Engineering Science and Technology, an International Journal 23 (2020) 405–420

Contents lists available at ScienceDirect

Engineering Science and Technology,

an International Journal
journal homepage: www.elsevier.com/locate/jestch

Full Length Article

Experimental investigation of the effects of process parameters on

material removal rate using Taguchi method in external cylindrical
grinding operation
Nesredin Chekole Deresse a, Vivek Deshpande a, Ismail W.R. Taifa b,⇑
a
Mechanical Engineering Department, G H Patel College of Engineering & Technology, Anand, Gujarat, India
b
Mechanical and Industrial Engineering Department, College of Engineering and Technology, University of Dar es Salaam, Dar es Salaam, Tanzania

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

Article history: Under the machining process, there are several factors which exert influence on material removal rate
Received 16 March 2019 (MRR), including cutting condition, tool variables, machine status and workpiece variables. In the cylin-
Revised 15 May 2019 drical grinding process (CGP), it is not easy to consider all process parameters that device MRR because it
Accepted 3 June 2019
needs much experimentation which results in the consumption of money, time and human resources.
Available online 20 June 2019
Thus, this study investigated the impact of process parameters in external CGP for EN45 steel material
using the Taguchi method. The performed experiments considered the L9 orthogonal array on a cylindri-
Keywords:
cal grinding machine. The considered machining variables are the depth of cut (DOC), feed rate (FR) and
EN45 steel
AISI 9260
work speed (WS) as response parameters before and after heat treatment processes. The heat treatment
Taguchi method process (HTP) changed the physical and chemical properties of materials. HTP for EN45 started by heating
Orthogonal array the workpiece slowly to 650–700 °C before reaching the final temperature of 870–930 °C. Important fac-
Material removal rate tors for this process included the workpiece transfer facilities, quenching medium, the type of the used
Cylindrical grinding operation furnace, the size and shape of the workpiece, among others. The effect of input and output parameters
was described through the ‘‘signal to noise ratio” (SNR) and ‘‘analysis of variance (ANOVA)” using
MinitabÒ 18 software. The significant factors and the optimum cutting conditions were drawn from
experiments. ANOVA table shows the impact level of the cutting depth (DOC) on MRR before heat treat-
ment was 65.2%. Then, after the heat treatment, an essential factor for MRR of grinding was found to be
the feed rate with 57.1%. The summary of the experimental results are as follows: DOC (0.025 mm), WS
(270 rpm) and FR (0.02 mm). The originality of this study is based on the presence of fewer or probably no
experimental investigation on the EN45 material as the workpiece that has been performed previously in
optimising process parameters using the Taguchi method on external cylindrical grinding and MRR. Thus,
the obtained results are important after having established the machining parameters for EN45 steel
materials.
Ó 2019 Karabuk University. Publishing services by Elsevier B.V. This is an open access article under the CC
BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

1. Introduction ing, filing, milling, reaming, boring, tapping, threading, shaping,

Globalisation brings fierce competition in the manufacturing
sector [1,2]. The great economic importance relies on the design
and operation of the manufacturing systems. The majority of the
manufacturing industries consider machining operation as a key
process [3] specifically in achieving the desired size, shape and
accuracy. There are several machining processes, i.e. turning,
grinding, drilling, sawing, welding, broaching, parting and groov-
⇑ Corresponding author.
E-mail addresses: taifaismail@yahoo.com, itaifa@udsm.ac.tz (I.W.R. Taifa).
Peer review under responsibility of Karabuk University.
planning, honing, among others. Of these, grinding is extensively
used during finishing operations [4,5] for discrete components
[6]. When requiring precise tolerances and smooth surfaces for
final machining of components, it is better to use a ‘‘cylindrical
grinding process” (CGP).
Grinding is a machining process which is a very costly process
[7,8]; thus, it should be used at optimal conditions. According to
Alajmi et al. [9], ‘‘in the grinding process, there is a trade-off
between faster material removal rates, with a reduction in cutting
time and its associated cost and shorter tool life or higher tool
cost.” The foremost operating input factors that impact the MRR,
output responses, temperature, surface damage, and surface

https://doi.org/10.1016/j.jestch.2019.06.001
2215-0986/Ó 2019 Karabuk University. Publishing services by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
406 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420

roughness, among other parameters, include (a) wheel parameters: machining parameters regarding EN45 steel material. Therefore,
dimension, shape, binder, structure, grade, grain size, abrasives; (b) this study mainly dealt with EN45.
workpiece details: chemical composition, mechanical properties,
fracture mode, etc; (c) machine details: table system, spindle sys-
1.2. Objectives
tem, static and dynamic characteristics, etc.; and (d) process
parameters: dressing condition, ‘‘work speed” (WS), ‘‘depth of cut”
The study aims at optimising machining parameters on MRR
(DOC) and ‘‘feed rate” (FR) [10]. These are in line with the demand
using the Taguchi method in ‘‘external cylindrical grinding opera-
increase for precision in parts and components, and surface fin-
tion”. The considered optimal cutting parameters are ‘‘work speed”
ishes in many areas, for example, aerospace, shipping, automotive,
(WS), ‘‘depth of cut” (DOC) and ‘‘feed rate” (FR) parameters. The
among others.
specific objectives are as follows.

a) To practice the design of experiment (DOE) on the cylindri-

1.1. Problem description
Under the machining process, there are several factors which
exert influence on material removal rates, including cutting condi-
tion, tool variables, machine status and workpiece variables. In the
cylindrical grinding process (CGP), it is not easy to consider all pro-
cess parameters that device material removal rate (MRR) because
it needs much experimentation which consumes time, human
resources and money. Henceforth, selection of the optimised cut-
ting parameters with optimal cutting conditions for the given
equipment and set up is an important process. The selection of
the optimised machining parameter is not an easy process. Like-
wise, to increase the quality of MRR at the same time, the optimal
cost of equipment CGP requires a systematic approach. Currently,
there are many studies related to the optimisation of cylindrical
grinding conditions when grinding different steels. Many of the
summarised studies in Table 1 optimised different kinds of steel.
However, through an extensive literature survey, we did not find
cal grinding process (CGP).
b) To determine the optimum cutting conditions to increase
MRR.
2. Literature review
2.1. Overview
The optimisation of machining parameters has been studied
comprehensively by several researchers in materials manufactur-
ing industries. For example, Shaji and Radhakrishnan [11] analysed
process parameters, i.e. work speed, infeed, mode of dressing and
feed as prominent parameters. Their study considered three levels
and L9 orthogonal array. Shaji and Radhakrishnan’s [11] study
involved ‘‘EN31 steel” (similar to AISI 52100) [11] toughened to a
‘‘bulk highest Rockwell hardness (HRC) of 60”. AISI stands for the
‘‘American Iron and Steel Institute”. Their study deployed the

Table 1
Summary of the related studies.

Material Tool Parameters Quality Most significant Source

parameter
EN31 Steel – Feed rate, WS, in feed, mode of dressing SR – Shaji and Radhakrishnan
[11]
Mild steel HSS SKH51 Rain size, wheel speed DOC, table speed SR, MMR Kwak [30]
Mild steel Al2O3 DOC, WS, FR SR Work speed Alagumurthi et al. [6]
RO 99 2400 P5661 – DOC, cutting speed, FR Feed rate Palanikumar [31]
AISI 4340 SiC Al2O3 DOC, WHS, pass, grinding speed – Alagumurthi et al. [12]
AISI 4140 hardened 38A-60K DOC, FR, WS SR roundness DOC Jirapatarasilp et al. [32]
5 L ± 3 HR V35
Hardened AISI 1040 Al2O3 Wheel speed, grinding speed passes, DOC SR, MMR Number of passes, Jagtap et al. [13]
WS
Hardened AISI 5120 58HR Al2O3 Wheel speed, grinding speed passes, DOC Number of passes, Jagtap et al. [14]
WS
EN24 WA 60K5V Work speed, wheel speed, DOC – Janardhan and Krishna
[33]
EN 24, EN31 Die steel Al2O3 Material hardness, work-piece speed, grinding SR – Pal et al. [34]
wheel
Mild steel – DOC, cutting speed MMR Cutting speed Kumar et al. [35]
EN353, EN31, EN24, AA46K5V40 DOC, hardness, work-piece speed Roughness Hardness George et al. [36]
EN24 Al2O3 DOC, table speed, wheel speed SR, MMR – Kumar et al. [37]
Mild steel Diamond Feed, DOC, wheel speed Speed, DOC Sudheesh and Govindan
[38]
AISI 0-1 – Quantity of passes DOC, WS MMR Number of passes Sridhar et al. [39]
AISI 316 hardened 55 HRC DOC, cutting speed, feed rate DOC Mekala et al. [40]
EN8 Workpiece speed, fluids, DOC SR, MMR – Thakor [41]
304 stainless steel Workpiece speed, fluids, DOC SR Work speed Ganesan et al. [42]
C40E steel 0.4-0.45 – DOC, speed, FR SR Feed Kumar et al. [43]
OHNS (Hardened) Al2O3 FR, spindle speed, DOC SR, MMR DOC, FR Deshmukh et al. [44]
EN15AM (0.3 to 0.4) – Cutting fluid, DOC, WS, feed, WHS MMR Workpiece speed Kumar and Singh Bhatia
[45]
AISI 8620 SS410 AISI 4140 WS, DOC, pass MMR Surface – Chaudhari and Harne
finish [46]
AISI D3 tool steel Workpiece speed, wheel speed, DOC SR All Ozay et al. [10]
EN8 Wheel speed, nanoparticle size, DOC, coolant rate, G ratio surface Coolant Patil and Patil [47]
lubricant finish

Note: FR = feed rate; SR = surface roughness; DOC = depth of cut; AISI = the American Iron and Steel Institute; MRR = ‘‘material removal rate”; WHS = wheel speed, WS = work
speed.
 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420
Taguchi techniques including ANOVA, SNR, orthogonal array and
factor effect analysis. Shaji and Radhakrishnan [11] concluded that
‘‘with the graphite application, the tangential force and surface
roughness are lower and normal force is higher compared to those
in the conventional grinding”.
Alagumurthi et al. [6] did a comparative study on optimising
grinding process using DOE. On this experiment, three process
parameters were used (i.e. DOC, wheel speed and work speed) with
two levels of factors at L4 orthogonal array. The study of Alagu-
murthi et al. [6] found the following optimum cutting conditions:
WS (300 rpm), DOC (0.02 mm) and wheel speed (WHS) (1750 rpm)
[6]. Alagumurthi et al. [12] also performed another study using
some passes, work speed, DOC and wheel speed as the process
parameters with three levels of L9 orthogonal array. Medium car-
bon structural steel (AISI 4340) was used for comparison of DOE
process. Thus, the following optimal conditions were selected:
DOC at level 1 (300 mm), WS at level 1 (65 rpm) and some passes
at level 3 (5 passes) and WHS at level 2 (2000 rpm).
Jagtap et al. [13] explored the outcome of the process parame-
ters on grinding operation to reduce surface roughness and max-
imise MRR of AISI 1040 steel. The established results include:
setting high grinding wheel speed at 1910 rpm, moderate WS of
224 rpm with a minimum amount of passes of 03 and deploying
higher depth of cut of 400 mm.
Jagtap et al. [14] hardened AISI 5120 steel (58HRC) as the work-
piece. The process parameters used a wheel speed, WS, number of
passes and DOC. The quality characteristics considered ‘‘surface
roughness” and MRR. The optimum results included DOC of
500 mm, number of the pass (3), WS (80 rpm) and WHS (1910 rpm).
2.2. Related studies
The most considered input parameters (controllable factors) are
summarised in Fig. 1, i.e. the percentage of the used factors by var-
ious researchers. The results show that DOC and WS were the most
significant parameters for cylindrical grinding. Table 1 depicts the
summarised information regarding the related studies performed
by other researchers.
2.2.1. Material removal rate (MRR)
MRR was explained by Patel and Deshpande [15] as ‘‘the mate-
rial or metal that is removed per unit time in mm3/sec. For each
revolution of the workpiece, a ring-shaped layer of material is
removed”. Eq. (1) can be used to compute MRR [15].
MRR ¼ v  f  d
whereby v = ‘‘cutting speed (mm/s)”; f = ‘‘feed (mm/rev)”;
d = ‘‘depth of cut (mm)” [15]; and MRR = mm3/s.
Fig. 1. The frequency occurrence of the used process parameters.
407
2.3. Identified research gap
A literature review in the cylindrical grinding process resulted
in the following gaps. First, most researchers studied the effect of
a few numbers of process parameters on CGP. Second, most of
the researchers had concluded by compromising the other objec-
tives, i.e. minimising surface roughness affects maximisation of
MRR. Last, the theoretical background shows that probably there
are no researchers that investigated EN45, even though such mate-
rials can be applied in several areas.
3. Experimental design methodology
3.1. Introduction
Several techniques can be applied to optimise manufacturing
operation, including grinding process. It is also advised to integrate
multiple related techniques [16–18] to establish statistically signif-
icant results, which can result in better conclusion and recommen-
dation. Some of the extensively deployed methods in developing a
process, product or running an operation include Design of exper-
iment (DOE) [19], one factor at a time (OFT) [20] and built-test-fix
(BTF) approach [21]. BTF approach is considered as the most prim-
itive approach. The optimisation process takes place once
resources are available without considering whether they are inac-
curate. OFT approach optimises a process by experimenting with
one factor at a time. Other process parameters are kept constant
until the effect of every factor is studied. OFT approach is the costli-
est approach and consumes much time. Under the OFT approach,
there is no consideration of factors at different levels [20–22].
DOE approach is a systematic and statistical method that helps
to solve engineering problems. It uses techniques and principles
mostly during the data collection phase for developing logical,
valid and reasonable engineering conclusions. DOE approach can
mostly be applied in four general engineering problems, i.e. charac-
terising or screening, comparative, modelling and optimising prob-
lems. DOE also helps to determine the cause-and-effect
relationship between various parameters or factors influencing
the studied operation and the outcome of the particular process
or operation. DOE approach consumes less time, and it is less
expensive compared to the OFT approach. Here, the emphasis is
laid predominantly on coming up with optimised outputs.
3.2. DOE approach
ð1Þ
DOE is a statistical approach which was applied simultaneously
to explore the effects of multiple parameters (variables). The major
approaches under DOE include full factorial and the Taguchi tech-
nique [22]. For this study, the authors applied the L9 orthogonal
array and used the Taguchi technique for the analysis. According
to Peace [23], ‘‘orthogonal means being balanced and not mixed”
and in the point of view to ‘‘experimental matrices”, orthogonal
means ‘‘statistically independent”. Selection of these processes
was due to the conducted literature survey which indicated how
effective has been ‘‘Taguchi approach” in optimising machining
process parameters for the related studies.
3.2.1. Full factorial design (FFD)
FFD is the designed experiment comprising a prudent fraction
(subset) of the planned experimental runs. There must be at least
two factors in doing so. According to Yerrawar and Arakerimath
[24], for FFD, experiments should have ‘‘experimental units” that
consider all possible combinations of all levels across the given
parameters. Such designed experiments should allow investigating
the influence of each parameter on the response variable together
408 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420

with the relationship between the considered parameters on the ing engineering activities, process and product, i.e. precedence, uni-
response variable. Experiments need input parameters. A set at two versality and reproducibility. Precedency leads to the readiness of
levels of each is typical in setting an experiment. Thus, ‘‘if there are technology; universality tunes a product (or process) to ensure that
k factors each at two levels; a full factorial design has 2k runs. Thus it meets or exceeds diversified customer requirements; and repro-
for six factors at two levels, it would take 26 = 64 trial runs” [24]. ducibility assures that the process, system or product functions as it
is required to perform in robust conditions [23].
3.2.2. Taguchi approach
Dr. Genichi Taguchi established a method to decrease the effort
3.3. SNR and performance measure
for an enormous determination of factor effects [25]. Taguchi tech-
nique is a ‘‘multi-stage process” that comprises idea or system
SNR stands for signal-to-noise ratio (SNR). Taguchi described
design, tolerance design and parameter design (design optimisa-
SNR as one of the performance measures. Process quality can be
tion) [26,23]. The three-stage processes advocated by ‘‘Dr Taguchi”
determined by first developing a technique that assesses the
to accomplish the required process quality are delineated in Fig. 2.
impact of input parameters on the response output. An average
In industries, it is significant to reduce variation as one way of
or signal value of response epitomises the required components
improving quality [27]. The process of reducing variation in indus-
that are near to a specific ‘‘target value”. The term ‘‘noise” charac-
tries for mass production is also supported by Box and Bisgaard [28]
terises unwanted parts of output characteristics. The combination
that ‘‘the enemy of mass production is variability. Success in reduc-
of these two by Taguchi provides SNR, which is used for measure-
ing it will invariably simplify processes, reduce scrap, and lower
ments. The mathematical evolution of SNR depends on three differ-
costs” [28]. Regarding mass production, one of the methods to
ent situations, i.e. ‘‘smaller is better”, ‘‘larger is better”, as well as
reduce variations is the ‘‘Taguchi method”. This method was devel-
‘‘target is best” (nominal is best) (see Table 2).
oped by ‘‘Dr Genichi Taguchi” for quality improvement. The Taguchi
The quality characteristics used as ‘‘smaller is better” include
method is also suitable for mass production [27]. The variation
shrinkage of the gasket, an impurity in water, bearing wear and
sources which can affect capacity in mass production can be due
an automobile fuel consumption. This case should be used when
to, first, ‘‘variation of part characteristics due to production varia-
neither a larger nor a smaller value is desirable, i.e. the specified
tion; second, a variation of part characteristics due to usage (dete-
value is most desired. The SNR for each product/process factors’
rioration, fatigue, wear, corrosion, etc.). It should be noted that here
level is calculated from the generated results of the SNR analysis
[there is] an interaction, e.g. between duty cycle variation and dete-
[21]. When the quality characteristic diverges from the ‘‘target
rioration)” [29]. Machining processes also require optimised
value”, there is an increase in the loss in a quadratic. Such a cate-
parameters to save time, cost and human resources for the materi-
gory includes product dimensions, for example, diameter, thick-
als manufacturers to stay into the business. All initiatives including
ness, and length; a service characteristic, e.g. the degree of
an incessant decrease in the variation of ‘‘product performance”
management involvement; and product characteristic, e.g. the oil
features, deviation in product specifications, selection of optional
viscosity [50].
machining parameters, among others, should be a ‘‘continuous
quality improvement programme” to meet or exceed the targeted
values. Now, for the mass production, there should be statistically
3.4. Steps for the Taguchi method
planned experiments which should be used to determine the set-
tings of process (and product) factors (parameters) to decrease
In most cases, there are five major phases (see Fig. 3) in using
‘‘performance variation” [26]. The required experiments can be car-
the parameter design under the Taguchi method. It is advised to
ried out either through computer simulation trials or through phys-
follow all phases, and for this study, all phases were followed
ical experiments. For this study, physical experiments were
closely.
conducted. Thus, there are three essential features in manufactur-

3.5. The selection process of the orthogonal array (OA)

‘‘Orthogonal array” can be chosen based on the factors and

Fig. 2. A three-stage process advocated by ‘‘Dr Taguchi” [48].
interaction, levels of factors and cost consideration. Parameter
determination involves methods like cause-and-effect diagram,
brainstorming and flow chart. The experiments for this study
involved a ‘‘degree of freedom (DOF)”. DOF is directly proportional
to the parameter levels. Thus, ‘‘increasing the number of levels of a
parameter increases the total degree of freedom in the experiment,
which in turn increases the total number of trials” [22]. Fig. 4
depicts the commonly used orthogonal arrays for experiment
design.

Table 2
Signal-to-noise ratios [49].

SNR Experimental goal Data characteristics SNR equations

P  
Smaller the better Minimise the response A target (optimal) value SNR ¼ 10  log X 2 =n
of zero that are non-negative
 
Nominal is best Target the response and base the Negative, zero, or positive SNR ¼ 10  log d2
SNR on standard deviations only
P   
Larger the better Maximise the response Positive SNR ¼ 10 log 1=X 2 =n

Note: SNR = signal-to-noise ratio; d = variance or standard deviation; n = number of measured parameters; X = mean.
 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420 409

Fig. 5. The used workpiece.

finishes and a high degree of accuracy. Table 4 depicts the technical

Fig. 3. Design of experiment application phases: the parallel process (the new specifications of the cylindrical grinding machine used in this
discipline) [23]. study.

4.2. Workpiece material

The term steel attributes to manganese, carbon, an alloy of iron,

and one or further important elements. The general form of desig-
nation is AISI X1 X2 XX3, where 1 (Alloy group): indicates major
alloying elements; 2 represents the specific alloy in the group,
and 3 is the carbon content. The experiments for this study used
EN45 mild steel (with an equivalent standard of AISI 9260) work-
pieces of length 130 mm and diameter 40 mm. EN45 has applica-
tion in spring, aeroplanes, rail transportation, machine tools,
military weaponry, bridges, swords and knives [52], among others.
There is a specific chemical composition that is important to be
considered when making an alloy. This helps for it to be sold as

Fig. 4. Frequently applied orthogonal array and its levels [51].

It is important to know the common experimental situations

and the equivalent experimental configurations (see Table 3). This
study considered ‘‘4 three-level factors, i.e. L-9 (34)”.

4. Experimental details

4.1. Machine tool

The importance of a cylindrical grinding machine (CGM) (Fig. 6)

Fig. 6. Hydraulic cylindrical grinding machine.
is to smoothen the diameter of the external or internal portion of
the workpiece that is rigidly supported or rotating. CGM also is
used for centreless grinding. CGM refers to the workpiece (see Table 4
Fig. 5) held in a chuck or between the supporting centres. It is used Technical specifications of the hydraulic cylindrical grinding machine.
to grind all types of materials (i.e. soft or hard) at very-fine surface
Parameter/item Hydraulic cylindrical grinder
Internal grinding 100 mm ID and 100 mm long
Table 3 job size
Experimental situations and equivalent experimental size [51]. External grinding 200 mm OD and 600 mm long
job size
Experimental Maximum possible Size of Taguchi Grinding wheel A60 L5 V10, 300 mm external diameter, 25 mm thick
situations conditions experiments and 76.2 mm internal diameter
7 three-level factors 2187 18 Table swivel either 2.5°
4 three-level factors 81 9 side
15 two-level factors 32,768 16 Maximum table 600 mm
11 two-level factors 2048 12 traverse
7 two-level factors 128 8
Note: mm = millimetre; ° = degree; A60 L5 V10 = grade; ID = inner diameter;
3 two-level factors 8 4
OD = outer diameter.
410 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420

Alloy Steel 9260. Such chemical composition includes: 0.56–0.64%

(C), 0.035% max (P), 0.04% max (S), 0.75–1.0% (Mn), 1.80–2.20% (Si)
and 96.085–96.89% (Fe) [52]. P, S, C, Mn, Si and Fe stand for Phos-
phorous, Sulphur, Carbon, Manganese, Silicon and Iron respec-
tively. The mechanical properties of EN45 are shown in Table 5.

4.3. Applied coolant and its characteristics

There are several categories of coolant, e.g. synthetic coolants,

soluble oils (emulsions of mineral oils in water) and straight oils
[8]. This study used Synthomaxx-111 as water-soluble cutting
oil. We used 45 L of cutting oil, and in that we mixed water in
1/3rd proportion. It is specifically ‘‘compounded soluble cutting
oil” which consists of a special emulsifier and petroleum oil. Such
a coolant blends easily with water. Synthomaxx-111 can be used in
CNC Lathe Machine for good cutting Nitrite and grinding, and Cre-
sol or Phenol-free extended sump life, better surface finish and Fig. 7. Cause-and-effect diagram or Ishikawa of the grinding process.
decrease of dumping cost. The coolant is applicable for metal cut-
ting and grinding operation. The purpose is to lessen ‘‘heat gener-
ation” and surge its ‘‘dissipation”.
Table 6
The considered factors (parameters) and levels.
4.4. Process parameter selection for quality characteristics
Factor Level

Ishikawa diagram (‘‘Cause-and-effect diagram”) was used to 1 2 3

categorise the factors (or ‘‘parameters”) that affect the quality of Feed (mm/min) 0.01 0.015 0.02
ground parts (see Fig. 7). The inputs for Fig. 7 were the output of Work speed (rpm) 80 150 270
DOC (mm) 0.01 0.02 0.025
the brainstorming sessions.
The ‘‘cause-and-effect diagram” is a technique used to analyse Note: mm = millimetre; rpm = revolutions per minute (min).
the process, product or problem dispersion. The diagram aims to
associate the effects and causes. The diagram has three main cate-
gories, i.e. cause enumeration, process classification and dispersion
analysis. From Fig. 7, it is clear the effect is the problem to be
Table 7
solved, i.e. quality of ground parts to obtain optimised machining L9 orthogonal array.
parameters.
Trial No. DOC (P) Work speed (Q) Feed Rate (R)
Before designing an experiment, a particular experiment must
be well planned. The careful planning process is the key process 1 1 1 1
2 1 2 2
to accomplish any DOE application. This step is also known as
3 1 3 3
brainstorming. Table 6 represents the considered factors and levels 4 2 1 2
in deciding the input process parameters and levels for experi- 5 2 2 3
menting based on brainstorming and operators’ manual for the 6 2 3 1
cylindrical grinding machine. The team (with specific knowledge 7 3 1 3
8 3 2 1
in machining processes) developed a list of factors. 9 3 3 2

4.5. Selection of orthogonal array

Table 8
The generated results were based on the L9 orthogonal array Experimental setups and cutting condition.
(OA) as the minimum possible array that used. L9 OA was selected Item Description
as displayed in Table 7. Table 8 represents the physical descrip-
Workpiece material Grade AISI 9255 (EN45 steel with length 130 mm
and diameter 40 mm)
Chemical composition 1.8–2.2% (Si), 0.75–1% (Mn), 0.56–0.64% (C),
Table 5
of the Alloy material 0.04% max (S), 0.035% max (P), 96.08596.89% (Fe)
Mechanical properties for EN45 mild steel (AISI 9260) [53].
Response variable Material removal rate (MRR)
Mechanical Properties Metric Control variables DOC (0.01, 0.02, 0.025 mm); Work speed
(Cutting parameter) (80, 150, 270 rpm); Feed rate (0.01, 0.015,
Tensile Strength, Yield 440–1149 MPa 0.02 rev/min)
Modulus of Elasticity 200 GPa Tool material SiC
Machinability 40% Machine Hydraulic cylindrical grinder
Shear Modulus 80.0 GPa Methodology Taguchi method
Tensile Strength, Ultimate 770–1525 MPa Software used for MinitabÒ 18 software
Poisson’s Ratio 0.29 data analysis
Bulk Modulus 160 GPa Orthogonal array L9 orthogonal array
Hardness, Brinell 184–235 selection
Elongation at Break 11–22% Objective function Larger the better
Hardness, Vickers 221 !
Equations n  
P 
Hardness, Knoop 233 SNR ¼ 10  log 1
Y2
=n
Hardness, Rockwell B 94 i¼1

Hardness, Rockwell C 15
Note: SiC = Silicon carbide; mm = millimetre; rpm = revolutions per minute (min);
Note: Mpa = Megapascal; Gpa = Gigapascal; % = Percentage. q = density; SNR = signal to noise.
 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420 411

tions of the experiment, experimental setups, chemical properties
and cutting conditions.
4.6. Data collection
The data collection process started from sample preparation by
cutting the workpiece to get the appropriate size and turning to
prepare the datum point of the next grinding operation. After turn-
ing operation, we pre-ground for further experimentation. During
the experimentation, we followed the subsequent procedures as
follows: sorting of grinding well, weighing process, set the work-
piece and cutting parameters to the appropriate condition, start
the grinding process and time measuring process by using a stop-
watch, measuring surface roughness and measuring weight.
5. Experimental observation and analysis
5.1. Experimental results
We set experiments to examine the impact of process factors
over the ‘‘output response characteristics” (i.e. MRR) before and
after heat treatment with the process parameters, i.e. DOC, FR,
and WS for single interactions. Tables 9 and 10 show the obtained
results. The study considered L9 orthogonal array, i.e. nine runs of
experiments were set on a ‘‘cylindrical grinding machine”. An anal-
ysis was performed using MinitabÒ 18 statistical software. The
MinitabÒ 18 generated Figs. 8–13 and Figs. 15–17. Fig. 18 was gen-
erated using MicrosoftÒ Excel 2016.
5.2. Analysis and discussion of the generated results
From experimental data, the SNR and mean of quality charac-
teristics were calculated. The main effects (response curves) were
applied to assess the ‘‘parametric effects” on the response charac-
teristics. All the gathered data from experiments were analysed
using ‘‘analysis of variance (ANOVA)” to generate optimal results.
Eqs. (2) and (3) computed SNR and MRR respectively. Eq. (2) con-
sidered the objective function that ‘‘smaller is better”.
Tables 11 and 12 depict the experimental results and SNR of
MRR before and after heat treatment.
n 
X  !
1
SNR ¼ 10  log =n ð2Þ
i¼1 Y2
    
Wb  Wa Wb  Wa
MRR ¼ =q  1000 ¼  1000 ð3Þ
Tm Tm  q
where Wb = workpiece weight before processing (g); Wa = work-
piece weight after processing (g) [54,55]; n = number of tests in tri-
als; Yi = result of a particular experiment; Tm = machining time (s);
and q = 7.85 g/cm3 density of AISI 9255; g = gram.
5.3. Effect on input parameters on MRR before heat treatment
Figs. 8 and 9 illustrate the mean values of MRR for each process
parameter at levels (1, 2 and 3) and SNR data. Fig. 8 displays the
MRR value of cylindrical grinding that drops from level 1 to 2
and upsurges from level 2 to 3 on the effect of DOC. The MRR value
of cylindrical grinding increases as the work speed increases and
the same effect is observed with feed rate. Table 13 shows the
response table of SNR for MRR: ‘‘larger is better” while Table 14
depicts the response table of means for MRR.
Fig. 10 is an ‘‘interaction plot” whereby the shown lines are not
‘‘parallel”. Interaction plot helps to depict how the connection
between a continuous response and one categorical factor relies
on the value of the ‘‘second categorical factor”. It can be observed
from Fig. 10 that the interaction between process parameters of
MRR was significant since the responses at different levels of the

Table 9
Experimental result before heat treatment.

* ** DOC (mm) Work speed (rpm) Feed rate (mm/min) Weight (g) Cycle time (s) MRR (mm3/s)
Before After
1 1 0.01 80 0.01 0.995 0.989 359 0.002129
4 2 0.01 150 0.015 1.005 1 336 0.001896
7 3 0.01 270 0.02 0.981 0.974 256 0.003483
8 4 0.025 80 0.015 0.968 0.962 198 0.00386
2 5 0.025 150 0.02 0.962 0.955 138 0.006462
5 6 0.025 270 0.01 0.955 0.95 122 0.005221
6 7 0.02 80 0.02 1 0.995 325 0.00196
9 8 0.02 150 0.01 1.009 1.005 346 0.001473
3 9 0.02 270 0.015 0.989 0.981 268 0.003803

Note: * = Order; ** = Trial.

Table 10
The experimental results after heat treatment.

* ** DOC (mm) Work speed (rpm) Feed rate (mm/min) Weight (g) Cycle time (s) MRR (mm3/s)
Before After
1 1 0.01 80 0.01 0.942 0.937 259 0.002459
4 2 0.01 150 0.015 0.925 0.92 239 0.002665
7 3 0.01 270 0.02 0.907 0.897 171 0.00745
8 4 0.025 80 0.015 0.93 0.925 143 0.004454
2 5 0.025 150 0.02 0.915 0.907 121 0.008422
5 6 0.025 270 0.01 0.893 0.887 130 0.005879
6 7 0.02 80 0.02 0.937 0.93 169 0.005276
9 8 0.02 150 0.01 0.92 0.915 123 0.005178
3 9 0.02 270 0.015 0.897 0.893 121 0.004211

Note: * = Order; ** = Trial.

412 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420

Fig. 8. The plot shows the foremost effects for SN Ration of MRR before heat treatment.

Fig. 9. Key effects for means of MRR before heat treatment.

N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420 413

Fig. 10. Interaction for MRR before heat treatment.

Fig. 11. Interaction for MRR before heat treatment.

414 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420

Fig. 12. Interaction for MRR before heat treatment.

Interval Plot of MR
RR (mm3//sec) vs Feed
d rate (mm//min)
95% CI for the Mean
0.007

0.006

0.005
mm3/sec)

0.004
MRR (m

0.003

0.002

0.001

0.000
0.010 0.015 0.020
Feed rate (mm/min)
The pooled standard deviation is used to calculate the intervals.
Fig. 13. Interaction for MRR before heat treatment.
 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420 415

differences are ‘‘statistically significant”. Thus, to establish the sta-

tistical significance, we assessed the confidence interval (a = 0.05)
for the differences of means. Using MinitabÒ 18 version, DOC had
Hardness Electric furnace DOF (2), Adj SS (0.000015), Ad MS (0.000007), F-Value (5.66) and
Testing machine P-Value (0.042). Since p < 0:05, hence, DOC is statistically signifi-
cant. Similarly, for work speed, Adj SS is 0.000003, Ad MS
(0.000002), F-Value (0.55) and P-Value (0.606). For Feed rate, the
p-value was 0.789. Therefore, ‘‘feed rate” and ‘‘work speed” were
both not statistically significant since their p  0:05. The model
Cooling by air summary indicated that ‘‘S” is 0.0011516, R-Sq (88.33%), R-sq
(Normalization)
(adj) (53.31%) and percentage contribution (C%) for DOC of 62.2%.
F is a statistical parameter (Fisher’s ratio); DOF (degree of free-
dom); MS (mean of squares); P (power level indicates statistical
significance); SS (sum of squares); C (%) is the percentage contribu-
Work piece tion. Eq. (4) determines the contribution in percentage.

Fig. 14. Heat treatment process. Sum of square term

combination almost interact with each other. The overall model
results depict that ‘‘interaction” is significant.
5.4. Selection of optimal levels
To investigate the process parameters, ANOVA was performed.
Fig. 11 indicates the interval plot of MRR against ‘‘depth of cut”
while Figs. 12 and 13 depict the interval plot for work speed and
feed rate respectively. In the interval plot (see Fig. 11), DOC
(0.02 mm) is the ‘‘lowest mean” while DOC (0.025 mm) is the high-
est mean. Based on Fig. 11, it is not easy to conclude whether any
Contribution ð%Þ ¼  100 ð4Þ
Total sum of square
Tables 13 and 14 comprise ranks based on Delta. This shows the
significance of the response parameter and the rank is given based
on the magnitude. The delta value and rank indicate that the DOC
has the highest effect on MRR. The results also indicate that the
optimal level suggested for MRR is P2Q3R3.
5.5. Optimal design estimation
Here the confidence intervals (CI) were predicted along with the
respective value of MRR. The 95% CI should comprise the average
response parameters values found from the ‘‘confirmation
experiments”. The optimal setting of the selected process parame-
ter is P2Q3R3 for MRR. The estimated mean of the response

Main Effects Plott fo

or SN ratioss
Data Means
DOC Work speed Feed
-43

-44
n of SN ratios

-45

-46
Mean

-47

-48

-49
1 2 3 1 2 3 1 2 3

Signal-to-noise: Larger is better

Fig. 15. Main effects for SN Ratio MRR after heat treatment.
416 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420

Main Efffects Plot for Means

Data Means
DOC Work speed Feed
0.0070

0.0065
Mean of Means

0.0060

0.0055

0.0050

0.0045

0.0040

1 2 3 1 2 3 1 2 3
Fig. 16. Main effects plot for MRR means after heat treatment.

Interactiion Plot for MRR

Data Means
1 2 3

0.008 DOC
1
0.006 2
DOC 3
0.004

0.008 Work
speed
0.006 1
Work speed 2
0.004 3

0.008 Feed
1
0.006 2
Feed 3
0.004

1 2 3 1 2 3

Fig. 17. Interaction plot of MRR after heat treatment.

characteristics SNR for MRR was calculated using Eqs. (5)–(7). The lP2Q3R3 ¼ P2 þ Q 3 þ R3  2ðTÞ ð6Þ
estimated mean of MRR is lP2Q 3R3 ¼ 0:005880.
lP2Q3R3 ¼ 0:005181 þ 0:004169 þ 0:003968  0:007434 ð7Þ
lP2Q 3R3 ¼ T þ ðP2  T Þ þ ðQ 3  T Þ þ ðR3  T Þ ð5Þ
 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420 417

Before After Fa (1, fe) = F0.05(1,2) = 18.51

For MRR,
0.009
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 ffi
0.008
MRR (mm3/sec)

1 1
0.007 CI ¼ 18:51  0:000001 þ ¼ 0:0047564
1:125 3
0.006
0.005 The 95% CI of the projected optimum SNR is:
0.004    
0.003 lP2Q 3R3  CI < lP2Q 3R3 < lP2Q 3R3 þ CI ð10Þ
0.002
0.001
0:0011236 < lP2Q3R3 < 0:0106364
0
0 1 2 3 4 5 6 7 8 9 10
Run of experiments 5.6. The confirmation of experiments before heat treatment
Fig. 18. The graph of MRR before and after heat treatment.
The last step in the first DOE iteration process was about an
experimental confirmation. It was completed by testing a specific
lP2Q 3R3 ¼ 0:005880 combination of levels and factors formerly evaluated. This step val-
idated the established conclusions during the analysis phase. The
where T = response parameter overall mean; PiQjRk = response optimal settings selected for the MRR value of EN45 is 0.8 mm@.
parameters average and i, j, k = factor levels of 1, 2, 3.

5.5.1. Confidence interval (CI) estimation Table 13

Taguchi analysis: MRR versus DOC, work speed, feed.
The CI used for the projected treatment condition average
applied in the confirmation experiment to validate prediction Level DOC (mm) Work speed (rpm) Feed rate (mm/min)
was calculated using Eqs. (8) to (10) [56]. 1 52.35 51.95 51.91
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
  2 45.90 51.62 50.37
1 1 3 53.06 47.73 49.04
CI ¼ F /ð1;feÞ Ve þ ð8Þ Delta 7.16 4.22 2.87
eff S
Rank 1 2 3

N
eff ¼
1 þ ðTotal degrees of freedom associated in estimated of meanÞ
Table 14
ð9Þ Response table of means for MRR.

Level DOC (mm) Work speed (rpm) Feed rate (mm/min)

9
eff ¼ ¼ 1:125 1 0.002503 0.002650 0.002941
1þ7 2 0.005181 0.003277 0.003186
where S = ‘‘sample size for confirmation of an experiment”; Ve = ‘‘er- 3 0.002412 0.004169 0.003968
Delta 0.002769 0.001519 0.001027
ror variance”; N = total number of results; F/,1; Ve = F ratio of the CI Rank 1 2 3
of (1-a) against DOF 1, DOF of error fe = 2.

Table 11
The experimental result and SN Ratio of MRR before heat treatment.

Order Trial no. DOC (P) (mm) Work speed (Q) (rpm) Feed rate (R) (mm/min) MRR (mm3/s) SNR (MRR)
1 1 0.01 80 0.01 0.002129 53.4365
4 2 0.01 150 0.015 0.001896 54.4432
7 3 0.01 270 0.02 0.003483 49.1609
8 4 0.025 80 0.015 0.00386 48.2683
2 5 0.025 150 0.02 0.006462 43.7927
5 6 0.025 270 0.01 0.005221 45.6429
6 7 0.02 80 0.02 0.00196 54.1549
9 8 0.02 150 0.01 0.001473 56.6359
3 9 0.02 270 0.015 0.003803 48.3975

Table 12
The experimental result and SN Ratio of MRR after heat treatment.

Order Trial no. DOC (P) (mm) Work speed (Q) (rpm) Feed rate (R) (mm/min) MRR (mm3/s) SNR for MRR
1 1 0.01 80 0.01 0.002459 52.1848
4 2 0.01 150 0.015 0.002665 52.1848
7 3 0.01 270 0.02 0.00745 51.4861
8 4 0.025 80 0.015 0.004454 42.5569
2 5 0.025 150 0.02 0.008422 41.4917
5 6 0.025 270 0.01 0.005879 44.6139
6 7 0.02 80 0.02 0.005276 45.5539
9 8 0.02 150 0.01 0.005178 45.7168
3 9 0.02 270 0.015 0.004211 47.5123
418 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420

The result was found to be within the 95% CI at
0:0011236 < lP2Q 3R3 < 0:0106364 and helped to predict the
selected optimal values’ corresponding characteristic of MRR.
Therefore, the optimal setting of process factors or parameters as
projected in the exploration (analysis) can be applied.
5.7. Effects after heat treatment
When performing heat treatment for EN45, it is important to
‘‘heat the steel slowly to 650–700 °C and thoroughly soak. Con-
tinue heating the steel to the final hardening temperature of
870–930 °C and allow the component to be heated through” [57].
This should be followed by the quenching process in oil whereby
the EN45 spring steel is tempered instantly after ‘‘quench-
ing whilst tools still hand warm”. The heating temperature, includ-
ing soaking, cooling times, heating rate, etc. differ due to factors
like the size and shape of each component. Other important factors
or elements during the ‘‘heat treatment process” are such as the
workpiece transfer facilities, quenching medium, and the type of
the used furnace [57].
The HTP changes the materials’ chemical and physical proper-
ties. There are several types of HTP; one being a ‘‘normalisation
process”. In order to accomplish the objective of how the parame-
ters of a process affect the output response characteristics after
heat treatment, the material was heated in a material laboratory
at 870 °C. The workpiece was normalised to room temperature,
and the hardness changed from 18 ± 1HRC to 36 ± 3HRC. After
the heat treatment process, we followed the same design of exper-
imental procedures. Fig. 14 depicts the processes which we fol-
lowed. The findings after the normalisation process and
experimental works through L9 orthogonal array are illustrated
in Figs. 15 and 16.
The interaction between process parameters of material
removal rates was significant since the response at different levels
of the combination almost interact with each other (see Fig. 17).
5.8. Selection of optimal levels after heat treatment
To explore the impact of the process factors on MRR, the ANOVA
was performed. The analysis in Table 15 shows that P-value is less
than 0.05 for feed rate and greater than 0.05 for DOC and work
speed. Thus, the feed rate is ‘‘statistically significant”.
5.9. Optimal design estimation after heat treatment
Here, the confidence interval (CI) was predicted along with the
respective value of MRR. The 95% CI should comprise the average
values for the response parameters found from the ‘‘confirmation
experiments”. The optimal setting of the selected process parame-
ter for MRR is P2Q3R3. The estimated mean of the response charac-
teristics was computed using Eqs. (5) to (7). The estimated mean
for MRR is lP2Q 3R3 ¼ 0:00976578. Similarly, the CI used for the pro-
jected ‘‘average of a treatment condition” applied in the ‘‘confirma-
tion experiment” to confirm that prediction was calculated using
Eqs. (8) to (10). Thus, for MRR, the 95% CI of the predicted optimum
SNR is: 0:581114 < lP2Q 3R3 < 0:600641.
5.10. The confirmation of the treatment
The last step in the first DOE iteration process is an experimen-
tal confirmation. It is completed by testing using a specific combi-
nation of levels and factors formerly evaluated. This step validates
the established conclusions during the analysis phase. The result
was found to be within the 95% CI at
0:58500567 < lP2Q 3R3 < 0:596766 and predicted the optimal
value of the selected corresponding characteristic of MRR. There-
fore, the experiments are proven to be used in the projected opti-
mal setting of process parameters.
5.11. Comparison of results before and after treatment
Fig. 18 depicts the effect of heat treatment processes on MRR.
MRR ‘after heat treatment’ is better than ‘before heat treatment’
since the value of MRR is increasing. So, for EN45 material in the
given matching condition, it gives a relatively good MRR after heat
treatment.
6. Significance of this study
This study constitutes a great contribution as it explores the ini-
tial optimal cutting condition by considering DOC, FR and WS
parameters to optimise MRR as quality characteristic. The study
utilised the design of experiment (DOE) on the CGP. The selected
optimal cutting parameter also has a substantial influence in
reducing the machining time and associated cost. Thus, the manu-
facturing industries can benefit from this systematic, rigorous
study that details the optimal cutting conditions for the EN45 steel
material using the Taguchi method. It is important to expand fur-
ther the study to establish more optimised values with a broader
margin of factors and experiments.
7. Conclusion, limitations and future work
The study was about the effect of DOC, FR and WS parameters as
machining parameters on CGP. The experiments for this study used
EN45 mild steel (with an equivalent standard of AISI 9260) work-
pieces of length 130 mm and diameter 40 mm. The machine and
wheel used are a hydraulic cylindrical grinder and the silicon car-
bide (SiC) wheel respectively. MRR was measured using weight
balancing. This study used Synthomaxx-111 as water-soluble cut-
ting oil. We used 45 L of cutting oil, and in that we mixed water in
1/3rd proportion. From the ANOVA table, it is seen the impact level
of the cutting depth (DOC) on MRR before heat treatment was

Table 15
ANOVA table (from MinitabÒ) of MRR after heat treatment.

Source DF Adj SS Adj MS F-Value P-Value C (%)

DOC 2 0.000007 0.000003 3.66 0.215 21.6
WS 2 0.000005 0.000003 2.89 0.257 15.1
FR 2 0.000018 0.000009 9.83 0.0092 57.1
Error 2 0.000002 0.000001 6.2
Total 8 0.000031
Summary of a model
S R-sq R-sq(adj) R-sq(pred)
0.0009492 94.24% 76.98% 0.00%

Note: F = statistical parameter (Fisher’s ratio); DOF = degree of freedom; MS = mean of squares; P = power level indicates statistical significance; SS = sum of squares.
 N.C. Deresse et al. / Engineering Science and Technology, an International Journal 23 (2020) 405–420
65.2%. After the heat treatment, the most important factor for MRR
of grinding was found to be the feed rate with 57.1%. The optimal
‘‘process parameters” for MRR are WS of 270 rpm, DOC of
0.025 mm and FR of 0.02 mm. Then after heat treatment, the pro-
cess parameters were found to be near to optimal state for MRR
include WS of 270 rpm, DOC of 0.025 mm and FR of 0.02 mm.
7.1. Limitations and future work
A limitation of this study is that the research involved a few
process parameters; for the future studies, a greater number of
process parameters would be considered. A further limitation is
that the study used a simple cylindrical grinding machine; how-
ever, in future work, the study will involve a precision cylindrical
grinding machine to compare the current findings and the future
results. Another limitation of this study arises from the fact that
despite that a satisfactory number of experiments were set; how-
ever, the number of experiments should be analysed using differ-
ent types of analysis like genetic algorithms. Moreover, since
there are less or no studies on EN45 steel materials, there is a pos-
sibility that the selected range of survey cutting mode parameters
of DOC (0.01 to 0.025 mm); WC (80 to 270 rpm) and FR (0.01 to
0.02 mm/min) in this study were not wide enough. Thus, further
study should increase the range of the selected parameters to
establish further optimised machining parameters. The final limi-
tation concerns the statistical parameter R-Sq and R-Sq adj
obtained from experimental data of before heat treatment are
low, i.e. 88% and 53% respectively. It is good if both the values
are above 95%. It is suggested to extend the study in future to
improve R-Sq values.
Funding
There is no specific grant from any funding agencies for this
study.
Declaration of Competing Interest
None.
Acknowledgments
We would like to extend our thankfulness to all people who
contributed their valuable ideas in this study. Their incredible sup-
port was highly important in completing this study.
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