Optimization of Machining Parameters In CNC Milling Machine

Using Taguchi Method

A project report submitted in partial fulfillment of the requirement

for the award of the degree

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING
Submitted by

Doddi.Gamya(316126520012)

Sanapala.Yamini(316126520049)

Paturi.Sai Kumar(31612520044)

Allaboina.Mahidhar(316126520064)

Booda.Aravind(316126520007)

Under the guidance of

Mr. R.D.V.Prasad
( Assistant professor)

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES

(AUTONOMOUS)
(Permanently Affiliated to Andhra University, Approved by AICTE, Accredited by NBA&
NAAC with ‘A’ grade)
Sangivalasa, Bheemunipatnam (mandal) Visakhapatnam (Dist.), Andhra Pradesh-531162
 Abstract
In this paper, an attempt is made to optimize parameters such as axial
depth of cut and radial depth of cut, feed, nose radius, cutting speed of Nickel
based alloy in CNC milling using Taguchi method using minitab software. The
analysis of optimum cutting conditions to get lower surface roughness and higher
material removal rate using the above mentioned method is focused in this paper.
The optimized results are obtained after conducting the experiments.
 Plan of Action

1. Literature Survey
2. Problem Identification
3. Selection of Technique
4. Selection of Material
5. Procurement of Machinery and other equipment if
necessary
6. Procurement of Material
7. Experimentation and Observation
8. Calculations (theoretical and software)
9. Results and Discussions

Equipment needed

1. CNC Milling machine.

2. Surface roughness measurement device.
3. Tool Maker’s Microscope
 INTRODUCTION

CNC MILLING MACHINE

CNC milling, the most common form of computer numerical control (CNC) machining,
performs the functions of both drilling and turning machines. CNC mills are categorized
according to their number of axis and are traditionally programmed using a set of codes that
represent specific functions.

Axis are labeled as x and y for horizontal movement, and z for vertical movement. A standard
manual light-duty mill is typically assumed to have four axis:

1) Table x
2) Table y

CNC MILLING 3) Table z

4) Milling Head z

The number of axis of a milling machine is often interpreted in varying ways. A five-axis CNC
milling machine has an extra axis in the form of a horizontal pivot for the milling head. The end
mill is positioned at an angle with respect to the table allowing extra flexibility for machining. A
six-axis CNC milling machine includes an additional horizontal pivot for the milling head,
perpendicular to the fifth axis.
CNC milling machines are traditionally programmed using a set of commands known as G-
codes. G-codes represent specific CNC functions in alphanumeric format.

CNC Milling Process

The  most conventional mechanical CNC machining processes, the CNC milling
process utilizes computerized controls to operate and manipulate machine tools
which cut and shape stock material. In addition, the process follows the same basic
production stages which all CNC machining processes do, including:
 Designing a CAD model
 Converting the CAD model into a CNC program
 Setting up the CNC milling machine
 Executing the milling operation

The CNC milling process begins with the creation of a 2D or 3D CAD part design. Then the
completed design is exported to a CNC-compatible file format and converted by CAM software
into a CNC machine program which dictates the actions of the machine and the movements of
the tooling across the workpiece. Before the operator runs the CNC program, they prepare the
CNC milling machine by affixing the workpiece to the machine’s work surface (i.e., worktable)
or workholding device (e.g., vise), and attaching the milling tools to the machine spindle. The
CNC milling process employs horizontal or vertical CNC enabled milling machines depending
on the specifications and requirements of the milling application and rotating multi-point (i.e.,
multi-toothed) cutting tools, such as mills and drills. When the machine is ready, the operator
launches the program via the machine interface prompting the machine to execute the milling
operation.

 the CNC milling process is initiated, the machine begins rotating the cutting tool at speeds
reaching up to thousands of RPM. Depending on the type of milling machine employed and the
requirements of the milling application, as the tool cuts into the workpiece, the machine will
perform one of the following actions to produce the necessary cuts on the workpiece:

1. Slowly feed the workpiece into the stationary, rotating tool.

2. Move the tool across the stationary workpiece.
3. Move both the tool and workpiece in relation to each other.

As opposed to manual milling processes, in CNC milling, typically the machine feeds
moveable workpieces with the rotation of the cutting tool rather than against it. Milling
operations which abide by this convention are known as climb milling processes, while
contrary operations are known as conventional milling processes.
 Generally, milling is best suited as a secondary or finishing process for an already machined
workpiece, providing definition to or producing the part’s features, such as holes, slots, and
threads. However, the process is also used to shape a stock piece of material from start to
finish. In both cases, the milling process gradually removes material to form the desired
shape and form of the part. First, the tool cuts small pieces—i.e., chips—off the workpiece to
form the approximate shape and form. Then, the workpiece undergoes the milling process at
much higher accuracy and with greater precision to finish the part with its exact features and
specifications. Typically, a completed part requires several machining passes to achieve the
desired precision and tolerances. For more geometrically complex parts, multiple machine
setups may be required to complete the fabrication process.

the milling operation is completed, and the part is produced to the custom-designed
specifications, the milled part passes to the finishing and post-processing stages of
production.

Literature Review
M. Vishnuvardhan et.al [1], in this paper, an attempt is made to optimize parameters such as
axial depth of cut and radial depth of cut, feed, nose radius, cutting speed of P20 steel in CNC
milling using Response Surface Methodology and Taguchi method using Design expert software.
The analysis of optimum cutting conditions to get lower surface roughness and higher material
removal rate using the above mentioned method is focused in this paper. The obtained results
were in turn analyzed using Analysis of variance (ANOVA). The optimized results are as
follows: At nose=0.8 mm, cutting speed=95 mm/min. feed=0.18 mm/min, Axial depth of cut=1.5
mm, Radial depth of cut=0.69 mm, the optimal values of surface roughness=0.615 μm and the
material removal rate=298.5 cm3/min are obtained. It is also observed that these optimized values
of parameters are same in both RSM & Taguchi method. In this way, the results from this study
shows that both these methods can determine the optimized values of parameter in CNC milling

Xuefeng wu et.al [2], in this we are studying about the characteristic of large mold and complex
surface of automobile cover mold, the mold processing of cover is analyzed, especially the mold
surface quantity. Roughness prediction is an important concept in the field of machines and
manufacture, especially for automobile cover mold manufacturing industry, not only to improve
its quality of product, reduce wear and tear.

The prediction model includes the definition of boundary conditions and the mathematical model
of regression analysis. The experimental model of regression analysis. the experimental results
and predicted values were compared on the basis of the experiment by way of range method,
analysis of variance and other methods to find the optimal milling conditions. With the
mathematical model used for the objective function and the milling parameters used for
independent variables,NSGA-2 algorithm is introduced to obtain multi-objective function
optimization pry the system the time of practical production is saved and the processing
efficiency is improved.

S.V. Alagarsamy et.al [3], in this paper, the machining parameters of brass C26130 alloy are
optimized during CNC end milling process by using Taguchi technique. By using this
experimental results, the combination of 750 rpm spindle speed, 20 mm/rev feed rate and 1 mm
depth of cut was identified as the optimum level for minimum surface roughness (SR) and the
combination of 750 rpm spindle speed, 60 mm/rev feed rate and 0.75 mm depth of cut was
identified as the optimum level for minimum tool wear (TW). Also, ANOVA results revealed
that the spindle speed and feed rate was identified as the highest influencing parameters on SR
and TW.

Biswajit Das et.al [4], in this paper, machining of in-situ Al-4.5%Cu-TiC metal matrix
composite is carried out with the input parameters considered as cutting speed, feed and depth of
cut and the response parameters as surface roughness and cutting force in CNC milling machine.
Taguchi’s α25 orthogonal array design is used for performing CNC operation on composite
plates. It was found that a cutting speed of 600 rpm, feed of 40 mm/min and depth of cut of 0.3
mm is the optimal combination of input parameters. ANOVA statistics exposed that cutting
speed is the most influencing factor in effecting the response parameters. Therefore, it is
concluded that the optimization procedure proposed in this paper significantly improved the
production of CNC milling of Al-4.5%Cu-TiC metal matrix composite.

M. Fakkir Mohamed et.al [5], CNC machine is used in production for a quick and effective
manufacturing process for new products. This method is to discuss parametric study of CNC
milling operation for surface roughness, material removal rate and machining time using taguchi
design methodology. It is an efficient method to study the response variables within few
experimental runs. The control parameters are spindle speed, feed rate & depth of cut on EN 19
& EN24 alloy steel. A total of 16 experimental runs were conducted to determine the surface
roughness, material removal rate and machining time. The Taguchi method is employed by using
MINITAB-16 software to identify the importance of machining parameters.
Joao Eduardo Ribeiro [6] The preparation of quality surfaces is very important process in the
surface engineering. The surface roughness will influence the quality and effectiveness of the
subsequent coatings for protection against corrosion, wear resistance and finishes quality of
decorative layers. For these reasons, the authors of the present work have focused in
manufacturing parameters that influence the surface quality of hardness metallic materials. In
this work, the effects of varying four parameters in the milling process, namely cutting speed,
feed rate, radial depth and axial depth. The influence of these parameters on the surface
roughness are analyzed individually and also the interaction between some of them for the
milling machining of hardened Steel (steel 1.2738), being used the Taguchi optimization method.
For this purposed was built a L16 orthogonal array and for each parameter were defined two
different levels, corresponding to sixteen experimental tests. From these tests were retrieved
sixteen surface roughness measurements The influence of each parameter in surface roughness
were then obtained by applying the analysis of variance (ANOVA) to experimental data. It is
noted that the minimum roughness measured was 1.05µm. This study also serve to determined
the contribution of each machining parameters and their interaction for surface roughness. The
results show that the radial cutting depth and the interaction between the radial and axial depth of
cut are the most revelevant parameters, being their contributions for the minimization surface
roughness about 30% and 24%, respectively.

N. Suresh Kumar Reddy et.al [7], Milling is the most common material removal process
characterized by high material removal rates for different materials. In general, machining leads
to high friction between tool and workpiece and can result in high temperatures, impairing
dimensional accuracy and the surface quality of products. Conventional cutting fluid usage do
not control heat generation effectively and also leads to pollution. Solid lubricant assisted
machining is a desirable technology to control cutting temperature and environmental friendly
technology. The present work investigates the role of solid lubricant assisted machining with
graphite and molybdenum disulphide on surface quality, cutting forces and specific energy while
machining AISI 1045 steel using cutting tools of different tool geometry i.e., radial rake angle
and nose radius. Solid lubricant machining indicator a considerable improvement in the process
performance in comparison with cutting fluids assisted machining (wet machining).
M. Putz et.al [8], in this we are quantifying the proportion of the thermal errors of machine tool,
tool & workpiece in the total thermal error for this purpose, the workpiece was subsequently
measured and both the machine interval and additionally built-in measuring sensors were used to
quantity displacement errors the static errors must also be detected these thermal states are
calculated buy regression analysis. The percentages of the single errors were calculated this gives
a clear statement about the time sequence and the thermal influence of the components regarding
to the total error in milling process.

Omid Yousefian A.Tarbutton et.al [9], this method was developed based on the voxelization
framework for digital manufacturing. By using different workpieces and cutter geometries can be
easily implemented into the method. Instead of the whole tool geometry, only the cutting helix is
voxelized in order to decrease the computational cast. The method has the ability to calculate the
engagement zone between the cutter and workpiece. Moreover, this model can be adjusted to run
on parallel framework which can significantly decrease the computational time. An analytical
model based on the discretized space was introduced for calculating the cutting force for each
cutting voxel on the cutting helix.
Yongjin Kwon C et.al [10], this is a study which tells the errors in closed loop measurement in
CNC milling. We generally use simple probe for to inspect the accuracy, the magnitude of the
measuring errors has to be minimized. This is done by conducting 3 sets of cutting experiments,
followed by experiment in 3 different levels & 3 factors on CNC machining center. And 3
different materials are used. During cutting, cutting force and spindle vibration signals were
collected & tool wear also recorded. The difference between 2 measurements was defined as
closed loop measurement error and analysis is carried to determine the factors affecting the
errors. This result shows improvement producing efficiency and improvement in part quality.

Razmarina Dubovaska et.al [11], this paper includes implementation of improved

methodologies of virtual simulation in CAD, CAM& CATIA V5. We know for implementing
any methodology we require the geometry of the cutting tools and materials. This technology
improves the quality, surface finish& achieves complex shape designing in automotive and
aerospace industries. This technique requires high level of programming for creating ISO
programs using CNC machine tools. All the simulations of experiments will show how good it
works and improves efficiency of machining process. At the same time manufacturers must have
advanced equipment and methods to achieve this. After achieving simulation successfully
volume of metal is taken on to the machine to make it basing on our requirement. This also
replaces manual labor which increases the quality of machining very significantly and speeds up
the work.

Anish Naira [12] Different kind of statistical optimization techniques are available for
optimizing the different parameters of a CNC end milling process. In this paper a comparison is
done between five different techniques such as principal components analysis, utility theory,
Grey relational analysis, technique of order preference by similarity to ideal solution and their
hybrid variants. The Taguchi optimization principle is common to all the methods which are
presented in the paper. The experiments were carried out and the different response features such
as surface roughness (Ra, Rz and Rq) and material removal rate (MRR) were measured and the
different optimization techniques were applied. Three different surface roughness values are used
for the analysis and they act as indices of surface quality whereas MRR acts as index of
productivity. Hence the optimization is carried out such that the resulting optimized parameters
will lead to a compromise between the productivity and the surface quality. The aim of the work
is to carry out multi objective optimization on a single process and compare the results.

M.K. Nor Khairusshima [13] Carbon Fibre Reinforced Plastic (CFRP) is extensively used
nowadays especially in the industries due to its desirable properties of high strength, light weight
and high resistance to corrosion. However, the machining of CFRP composites requires great
specification and requirement as it is difficult to be machine. Besides, improper technique and
parameters used to machine CFRP may result in poor surface quality such as high surface
roughness and delamination. This study was done on a CFRP panel with solid uncoated carbide
tool with diameter of 8 mm was used as cutting tool. Thus, this project investigates the influence
of the cutting parameters which are spindle speed, feed rate and depth of cut to the surface
quality of the CFRP by undergoing milling operation. The cutting parameters used during the
milling operation of the CFRP panel ranged from 500 rpm to 3500 rpm for the cutting speed,
feed rate from 100 mm/min to 900 mm/min and lastly 0.5 mm to 2.0 mm range for depth of cut.
15 runs of experiments is performed based on the Central Composite Design (CCD) of Response
Surface Methodology. Through this study, the optimum cutting parameters during milling of
CFRP is determined and the main factors affecting the surface quality are also highlighted.
Based on the developed mathematical model, the feed rate was identified as the primary
significant parameter that influenced surface roughness and delamination. In conclusion, the
influence of the cutting parameters on the CFRP panel is higher cutting speed, lower feed rate
and lower depth of cut resulted in low surface roughness and delamination factor. Feed rate was
identified to be the primary significant cutting parameter that contributes to low surface
roughness and delamination factor. The optimized cutting parameters were cutting speed, feed
rate and depth of cut of 3061 rpm, 211.34 mm/min and 0.72 mm respectively with surface
roughness of 1.34 um and delamination factor of 1.08.

Mehmet Emre Kara [14] Turn-milling is a relatively new machining process technology
offering important advantages such as increased productivity, reduced tool wear and better
surface finish. Because two conventional cutting processes turning and milling are combined in
turn-milling, there are many parameters that affect the process making their optimal selection
challenging. Optimization studies performed on turn-milling processes are very limited and
consider one objective at a time. In this work, orthogonal turn-milling is considered where
spindle and work rotational speeds, tool-work eccentricity, depth of cut and feed per revolution
are selected as process parameters. The effects of each parameter on tool wear, surface
roughness, circularity, material removal rate (MRR) and cutting forces were investigated through
process model based simulations and experiments carried out on a multi-tasking CNC machine
tool. The results are used to select process parameters through multi-objective optimization.

M. Midhun ,J.Dileeplal [15] This paper mainly focuses on the impact of input parameters like
feed, spindle speed, axial depth of cut, and radial depth of cut on the output characteristics of
CNC milling process of aluminium 2219. Material removal rate, surface roughness, and flatness
are taken as the performance measures. The optimum process parameters and corresponding
output responses are found out using Taguchi analysis. The multi-objective optimization based
on grey relational analysis is used to attain maximum material removal rate simultaneously with
minimum flatness and surface roughness. ANN models were developed using back propagation
algorithms to predict the performance characteristics.