Original Article

Proc IMechE Part B:

J Engineering Manufacture
1–10
Multi-response optimization in Ó IMechE 2016
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DOI: 10.1177/0954405415624349

tool vibration and surface roughness pib.sagepub.com

using response surface methodology

GHV Prasad Babu1, BSN Murthy2, K Venkatarao3 and Ch Ratnam4

Abstract
Turn milling is one of the machining processes used to mill circular work pieces while the work piece rotates about its
own axis. Orthogonal milling is one of the turn milling processes where the bottom part of cutter removes material
from the rotating work piece with high metal removal rate. In this article, tool condition was studied by analyzing surface
roughness and vibration of cutter with the use of response surface methodology. According to design of experiments,
16 experiments were conducted on ASTM B139 phosphor bronze with high-speed steel end mill cutter on four-axis
milling machine. The response surface methodology was used to find out significant parameters that are affecting surface
roughness and amplitude of cutter vibration. A multi-response optimization technique was used to identify optimum cut-
ting parameters for less surface roughness and amplitude of cutter vibration.

Keywords
Ortho milling, turn milling, response surface methodology, multi-response optimization, tool vibration

Date received: 8 February 2015; accepted: 30 November 2015

Introduction parameters. It is the responsibility of manufacturer to

Milling is one of the widely used processes for high
metal removal rate and production of complex shapes.
Turn milling was defined by Sandvik Coromant as ‘‘the
milling of a curved surface, where the work piece is
rotated around its center point using a fourth machin-
ing axis.’’1 The turn milling process is a new technology
in manufacturing process, where the rotary tool is
moved against the rotating work piece.2 There are two
types of turn milling processes: orthogonal turn milling
and tangential turn milling. As shown in Figure 1, work
piece is fixed in the chuck of the machine, a mill cutter
is fixed to the spindle of four-axis milling machine and
the rotating cutter is applied against the rotating work
piece to remove material from the surface work piece.
Turn milling process is a new technology that combines
two conventional machining processes like turning and
milling.3 This new technology is an alternative process
that gives improved productivity especially in machin-
ing of hard and large diameter work pieces.
Functional performance and life of a machined com-
ponent are greatly affected by surface quality. Surface
roughness is one of the important parameters that is to
be controlled during machining by controlling cutting
produce components with good surface quality because
the surface quality is the prime requirement of con-
sumer. Surface roughness is having small wave length
of surface irregularities. These surface irregularities or
roughness is produced by different factors like geome-
try of cutting tool, tool feed rate, tool vibration and
tool wear. To obtain good surface quality, these factors
must be controlled for prediction of surface quality.
Many authors reported that there is a correlation
between surface roughness and vibrations of cutter in
1
Department of Mechanical Engineering, Priyadarsini College of
Engineering & Technology, Nellore, India
2
Department of Mechanical Engineering, GIT, GITAM University,
Visakhapatnam, India
3
Department of Mechanical Engineering, PBR Visvodaya Institute of
Technology & Science (VITS), Kavali, India
4
Department of Mechanical Engineering, Andhra University,
Visakhapatnam, India
Corresponding author:
K Venkatarao, Department of Mechanical Engineering, PBR Visvodaya
Institute of Technology & Science (VITS), Kavali, 524201, Andhra
Pradesh, India.
Email: kvenkatrama@gmail.com

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2 Proc IMechE Part B: J Engineering Manufacture
Figure 1. Orthogonal milling on turn mill center (four-axis
milling machine).
any machining process. Lin and Chang4 and Kirby
et al.5 found a strong correlation between vibrations
and surface roughness in turning process. In metal cut-
ting, there is a relative motion between work piece and
cutting tool. The cutting tool is getting dynamic excita-
tion due to deformation of metal that results in vibra-
tion of tool. The relative motion and vibration of tool
affect the surface quality of the product. These vibra-
tions are to be maintained minimum to reduce surface
roughness and tool wear. Vibration is defined as the
repetitive motion of an object or objects relative to a
stationary frame referred to as the equilibrium of the
vibration. Vibrations are measured in terms of displace-
ment, velocity or acceleration.
There are two types of sensors used to measure
vibration of cutter and work pieces: contact and non-
contact sensors. The use of contact sensors is the most
commonly used technique today to measure vibration
of cutting tool or work piece in machining process. The
contact sensors are placed on stationary heads of cut-
ters and work pieces to measure their vibration. But it
is difficult to measure vibration of rotating cutter like
mill cutter and work piece in turning process. Tatar and
Gren6 stated that the measurement of spindle and tool
vibration is more important for tool condition monitor-
ing in high-speed milling process. Since the vibration of
mill cutter is a result of relative motion between work
piece and tool, it is required to measure vibration of
cutter as close as to machining. They have used laser
Doppler vibrometers (LDVs) to measure vibration of
mill cutter. In recent applications, LDVs are used as
non-contact methods to measure vibration of cutting
tool or work piece accurately. The LDV is capable of
giving reliable information of tool vibration.7
LDV was developed by Yeh and Cummins8 as the
measuring process involves measuring the Doppler shift
of the laser radiation that is scattered by the moving
particles. Later, this technique was developed as LDV.
Sriram et al.9 discussed the use of LDVs in the field of
light weight structures. Frequency domain of LDV out-
put signal is scanned to obtain deflection shape of the
vibrating structure. Rantatalo et al.10 have used the
LDV in milling process to measure vibrations of rotat-
ing arbor in horizontal milling machine. Venkatarao
et al.7 have used LDV to measure vibration of rotating
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work piece in boring of steels on horizontal computer
numerical control (CNC) lathe machine. Prasad et al.11
have used LDVs to measure vibration of mill cutter in
milling process. Fast Fourier transformation (FFT) was
used for generating features from an online acousto-
optic emission (AOE) signals to develop a database for
appropriate decisions. The FFT transforms the AOE
signals into time domain with different time frequency
zones. In this work, the LDV was adopted for online
data acquisition of mill cutter vibration, and a high-
speed FFT analyzer was used to process the AOE sig-
nals obtained from LDV.
Optimization of cutting parameters is very impor-
tant in metal cutting in order to produce products in
right time with right quality at reduced production cost.
Good surface quality and improved tool life can be
achieved by the optimization of cutting parameters in
any machining process. In tool condition monitoring,
different types of techniques and analytical models have
been developed for optimization of cutting parameters
of cutting speed, feed rate, depth of cut, tool material,
tool geometry, type of machining and cutting fluids
and so on. Savas and Ozay2 have used genetic algo-
rithms for optimization of cutting parameters to get
good surface quality in tangential milling. They have
investigated the effect of cutting parameters such as
depth of cut, tool speed, work piece speed and feed rate
on surface roughness. They have used the genetic algo-
rithm for each cutting parameter and found optimum
cutting parameters for minimum surface roughness.
Different optimization strategies were developed by
different researchers using algorithms to optimize cut-
ting parameters. Alberti et al.12 developed an
algorithm-based system to select optimal cutting para-
meters in conventional as well as high-speed milling
process. They have used the algorithm-based system to
select optimum parameters for reduction in production
time in both conventional milling and high-speed
milling operations while ensuring optimal finishing
conditions. Optimization of cutting parameters helps to
improve production rate by reducing production time
with improved tool life and less power consumption.
This gives less production time and maximum profit in
manufacturing. Baskar et al.13 have developed optimi-
zation strategy with hill climbing algorithm and genetic
algorithm for the optimization of parameters in face
milling, corner milling, pocket milling and slot milling.
They have obtained maximum profit with the help of
developed strategy through optimization of cutting
parameters. Production cost of a unit is affected by
direct and indirect costs.14 Senthil Kumar et al.14 have
used genetic algorithms to select optimum cutting para-
meters in order to reduce production cost by improving
tool life. They found that the zirconia toughened alu-
mina ceramic cutting tool has more life and it is able to
machine at lower production cost.
Sahin15 has prepared design of experiments with cut-
ting parameters and experiments were conducted
according to design of experiments. Signal-to-noise
Babu et al.
ratios of experimental results were calculated by
Taguchi method and analysis of variance (ANOVA)
was used to analyze the ratios to identify significant
cutting parameter which is having more influence on
the tool life. The Taguchi and ANOVA both can give
optimum cutting parameters for higher tool life.
Response surface methodology (RSM), artificial neural
networks and support vector regression were used by
Amit Kumar16 to develop the empirical models for pre-
diction of surface roughness, tool wear and power con-
sumption in turning process.
Turn milling with end mill cutter is a complex task,
and there is little work carried out on behavior of cut-
ter vibration in turn milling. Different levels in the cut-
ting parameters affect surface roughness and vibration
amplitude. Changes in amplitude of cutter vibration
were not studied much. In this work, experiments (turn
milling) were conducted on four-axis milling machine
on phosphorous bronze work piece with high-speed
steed (HSS) mill cutter. A LDV was used for online
data acquisition of mill cutter. RSM was used to opti-
mize cutting parameters for minimum surface rough-
ness and amplitude of cutter vibration.
Materials and methodology
In this work, experiments were conducted on ASTM
B139 phosphor bronze metal. It is a Morgan standard
alloy and it is used in electrical and industrial applica-
tions and so on. Bushings, gears, pinions, screw
machine products, thrust washers, valve parts and
shafts are made due to its excellent cutting ability.
Chemical composition of this material is shown in
Table 1, and it has machinability rating of 80 on
100-point scale.
HSS mill cutter was used in this work to perform
turn milling on the phosphor bronze work piece. The
end mill cutters are having cutting teeth at one end as
well as on the sides. Specifications of the end mill cutter
used in this work are given in Table 2.
RSM was used in this article to find out relationship
between one or more output variables (dependent or
response variables) and a set of input variables (inde-
pendent variable or experimental factors). RSM model
is used to optimize cutting parameters, to identify
Table 1. Chemical composition of ASTM B139.
Sn P Fe
3.89 0.38 0.1
Table 2. Specifications of end mill cutter.
Cutter diameter Clearance angle
10 mm 15°
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3
significant cutting parameter that affects the machining
characteristics like surface roughness and mill cutter
vibration.
A prediction model was developed by Choudhuri
and El-Baradie17 using RSM for prediction of surface
roughness in machining of EN 24T steel. They have con-
ducted dry machining with uncoated carbide inserts and
studied the effect of cutting speed, feed and depth of cut
on surface roughness. RSM shows effect of individual
factors and two factors interaction on the responses and
it also identifies significant factors. The RSM combined
with factorial design of experiments is a better alterna-
tive to the traditional one-variable-at-a-time approach
for studying the effects of cutting variables on responses
such as surface roughness and tool life.17–20 Sahin and
Motorcu18 studied the effect of cutting parameters such
as cutting speed, feed rate and depth of cut on turning
of hard material with cubic boron nitride tool. They
used RSM to predict surface roughness and a good cor-
relation was found between them.
Bhardwaj et al.19 have used RSM with center com-
posite rotatable design in turning of AISI 1019 steel to
find out influence parameter on surface roughness.
Prediction models were also developed for accurate
prediction of surface roughness. Feed rate was found
as significant parameter on surface roughness, while
the depth of cut has no significant effect. In RSM, the
quantitative relationship between input and output
variables is presented as follows20
y = f(x1 , x2 , x3 , . . . , xn )6er ð1Þ
where ‘‘y’’ is the desired response; ‘‘f’’ is the response
function, dependent variable; x1, x2, x3, ., xn are inde-
pendent variables; and ‘‘er’’ is the fitting error.
In this article, according to the central composite
design (CCD), 16 experiments have been performed on
phosphorus bronze metal.
Experimental work
In this work, 16 experiments were performed on four-
axis milling machine by varying three cutting para-
meters such as cutting speed, feed rate and depth of cut.
Each parameter was taken with four levels as shown in
Pb Zn Cu
3.5 3.4 Remaining
Rake angle Helix angle No. of flutes
12° 35° 2
4 Proc IMechE Part B: J Engineering Manufacture

Table 3. Process parameters and their levels.

Factors Units Level 1 Level 2 Level 3 Level 4

Cutting speed (V) m/min 75 83 91 99

Feed rate (F) mm/min 3.27 5.24 8.24 10
Depth of cut (D) mm 0.25 0.50 0.75 1.00

Table 4. Design of experiments and experimental results.

S. no. Design of experiments Ra (mm) Y (mm) H (HBS)

V (m/min) F (mm/min) D (mm)

1 75 3.27 0.25 4.11 63.13 111.00

2 75 5.24 0.50 5.71 73.23 111.66
3 75 8.24 0.75 6.81 50.13 110.66
4 75 10.0 1.00 7.18 85.40 102.66
5 83 3.27 0.50 4.26 62.50 142.66
6 83 5.24 0.25 5.15 66.22 132.00
7 83 8.24 1.00 6.06 78.05 111.00
8 83 10.0 0.75 8.05 104.3 118.00
9 91 3.27 0.75 6.16 76.30 118.66
10 91 5.24 1.00 6.67 80.10 124.66
11 91 8.24 0.25 6.75 83.60 124.66
12 91 10.0 0.50 8.36 72.06 116.33
13 99 3.27 1.00 5.48 64.80 117.66
14 99 5.24 0.75 7.89 98.00 121.00
15 99 8.24 0.50 9.68 108.7 130.66
16 99 10.0 0.25 10.31 114.2 136.33

Table 3. The cutting parameters were assigned to each

column and 16 combinations of parameters were given
as shown in Table 3.
The following sequential procedure was used to
carry out the experiment under dry condition.
Specifications of the work piece are taken as length of
90 mm, diameter of 50 mm:

1. Each trial was started with a new cutter with one

test condition (trial) and machining was stopped at
the end of each pass.
2. An LDV was placed in front of the machine and
the LDV produces a laser beam to the rotating mill
cutter to measure vibration signals and the set-up
of experiment is shown in Figure 2.
3. After each pass, the work piece was removed and
its surface roughness and hardness were measured. Figure 2. Experimental set-up for orthogonal milling.

The above steps were repeated and remained the

same in the experiment with a new cutter.
Experimental data of 16 experiments, surface rough-
ness (Ra), amplitude of cutter vibration (Y) and hard-
ness (H) are shown in Table 4.
Results and discussion
Experimental results of surface roughness, amplitude of
cutter vibration and hardness are shown in Table 4. In
each experiment, cutter vibration and surface roughness
on machined surface were measured in microns.
In this work, LDV was used for online acquisition
of cutter vibration data in the form of AOE signals as
shown in Figure 3. FFT analyzer was used for generat-
ing features from online AOE signals to develop a data-
base for appropriate decisions. The FFT transforms
the AOE signals into time domain with different time
frequency zones and it helps to find out amplitude of
cutter vibration (Figure 4).

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Babu et al.
Figure 3. Time domain spectrograph for the first experiment.
Figure 4. Frequency domain spectrograph for the first experiment.
Effect of cutting parameters, feed rate, cutting speed
and depth of cut on the surface roughness and ampli-
tude of cutter vibration are shown in Figures 5 and 6,
respectively. The trends of effect of these machining
parameters help to identify which parameter and inter-
action of parameters are significant on the surface
roughness and mill cutter vibration.
Based on the experimental results and experimental
parameters shown in Table 4, two-factor interaction
response function for surface roughness and amplitude
of cutter vibration can be expressed as function of pro-
cess parameters. Quadratic models for the surface
roughness and amplitude of vibration velocity are given
by the following equations
Ra = 6:77 + 1:22  A + 1:38  B + 0:3  C
ð2Þ
+ 0:58  AB  0:42  AC  9:63  BC
Y = 79:93 + 22:13  A + 7:21  B + 3:80  C
ð3Þ
+ 8:97  AB  7:33  AC + 14:88  BC
Effect of parameters on surface roughness
Effect of cutting speed, feed rate and depth of cut on
the surface roughness are shown in Figure 5. Figure
5(d) is the normal probability plot of the residuals for
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5
the response of surface roughness. The plot indicates
the fall of residuals along the straight line and it repre-
sents the normal distribution of errors. Figure 5(a)–(c)
shows the effect of interaction of cutting parameters on
the surface roughness. Figure 5(a) shows the effect of
interaction of cutting speed and feed rate on the surface
roughness. The surface roughness is more at cutting
speed of 90 m/min and 10 mm/min and it is less at cut-
ting speed of 75 m/min and feed rate of 3.27 mm/min.
Figure 5(b) shows the effect of interaction of cutting
speed and depth of cut on the surface roughness. The
surface roughness is found less at cutting speed of 75 m/
min and depth of cut of 0.25 mm. Figure 5(c) shows the
effect of interaction of depth of cut and feed rate on the
surface roughness. The surface roughness is found less
at interaction of depth of cut of 0.25 mm and feed rate
of 3.27 mm/min. Increased feed rate in any machining
process will lead to generation of heat and therefore
contributes high surface roughness.21 Increased cutting
speed and feed rate will remove high amount of mate-
rial, but it leads to wear on cutting edges due to abra-
sion between cutting edges and work piece. The end
mill cutter has two cutting edges and they remove mate-
rial one after another cutting edge. That is why damage
takes place on cutter due to repeated impact loads
applied.
6 Proc IMechE Part B: J Engineering Manufacture

Figure 5. (a) Effect of feed and cutting speed on Ra, (b) effect of depth of cut and cutting speed on Ra, (c) effect of depth of cut and
feed rate on Ra and (d) normal probabilities of residuals for Ra.

Table 5. ANOVA for surface roughness.

Source Sum of squares df Mean square F value p value Prob . F

Model 40.07 6 6.68 9.70 0.0017

A-V 4.38 1 4.38 6.37 0.0325
B-F 6.07 1 6.07 8.83 0.0157
C-D 0.26 1 0.26 0.38 0.5541
AB 0.59 1 0.59 0.86 0.3769
AC 0.28 1 0.28 0.41 0.5369
BC 1.629E24 1 1.629E24 2.368E24 0.9881
Residual 6.19 9 0.69
Correlation total 46.26 15

In this article, ANOVA has been used to find out
significant cutting parameters and significant interac-
tion of cutting parameter on the surface roughness. In
the ANOVA, at confidence level of 95%, the experi-
mental values were evaluated. The individual cutting
parameters and interaction of cutting parameters which
are having p value less than 0.05 are significant. Values
of ‘‘Prob . F’’ that is, p value, less than 0.0500 indicate
model terms are significant.19,22 According to Table 5,
cutting speed and feed rate are significantly effective on
the surface roughness because the p values of cutting
speed and speed are 0.0325 and 0.0157, respectively.
There is no significant effect of depth of cut on surface
roughness. Previous researchers have also claimed the

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Babu et al. 7

Figure 6. (a) Effect of feed and cutting speed on Y, (b) effect of depth of cut and cutting speed on Y, (c) effect of depth of cut and
feed rate on Y and (d) normal probabilities of residuals for amplitude of tool vibration.

similar results that cutting speed and feed rate have
more effect on the surface roughness.23–25
Effect of parameters on amplitude of cutter vibration
Effect of cutting speed, feed rate and depth of cut on the
amplitude of cutter vibration are shown in Figure 6.
Figure 6(d) is the normal probability plot of the resi-
duals for the response of cutter vibration. The plot indi-
cates the fall of residuals along the straight line and it
represents the normal distribution of errors. Figure
6(a)–(c) shows the effect of interaction of cutting para-
meters on the cutter vibration. Figure 6(a) shows the
effect of interaction of cutting speed and feed rate on the
amplitude of cutter vibration. The vibration amplitude
is found to be less at interaction of cutting speed of
75 m/min and feed rate of 3.27 mm/min. Figure 6(b)
shows the effect of interaction of cutting speed and
depth of cut on the vibration amplitude. The vibration
amplitude is found to be less at interaction of cutting
speed of 75 m/min and depth of cut of 1 mm. Figure 6(c)
shows the effect of interaction of depth of cut and feed
rate on the vibration. The amplitude was found to be
less at interaction of depth of cut of 1 mm and feed rate
of 10 mm/min. High-speed machine is used in machining
for high productivity by reducing production time. The
machine tools are having high dynamic movements
because of high cutting speeds. High dynamic move-
ments in machine tools reduce its rigidity and it leads to
generation of vibrations while machining.
Similar to the surface roughness, the ANOVA has
been used to find out significant cutting parameters and
interaction of cutting parameter on the amplitude of
cutter vibration. According to Table 6, cutting speed is
significantly effective on the amplitude of vibration.
The ANOVA was performed at the confidence level of
95%, and the cutting parameters which are having p
value less than 0.05 are significant.22 As shown in

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8 Proc IMechE Part B: J Engineering Manufacture

Table 6. ANOVA for amplitude of cutter vibration.

Source Sum of squares df Mean square F value p value Prob . F

Model 3408.33 6 568.06 3.25 0.0451

A-V 1431.23 1 1431.23 8.19 0.0187
B-F 164.59 1 164.59 0.94 0.3570
C-D 42.17 1 42.17 0.24 0.6349
AB 141.27 1 141.27 0.81 0.3919
AC 87.69 1 87.69 0.50 0.4965
BC 388.53 1 388.53 2.22 0.1700
Residual 1571.95 9 174.66
Correlation total 4980.28 15

Figure 7. Multi-objective functions for surface roughness and amplitude of cutter vibration.

Table 6, the cutting speed has p value of 0.0187 and it is
to be said as significant parameter on the cutter vibra-
tion. Pettersson et al.26 have also proved that the cut-
ting speed has significant effect on the cutter vibration.
Optimum values of multi-objective
function
The objective of this work is to find out optimum cut-
ting parameters to achieve less surface roughness and
amplitude of cutter vibration in order to reduce power
consumption and production time and to improve tool
life. Newman et al.27 stated that 6%–40% of energy
savings can be achieved in metal cutting with optimum
cutting parameters. Optimum values for multi-objective
of surface roughness and amplitude of cutter vibration
were done using Minitab 16 and the results are shown
in Figure 7. Desirability function was introduced in
1980 to optimize cutting parameters. The desirability
function uses a gradient algorithm and it finds desir-
ability with maximum value between 0 and 1. If the
desirability value closes to 0, then the response is
completely unaccepted and if the desirability value is 1
or close to 1, then the response is accepted.28
There are three types of individual desirability func-
tions: larger the better, smaller the better and nominal
the better. In this study, smaller the better function was
used for surface roughness and amplitude of cutter
vibration, because these two responses should be less
for any product to obtain good product quality and
tool life. According to Figure 7, optimum cutting para-
meters were found as 75 m/min of cutting speed,
3.9498 mm/min of feed rate and 0.250 mm of depth of
cut. Desirability values were found to be 0.95899 and
0.99689 for surface roughness and amplitude of cutter
vibration, respectively, and composite desirability was
also as 0.9774. All the desirability values were to be
found very close to 1, and then the responses can be
accepted.28
Conclusion
Optimization of cutting parameters to improve surface
quality and production rate at low power consumption

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Babu et al.
was found using multi-objective optimization tech-
nique. Turn milling experiments were conducted on
ASTM B139 phosphor bronze with HSS mill cutter on
four-axis milling machine. RSM approach was used to
identify significant cutting parameters which are affect-
ing surface roughness and amplitude of cutter vibra-
tion. The following conclusions can be drawn from this
study:
1. Effect of cutting parameters on amplitude of mill
cutter vibration was measured with LDV by focus-
ing optic signal on rotating cutter. Changes in the
amplitude of cutter vibration due to tool wear can
be used for online tool condition monitoring.
2. The AOE signals are very sensitive and they iden-
tify changes in cutting zone due to vibrations.
3. Surface roughness and amplitude of cutter vibra-
tion were analyzed using RSM. Cutting speed and
feed rate were found to be significant cutting para-
meters on surface roughness and the cutting speed
was found to be significant on amplitude of cutter
vibration.
4. The proposed multi-objective technique shows the
cutting speed of 75 m/min, feed rate of 3.9498 mm/
min and depth of cut of 0.25 mm are the optimal
combination of milling parameters for minimum sur-
face roughness and amplitude of cutter vibration.
Declaration of Conflicting Interests
The author(s) declared no potential conflicts of interest
with respect to the research, authorship and/or publica-
tion of this article.
Funding
The author(s) received no financial support for the
research, authorship and/or publication of this article.
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