66.67
DOC
3.5

3.0

2.5

2.0

1.5
0.50 1.25

Main effect plot-surface roughness

From the graph it can be seen that speed has a negative effect on surface roughness
whereas feed and depth of cut has a positive effect. In other words, to have a better surface
finish the cutting speed should be high, feed rate should be low and depth of cut should be
small.

Interaction Plot

Interaction Plot (data means) for Surface Roughness

33.33 66.67 0.50 1.25

Speed
3.2
54.28
104.55
Speed 2.4

1.6

Feed
3.2
33.33
66.67
Feed 2.4

1.6

DO C

Interaction plot-surface roughness

 The effect of interaction between feed and depth of cut is more as compared to the
other interactions. But this interaction is also not significant as the P value is more than 0.05.

Linear Regression Equation

The linear regression equation for the surface roughness (SR), taking only the
significant terms, in coded form can be written as,

SF= 2.51-0.8663×S’ ..... ( )

Converting to un-coded and simplifying,

SR= ....... ( )

Random Test Cases

Two random experiments were conducted to test the validity of the mathematical
model. The input parameters were selected within the maximum and minimum levels of the
input parameters.

SPEED FEED DOC MEASURED CALCULATE %

(m/min) (mm/min) (mm) D ERROR
(Ra)
(Ra)

67.6 42.85 0.75 3.02 2.91 3.64

97.51 60 1 1.72 1.886 9.65

Average error 6.645

Table.Results of random tests-surface roughness