International Journal of Mechanical Engineering and Technology (IJMET)

Volume 8, Issue 8, August 2017, pp. 855–865, Article ID: IJMET_08_08_093

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ISSN Print: 0976-6340 and ISSN Online: 0976-6359

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EFFECT OF MACHINING PARAMETERS ON

SURFACE ROUGHNESS OF DIFFERENT
MATERIALS WITH CNC MILLING AN
EXPERIMENTAL APPROACH
T. Vanaja
Assistant Professor, Department of Mechanical Engineering,
Institute of Aeronautical Engineering, Dundigal, Hyderabad, India

C. Labesh Kumar
Assistant Professor, Department of Mechanical Engineering,
Institute of Aeronautical Engineering, Dundigal, Hyderabad, India

Dr. CH V K N S N Moorthy
Professor, Department of Mechanical Engineering,
Institute of Aeronautical Engineering, Dundigal, Hyderabad, India

VVSH Prasad
Professor, Department of Mechanical Engineering,
Institute of Aeronautical Engineering, Dundigal, Hyderabad, India

ABSTRACT
Surface roughness plays an important role in determining how a real object will
interact with its environment. Rough surfaces usually wear more quickly and have
higher friction co-efficient than smooth surfaces. Roughness is often a good predictor
of the performance of a mechanical component, since irregularities in the surface may
form nucleation sites for cracks or corrosion and also roughness may promote
adhesion. Surface roughness has a major impact in precision manufacturing although
high roughness value is undesirable; it can be difficult and expensive to control in
manufacturing. Decreasing the roughness of a surface will usually increase its
manufacturing costs. This often results the trade-off between the manufacturing cost of
a component and its performance in application. The present work deals with the
effects of various milling parameters such as spindle speed, feed rate, depth of cut and
coolant flow on the surface roughness of finished components. Work will be carried
out in different materials on CNC milling machine using carbide inserts to find the
optimum parameters of surface roughness after machining. Design of experiments is
used for validation of this experiment. The analysis of mean and variance technique is
employed to study the significance of each machining parameter on the surface
roughness.

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 Effect of Machining Parameters on Surface Roughness of Different Materials with CNC Milling
an Experimental Approach

Key words: Surface Roughness, CNC Milling Machine, Taguchi Analysis, ANOVA
method, S/N ratio.
Cite this Article: T. Vanaja, C. Labesh Kumar, Dr. CH V K N S N Moorthy, VVSH
Prasad Effect of Machining Parameters on Surface Roughness of Different Materials
with CNC Milling an Experimental Approach, International Journal of Mechanical
Engineering and Technology, 8(8), 2017, pp. 855–865.
http://iaeme.com/Home/issue/IJMET?Volume=8&Issue=8

1. INTRODUCTION
Surface roughness has received serious attention for many years. The determination of the
machinability of materials is done by the measure of surface finish. It greatly affects the
functional performance of mechanical parts such as wear resistance, fatigue strength, heat
generation and transmission, corrosion resistance, etc.., hence, the proper selection of cutting
tools and process parameters is essential to achieve the desired quality of surface finish.
Optimization seeks to maximize the performance of system while satisfying the design
constraints. Metal cutting is one of the important widely used manufacturing processes in
engineering industries. The study of metal cutting focuses the work material, tools, machining
parameters and cutting fluid which influencing process efficiency and output quality
characteristics. EN8 steel is a popular grade of medium carbon steel, which readily
machinable in any condition which best suitable for high tensile strength and wear resistance
components. It is available in heat treated forms possess good homogeneous metallurgical
structure and gives consistent machining and mechanical properties. Aluminium is well
known material and has got wide applications. These two materials are used in this research
work. Taguchi design of optimization is used to predict surface roughness created using CNC
milling operation. Using RSM the surface modelling and optimization in milling process
results were found. High cutting speed, feed and depth of cut were adopted for low surface
roughness is obtained for high hardened steel and Aluminium. Experimentally investigated
the effect of cutting parameters on the steel and Aluminium.

2. EXPERIMENTAL SETUP
The test was conducted on the CNC Milling machine with a maximum spindle rpm of 6000
and motor torque is 7 Nm with using coolants.

2.1. CNC Milling Machine Specifications

Table 1
Features Capacity
Type of feed A.C. servo drive with ball screw and pre-loaded nut.
Feed range 1 mm/min to 10,000 mm/min
Feed override 0-150%
Rapid traverse 15,000 mm/min
Rapid override 0-100%
Rotary encoder built in the servo
Position feed back motor
Motor torque 7 Nm
Max.Working torque 250 mm
Max.stroke(between dead stop) 445 mm
Spindle face to table top 150-400 mm
Braking torque 8 Nm
Axial thrust 350 Kg

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 T. Vanaja, C. Labesh Kumar, Dr. CH V K N S N Moorthy, VVSH Prasad

Table 2
Features Capacity
No. of spindles 1No
Spindle bearing diameter 50 mm (Quadraplex)
Spindle taper ISO 30
Tool holder taper BT 30
Spindle speed range 60 to 6000 rpm
Standard (indirect drive) 80to 8000 rpm
5.5 KW max at 30 min of continuous
running
Constant power range 3.7 KW for continuous running
Spindle speed override 50-120%
Type of motor A.C motor with transistor (PWM)control
Velocity feed back (STD) Taco generator
Speed feed back Rotary encoder (built-in)
2.2. Tool Dimensions

Carbide Inserts: CNMG

C - Shape: diamond
N - Clearance angle: 00
M - Tolerance: corner point 0.002 to 0.005 inches
G - Hole: cylindrical

Figure 1 CNMG Carbide Inserts

EN-8 block
length ×breadth ×height = 140×80×50

Figure 2

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 Effect of Machining Parameters on Surface Roughness of Different Materials with CNC Milling
an Experimental Approach

Aluminium Block
length ×breadth ×height = 170×100×50

Figure 3

Medium Carbon Steel EN 8

EN 8 is an alloyed medium carbon steel grade with reasonable tensile strength. it is normally
supplied in cold drawn or as rolled condition.. EN 8 is widely used for applications which
require better properties than mild steel but does not justify the costs of an alloy steel. EN 8 is
available from stock in bar and can be cut to your requirements.

2.3. Composition of EN 8
Table 3
Metal Composition
C 0.36-0.44 %
Si 0.10-0.40 %
Mn 0.60-1.0 %
Ph 0.05 %
S 0.05 %

2.4. Composition of Aluminium

Table 4

Metal Composition
Aluminium Balance
Magnesium 0.8-1.2
Silicon 0.4-0.8
Copper 0.15-0.40
Titanium Max 0.15
Manganese Max 0.15
Chromium 0.04-0.35

2.5. Surface Roughness Tester

The surface roughness values are measured by Talysurf Surface Roughness Tester stylus tip
radius of 5µm

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 T. Vanaja, C. Labesh Kumar, Dr. CH V K N S N Moorthy, VVSH Prasad

3. METHODOLOGY
• Checking and preparing the CNC milling ready for performing the machining operation.
• Cutting EN-8 Steel and aluminium bars by power saw and performing initial end milling
operation in CNC milling to get desired dimension of the work pieces.
• Selection of appropriate tool depending upon the cutting parameters i.e. speed, feed, depth of
cut and material diameter and coolant flow is done depending upon the experiment design.
• Cutting parameters speed, feed, and depth cut are selected going through the study of different
literature and also in the view of machine standard specifications.
• Performing face milling operation on EN-8 Steel and aluminium specimens in various
combinations of process control parameters like: speed, feed, depth of cut.
• Measuring surface roughness and surface profile with the help of a Talysurf Surface
Roughness Tester.
• After getting the different parameter to optimize the surface roughness by using Taguchi
method.

4. DESIGN OF EXPERIMENTS
For each factor three levels where specified the columns are spindle speed, feed, depth of cut
the test was performed for each combination and resulting in a total of 27 experiments which
allows the ANOVA results

Table 5
Experiment Spindle Feed Depth
number speed(rpm) (mm/tooth) Of cut(mm)
1 370 0.2 0.1
2 370 0.2 0.05
3 370 0.2 0.2
4 370 0.1 0.1
5 370 0.1 0.05
6 370 0.1 0.2
7 370 0.3 0.1
8 370 0.3 0.05
9 370 0.3 0.2
10 310 0.2 0.1
11 310 0.2 0.05
12 310 0.2 0.2
13 310 0.1 0.1
14 310 0.1 0.05
15 310 0.1 0.2
16 310 0.3 0.1
17 310 0.3 0.05
18 310 0.3 0.2
19 450 0.2 0.1
20 450 0.2 0.05
21 450 0.2 0.2
22 450 0.1 0.1
23 450 0.1 0.05
24 450 0.1 0.2
25 450 0.3 0.1
26 450 0.3 0.05
27 450 0.3 0.2

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 Effect of Machining Parameters on Surface Roughness of Different Materials with CNC Milling
an Experimental Approach

5. RESULTS AND DISCUSSION

After milling of steel and aluminium

Figure 4

The results for the milling of EN 8 and aluminium are be given with ANOVA tables

Table 6 ANOVA for EN 8

DOF SSd Ms P%
Up Down Up Down Up Down Up Down
PARAMETER milling milling milling milling milling milling milling milling
Spindle speed 2 2 285.15 280.59 142.5792 140.295 41.65 32.11
Feed rate 2 2 142.58 69.294 71.290 34.647 20.82 7.9
Depth of cut 2 2 33.010 5.16 16.5052 2.58 4.82 5.9

Table 7 ANOVA for Aluminium

DOF SSd Ms P%
Up Down Up Down Up Down Up Down
PARAMETER milling milling milling milling milling milling milling milling
Spindle speed 2 2 1.695 111.296 0.847 55.648 0.6 5
Feed rate 2 2 1.909 95.893 0.954 47.946 0.7 4.3
Depth of cut 2 2 4.439 17.29 2.219 8.645 1.7 7.1

Results from Minitab and Talysurf

5.1. Results of EN 8 Up Milling

Figure 5 Main Effect Plot for EN 8 Up Milling

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 T. Vanaja, C. Labesh Kumar, Dr. CH V K N S N Moorthy, VVSH Prasad

From the above figure it is observed that the surface roughness of speed is high for level 1
and gradually decreases with speed of level 2 and slightly increases with third speed. Feed for
up milling of EN 8 slightly increases from level 1 to level 2 and there will be sudden increases
to higher value in level 3. For depth of cut surface roughness is high at level 1 and decreases
at level 2 and again increases at level 3.

Table 8 Optimal values of EN 8 for up milling

Parameters Optimum values
Speed (rpm) 310
Feed (mm/tooth) 0.2
Depth of cut (mm) 0.2

Taguchi method of optimization with design of experiments has been successfully

implemented and results are obtained. Surface roughness is optimum at low speed, medium
feed and high depth of cut for EN 8 up milling. Optimal values are tabulated in the below
table

Figure 6

Table 9 Test results of EN 8 for Up Milling

Surface roughness (Ra) values
Ra 1 Ra 2 Ra 3 Average S/N Ratio
0.439 0.413 0.462 0.438 7.710

5.2. Results of EN 8 Down Milling

Figure 7

From the above figure it is observed that the surface roughness decreases from level 1 to
level 2 and slightly increases from level 2 to level 3.the surface roughness of feed slightly

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 Effect of Machining Parameters on Surface Roughness of Different Materials with CNC Milling
an Experimental Approach

increases from level 1 to level 2 and drastically increases from level 2 to level 3. The surface
roughness for depth of cut gradually decreases from level 1 to 2 and slightly increases from
level 2 to level 3.

Table 10 Optimal values of EN 8 for down milling

Parameters Optimum values
Speed (rpm) 310
Feed (mm/tooth) 0.3
Depth of cut (mm) 0.2

Taguchi method of optimization with design of experiments has been successfully

implemented and results are obtained. Surface roughness is optimum at low speed, high feed
and high depth of cut for EN 8 up milling. Optimal values are tabulated in the below table.

Figure 8

Table 11 Test results of EN 8 for down Milling

Surface roughness (Ra) values
Ra 1 Ra 2 Ra 3 Average S/N Ratio
0.298 0.307 0.397 0.334 9.525

5.3. Results of Aluminium up Milling

Figure 9

From the above figure it is observed that the surface roughness gradually decreases from
level 1 to level 2 and level 2 to level 3.The surface roughness of feed increases from level 1 to

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 T. Vanaja, C. Labesh Kumar, Dr. CH V K N S N Moorthy, VVSH Prasad

level 2 and decreases from level 2 to level 3. The surface roughness for depth of cut gradually
decreases from level 1 to 2 and from level 2 to level 3

Table 12 Optimal values of Aluminium for Up milling

Parameters Optimum values
Speed (rpm) 760
Feed (mm/tooth) 0.4
Depth of cut (mm) 0.2

Taguchi method of optimization with design of experiments has been successfully

implemented and results are obtained. Surface roughness is optimum at medium speed,
medium feed and low depth of cut for Aluminium up milling. Optimum values are tabulated
in the below table.

Figure 10

Table 13 Test results of Aluminium for up Milling

Surface roughness (Ra) values

Ra 1 Ra 2 Ra 3 Average S/N Ratio
0.057 0.088 0.076 0.073 22.733

5.4. Results of Aluminium down Milling

Figure 11 Main Effect Plot for Aluminium Down Milling

From the above figure it is observed that the surface roughness decreases from level 1 to
level 2 and suddenly increases from level 2 to level 3.The surface roughness of feed decreases
from level 1 to level 2 and increases from level 2 to level 3. The surface roughness for depth
of cut gradually increases from level 1 to 2 and then decreases from level 2 to level 3

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 Effect of Machining Parameters on Surface Roughness of Different Materials with CNC Milling
an Experimental Approach

Table 14 Optimal values of Aluminium for Down milling

Parameters Optimum values
Speed (rpm) 385
Feed (mm/tooth) 0.4
Depth of cut (mm) 0.2

Taguchi method of optimization with design of experiments has been successfully

implemented and results are obtained. Surface roughness is optimum at low speed, low feed
and low depth of cut for Aluminium up milling. Optimal values are tabulated in the below
table.

Figure 12

Table 15 Test results of Aluminium for Down Milling

Surface roughness (Ra) values

Ra 1 Ra 2 Ra 3 Average S/N Ratio
0.108 0.090 0.107 0.101 19.913

6. CONCLUSIONS
The optimization of parameters by the taguchi's orthogonal array has proved to be an
excellent tool. This experimentation has provided a significant result by considering small
experimentation values. The three parameters are contributing to the response and all have
been considered for experimentation of up milling and down milling. Among the parameters
EN 8 up milling speed is 310 rpm, feed 0.2 mm/tooth and 0.2 depth of cut. EN 8 down
milling optimum parameters have been obtained at speed 310 rpm, feed 0.3 mm/tooth and
depth of cut 0.2mm For Aluminium up milling optimal parameters obtained at speed 760 rpm,
feed 0.4 mm/tooth and depth of cut 0.2mm and for Aluminium down milling speed is 385
rpm, feed 0.6 mm/tooth and 0.35 mm depth of cut. The S/N ratios of predicted values and
verification test values are valid when compared with optimum values. The S/N ratios are
found to be within the limits of the predicted value and the work has fulfilled by the objective.

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