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Optimization the Machining Parameters in Turning of Hardened Hot Work

Tool Steel Using Cryogenically Treated Tools

Article in Surface Review and Letters · October 2019

DOI: 10.1142/S0218625X19501774

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Surface Review and Letters, Vol. 27, No. 5 (2020) 1950177 (14 pages)
°c World Scienti¯c Publishing Company
DOI: 10.1142/S0218625X19501774

OPTIMIZATION OF THE MACHINING PARAMETERS IN

TURNING OF HARDENED HOT WORK TOOL STEEL
USING CRYOGENICALLY TREATED TOOLS

ENGIN NAS* and NURSEL ALTAN ÖZBEK†

Machine and Metal Technologies Department,
Dr. Engin PAK Cumayeri Vocational School,
Duzce University, 8100 Duzce,
€ Turkey
*enginnas@duzce.edu.tr
†nurselaltan@duzce.edu.tr

Received 13 June 2019

Revised 23 September 2019
Accepted 9 October 2019
Published 20 November 2019

This paper addresses an approach based on the Taguchi method with gray relational analysis for
optimizing the turning parameters of hardened DIN 1.2344 hot work tool steel (54 HRC) with
multiple performance characteristics. A gray relational grade obtained from the gray relational
analysis was used for the performance characteristic in the Taguchi method L18 (2 1
3 2 Þ. The
optimal turning parameters for surface roughness and tool wear were determined using the pa-
rameter design proposed by the Taguchi method. Dry turning tests were carried out using cryo-
genically treated and untreated uncoated carbide cutting tools. The cutting tool (Untreated and
Deep Cryogenic Treated), cutting speed (200, 250 and 300 m/min) and feed rate (0.09, 0.12 and
0.15 mm/rev) were selected as experiment parameters. The analysis results revealed that the feed
rate (72.84%) was the dominant factor a®ecting surface roughness and the cutting speed (93.93%)
was the dominant factor a®ecting °ank wear. The optimum turning parameters for the lowest
Ra values were A2B1C2 and for the lowest Vb values were A1B3C2. According to the results of gray
relational analysis, the optimum parameters for minimum average surface roughness and minimum
°ank wear were A1B2C2.

Keywords: Optimization; cryogenic treatment; surface roughness; tool wear.

1. Introduction methods and requiring limited data, the gray rela-

By setting the parameters and reducing the sensitiv-
ity of the performance to variations, the Taguchi
method enables optimization of performance char-
acteristics. This makes it a powerful experimental
design tool.1–4 In order to deal with weak, inadequate
or erratic systems and meet essential mathematical
speci¯cations, the gray relational analysis was ini-
tially proposed in 1982 by Deng.5 By avoiding the
intrinsic inadequacies of traditional statistical
tional analysis is capable of estimating the behavior of
an erratic system in addition to providing e®ective
solutions to problems of uncertain, multiple-input
and discrete data. It has been successfully applied
in various manufacturing processes to resolve the
complex interactions among multiple quality char-
acteristics and to optimize parameter settings.6
The e®ects of feed rate, cutting speed and cutting
depth on surface roughness were investigated by

1950177-1
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E. Nas & N. Altan Ozbek
Fnides et al., who used ceramic cutting tools in the
turning of hardened AISI H11 steel. The ¯ndings
obtained using the statistical model demonstrated
that the dominant in°uence on the surface roughness
was feed rate, followed by cutting speed, whereas
cutting depth had no signi¯cant e®ect.7 Ranganathan
and Senthilvalen developed a mathematical model for
process parameters (cutting speed, feed rate and
depth of cut) on surface roughness and tool wear in
the turning of AISI 316 austenitic stainless steel using
tungsten carbide tools. Among the di®erent process
parameters during turning, the cutting speed was
more e®ective, with both feed rate and depth of cut
exhibiting only a lesser extent of in°uence.2 Response
surface methodology (RSM) was used by Lalwani
et al. to investigate the cutting parameter e®ects on
surface roughness and cutting forces by using coated
ceramic cutting tools in the ¯nish hard turning of
MDN250 steel. The study showed that feed rate and
depth of cut were the dominant contributing factors
to the forces model and that the data from the cutting
forces were best ¯tted by a linear model. The surface
roughness variation was best described by a nonlinear
quadratic model, with the feed rate shown as the
signi¯cant contributing factor.3 Tsao used the gray-
based Taguchi method for optimization of parameters
in the milling of A6061P-T651 aluminum alloy with
multiple performance characteristics. The results of
the experiments demonstrated the successful deter-
mination of the optimum milling process parameters
for the alloy, with surface roughness reduced from
0.44
m to 0.24
m and °ank wear from 0.177 mm to
0.067 mm. This led to a multiple performance char-
acteristic improvement in the milling qualities via the
gray-based Taguchi method.4 Ghani et al. imple-
mented Taguchi methodology to optimize milling
parameters (cutting speed, feed rate and depth of cut)
in the machining of hardened steel using TiN-coated
carbide insert tools. Analysis of the ¯ndings deter-
mined the optimum (low) cutting force and surface
roughness milling parameters.5 In the turning of
SKD-11 and SKD-61 steels, optimization of the pro-
cess parameters was carried out by Fong and Chen
using gray relational analysis. Taguchi experiments
were conducted with eight independent variables in-
cluding feed rate, cutting speed, depth of cut, insert
type, coating type, nose radius, chip-breaker geome-
try and coolant method. The response variables of
dimensional precision, surface roughness and
1950177-2
accuracy were analyzed and optimum turning para-
meters were determined according to a gray relational
degree maximizing accuracy and dimensional preci-
sion, while minimizing surface roughness.6 The
Taguchi method and gray relational analysis were
used by Lin for optimization of turning process pro-
cedures for multiple performance characteristics. The
optimum feed rate, cutting speed and depth of cut
were determined with cutting force, tool life and
surface roughness considered as performance char-
acteristics.7 In order to minimize cutting forces and
surface roughness in the high-speed turning of Inconel
718, Pawade and Joshi optimized the process by
using the Taguchi-gray relational analysis (TGRA).
They carried out 27 experimental trials using the
Taguchi orthogonal array to obtain the best combi-
nation of factor levels, which were evaluated accord-
ing to the cutting forces and surface roughness as
response variables. When the single-weighted gray
relational degree for the two performance character-
istics was examined, the e®ect of the control factors
on these response variables was then determined.8
In the machining of parts, surface quality is one of
the most frequently speci¯ed customer requirements.
Surface roughness is considered the main indication of
surface ¯nish on machined parts. Surface roughness
mostly results from the process parameters of tool
geometry including nose radius, edge geometry and
rake angle and cutting conditions, which include
cutting speed, feed rate and depth of cut.9 Surface
roughness is a signi¯cant factor in many application
areas and plays an important role in the evaluation of
machining precision.10,11 Tool life is important for
increased productivity and therefore constitutes an
important economic feature.12–16 In order to extend
the serviceable life of tools, the widespread practice
has been to apply heat treatment to the tool mate-
rials. This process is performed in order to allow
greater control over the variety of properties exhib-
ited by the speci¯ed tool material. This cryogenic
treatment can enhance productivity by providing
longer tool life, lower surface roughness values and
better dimensional accuracy, in addition to requiring
lower cutting temperatures and consuming less power
during the metal cutting process.17,18 Cryogenic
treatment involves holding the metal at a pre-
determined temperature for a speci¯c amount of time
and then bringing it gradually to room temperature.
As a result, the residual austenite is transformed into
 Optimization of the Machining Parameters in Turning of Hardened Hot Work Tool Steel
martensite, secondary carbide precipitates form in
the nucleation regions and high wear resistance is
developed in the material.19–22
In this study, the gray-based Taguchi method was
used to optimize the turning process parameters of
hardened DIN 1.2344 hot work tool steel with per-
formance characteristics including low surface
roughness and minimum °ank wear after turning.
Deep cryogenic treatment was applied to the cutting
tools at 185  C for 24 h. The optimum cutting tool,
cutting speed and feed rate parameters were deter-
mined for minimum surface roughness and °ank
wear.
2. Experimental Methods
2.1. Turning experiments
The study used hardened DIN 1.2344 hot work tool
steel (54 HRC); its chemical composition can be seen
in Table 1. DIN 1.2344 steel was supplied in dimen-
sions of ø43
400 mm for the experiments. Experi-
ments were carried out on an ACCUWAY JT 150
model CNC lathe.
2.2. Cutting tools
Sandvik Coromant supplied the uncoated tungsten
carbide cutting tools (SNMG 120408-QM with ge-
ometry code H13A) and the tool holder having the
speci¯cation of PSBNR2525 were used in this inves-
tigation. The cutting tools were subjected to deep
cryogenic treatment at 185  C for 24 h and then
tempered at 200  C for 2 h. In the experiments, both
cryogenically treated and untreated tools were used.
2.3. Surface roughness and tool wear
measurement
The Surtronic 25 portable surface roughness tester
(Taylor Hobson) was used to measure the average
surface roughness (Ra) of the workpiece. Three sur-
face roughness measurements were carried out for
Table 1. Chemical composition of DIN 1.2344 steel.
Element C Si Mn
(%) 0.35–0.42 0.80–1.20 0.25–0.50
each machined surface and the mean value of these
measurements was taken as the average surface
roughness (Ra). The DinoCapture 2.0 handheld dig-
ital microscope (with polarization and high magni¯-
cation capabilities) was used to measure the °ank
wear (Vb) of the cutting tool.
3. Experimental Design and Optimization
3.1. Taguchi method
Many industrial innovations have been introduced
through developing technology. When using these
innovations to develop a product, it is necessary to
determine the optimal parameters. In the ¯eld of
manufacturing, optimization methods have been de-
veloped to determine the impact values of the para-
meters used during product processing. One of these,
the Taguchi method, enables the control of variables
that are uncontrollable and cannot be accounted for
in traditional experimental design. In determining the
performance characteristic control factor level against
these factors, in the Taguchi method, the objective
function values are converted to a signal/noise (S/N)
ratio, i.e. the desirable signal ratio for the undesirable
random noise value showing the experimental data
quality characteristics.4 Table 2 presents. the para-
meters and their levels utilized in the experimental
study, with three levels of feed rate, three levels of
cutting speed and two levels of cutting tool. The
Taguchi L18 (2 1
3 2 ) orthogonal array was chosen as
the most suitable for determination of the optimum
cutting parameters and for analyzation of the ma-
chining parameter e®ects.
The \smaller-the-better" characteristic was se-
lected for this study because low surface roughness
and °ank wear values were the desired quality char-
acteristic factors. Equation (1) expresses the S/N
ratio of the \smaller-the-better" characteristic.
S 1 Xn
The smaller-the-better : ¼ 10 log y 2;
N n i¼1 i
ð1Þ
P S Cr Mo V Fe
0.025 0.002 4.80–5.50 1.20–1.50 0.85–1.15 Remaining
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E. Nas & N. Altan Ozbek

Table 2. Test factors and levels. where k represents the gray relational coe±cient at
the point and  represents a coe±cient between 0
Parameters Symbol Level 1 Level 2 Level 3
and 1. Equations (4)–(6) are then calculated:
Cutting speed, A 200 250 300 oi ðkÞ ¼ jx0 ðkÞ  xj ðkÞj; ð4Þ
Vc (m/min)
Feed rate, f (mm/rev) B 0.09 0.12 0.15 min ¼ min minjx0 ðkÞ  xj ðkÞj; ð5Þ
j k
Cutting Tools, CT C U DCT
U: untreated DCT: Deep Cryogenic Treated max ¼ max maxjx0 ðkÞ  xj ðkÞj: ð6Þ
j k

Finally, the gray relational degree ðx0 ; xi Þ was

where n represents the number of experimental calculated using Eq. (7):
replicates and Yi is the average measured value of the
experimental data i. 1 Xn
ðx0 ; xi Þ ¼ "ðx0 ðkÞ; xj ðkÞÞ; ð7Þ
n k¼1

where ðx0 ; xi Þ represents a measure of the geometric

3.2. Gray relational analysis
similarity between the gray system xi series and the
Gray correlation analysis, which is one of the multi- reference x0 series. The size of the gray associative
factorial decision-making methods, forms gray corre- level indicates a strong correlation between xi and x0 .
lation levels in order to evaluate performance char- The gray relational level is \1" when the two series
acteristics. One of the most commonly used methods are the same. The degree of similarity between the
in normalization is linear data preprocessing. In comparison and the reference series is denoted by the
considering the normalization of the factor series, gray relational degree.
one of the criteria (\higher-the-better", \lower-the-
better", \nominal-the-better" or \best ideal") re°ects
the characteristic of the series. If the value of the 4. Experimental Results
points on the peak is low, it is a desirable feature. The
The cutting parameter e®ects on surface roughness
points that receive low values in linear normalization
can be seen in graphical form in Fig. 1. Lower surface
are those close to \1". Higher value points will have
roughness values were achieved using the cryogeni-
values close to \0".
cally treated cutting tools. This ¯nding was linked to
In general, the \smaller-the-better" was the
the enhanced hardness and abrasive wear resistance
expected value for surface roughness and °ank wear
of the DCT inserts following cryogenic treatment.22,23
in the turning of DIN 1.2344 hot work tool steel. The
It is accepted that surface roughness values rise as a
normalized results were then expressed as in Eq. (2):
result of deterioration of the cutting insert geometry
max x 0i ðkÞ  x 0i ðkÞ caused by tool wear.24,25 Di®erent types of tool wear,
xi ðkÞ ¼ ; ð2Þ
max x 0i ðkÞ  min x 0i ðkÞ such as damage on the cutting nose, greatly a®ect the
surface roughness and dimensional accuracy.26,27 In
where x 0i ðkÞ is the i series k value in the range, xi ðkÞ is
this study, microhardness measurement results
the value after normalization of the i series k value in
showed that deep cryogenic treatment of the cutting
the range, min x 0i ðkÞ is the minimum value in the i
tools produced an increase of 5.6% in the hardness of
series and max x 0i ðkÞ is the maximum value in the i
the tungsten carbide cutting tools. The hardness of
series. Deng stated that higher normalized results
the U tool was measured as 1343.15 Vickers, while the
indicate better performance and that the best nor-
hardness of the DCT tool was 1419.1 Vickers.
malized result should equal \1".5 The relationship
With both cutting tools, the surface roughness
between the ideal (best) and the actual experimental
values were reduced when the cutting speed was in-
results are expressed by the calculation of the gray
creased from 200 m/min to 250 m/min. However, Ra
relational coe±cient "ðx0 ðkÞ; xj ðkÞÞ as in Eq. (3):
values increased again when the cutting speed
min þ max reached 300 m/min. This can be associated with a
"ðx0 ðkÞ; xj ðkÞÞ ¼ ; ð3Þ
oi ðkÞ þ max decrease in the built-up edge (BUE) tendency at

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 Optimization of the Machining Parameters in Turning of Hardened Hot Work Tool Steel

Fig. 1. (Color online) Cutting parameter e®ects on surface roughness.

higher cutting temperatures. The BUE changes tool
geometry by adhering to the cutting edge, thus ad-
versely a®ecting the surface roughness. It is ac-
knowledged that cutting temperatures increase with
increased cutting speed and that this temperature
increase causes BUE on the cutting edge, which in
turn reduces hardness and strength. The BUE ten-
dency decreases at higher cutting speeds because the
BUE is removed by the e®ects of cutting stresses.28,29
However, surface roughness has been observed to in-
crease when the cutting speed reached 160 m/min.
This is due to the fact that higher cutting speeds
cause tools to wear more rapidly.24,25 The lowest
surface roughness values were obtained at the lowest
feed rate of 0.09 mm/rev in both tools. The surface
roughness values also increased considerably with the
increase in feed rate. With the increase of the feed
rate, the chip section increased and as a result, the
load acting on the tool increased because at the in-
terface of the tool and the chip the friction was
rising.23 The increase in friction and cutting forces
caused an increase in surface roughness. Furthermore,
feed rate increases generate helicoid furrows because
of the tool shape, thus the helicoid tool-workpiece
movement was another reason for the increase in
surface roughness.24
The °ank wear changes depending on the cutting
speed of the cutting tools demonstrated that the
cryogenically treated tools generally su®ered less
°ank wear (Fig. 2). This was linked to the greater
hardness and abrasive wear resistance of the DCT
inserts following cryogenic treatment. Özbek et al.

Fig. 2. (Color online) Cutting parameter e®ects on °ank wear (Vb).

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E. Nas & N. Altan Ozbek

(a)

(b)

Fig. 3. (Color online) SEM images of cutting tools at 200 m/min cutting speed and 0.12 mm/rev feed rate: (a) U; (b) DCT.

found that new  carbide particles were formed in the Furthermore, with both cutting tools, °ank wear in-
microstructure of 12- and 24-h-deep cryogenically tensi¯ed with rising cutting speed. This can be at-
treated tungsten carbide tools and thus, the hardness tributed to the elevated temperatures in the cutting
and resistance to abrasive wear was increased.25 zone generated by the higher cutting speeds.26,30,31

Fig. 4. (Color online) SEM images and EDS analyses of U tool at 250 m/min cutting speed and 0.15 mm/rev feed rate.

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 Optimization of the Machining Parameters in Turning of Hardened Hot Work Tool Steel
Fig. 5. (Color online) SEM images and EDS analyses of DCT tool at 250 m/min cutting speed and 0.15 mm/rev feed rate.
When the °ank wear changes according to feed rate
were examined, a decrease in cutting tool wear was
seen with the increasing feed rate in both tools.
Moreover, with both cutting tools, the cutting speed
had a greater e®ect than the feed rate on the °ank
wear.
The abrasive wear mechanism caused °ank wear
in both tools regardless of heat treatment. Flank
wear measured in all tools was in the range of
0.081–0.153 mm. In Fig. 3, SEM photographs of the
cutting tool wear surfaces are presented. Flank wear
and nose wear are clearly visible on the cutting tools.
There was less °ank wear observed on the DCT tool
than on the U tool. However, in the U tool, notch
wear was seen at a 200 m/min cutting speed and
0.12 mm/rev feed rate. This resulted from the en-
hanced wear resistance of the cutting tool provided
by the cryogenic treatment.22 In addition, the adhe-
sive wear mechanism caused BUE to form on the tool
cutting edges. Figures 4 and 5 show the EDS analysis
for the determination of °ank wear and BUE in the
cutting tools. The photographs show that there were
layers of BUE welded to the cutting edge of the tools.
The EDS analysis detected the elements of Fe and Al
at the cutting edge of both tools as evidence of BUE
formation.
1950177-7
5. Analyses
5.1. Analysis of the signal-to-noise
(S/N) ratio
Table 3 shows the S/N ratios and experimental Ra
and Vb results obtained via the Taguchi L18 experi-
mental design on the hardened DIN 1.2344 hot work
tool steel. The most e®ective among the control fac-
tors of cutting speed, feed rate and tool type were
determined for the optimal levels of the Ra and Vb
performance characteristics using the Taguchi-based
response table. Table 4 presents the S/N response
table and shows the cutting speed as the most e®ec-
tive parameter on the Vb and the feed rate as the
most e®ective on the Ra. The graphs in Figs. 6 and 7
show the control factor e®ects on the S/N values for
Ra and Vb in the hard turning of hardened DIN
1.2344 steel. The optimal cutting parameters (lowest
values) for Ra (Fig. 6) were the 2nd level (A2–250
m/min) of cutting speed, the 1st level (B1–0.09 mm/
rev) of feed rate and the 2nd level (C2–DCT tool) of
cutting tool type. The optimal cutting parameters
(lowest values) for Vb (Fig. 7) were the ¯rst level
(A1–200 m/min) of cutting speed, the third level
(B3–0.15 mm/rev) of feed rate and the second
level (C2–DCT tool) of cutting tool type.
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E. Nas & N. Altan Ozbek

Table 3. Experimental results and S/N ratios.

Control factors
Surface roughness, Flank wear, S/N ratio S/N ratio
Exp. no A (Vc) B (f) C (CT) Ra (
m) Vb (mm) for Ra (dB) for Vb (dB)

1 200 0.09 U 0.741 0.096 2.603 20.355

2 200 0.12 U 0.876 0.102 1.146 19.828
3 200 0.15 U 1.225 0.087 1.762 21.210
4 250 0.09 U 0.395 0.125 8.060 18.062
5 250 0.12 U 0.754 0.117 2.448 18.636
6 250 0.15 U 0.962 0.121 0.3337 18.344
7 300 0.09 U 0.668 0.153 3.504 16.306
8 300 0.12 U 0.649 0.148 3.755 16.595
9 300 0.15 U 0.971 0.152 0.252 16.363
10 200 0.09 DCT 0.589 0.100 4.602 20.000
11 200 0.12 DCT 0.716 0.086 2.905 21.310
12 200 0.15 DCT 1.325 0.081 2.444 21.830
13 250 0.09 DCT 0.487 0.118 6.243 18.562
14 250 0.12 DCT 0.849 0.116 1.4252 18.711
15 250 0.15 DCT 0.865 0.112 1.259 19.016
16 300 0.09 DCT 0.576 0.144 4.796 16.833
17 300 0.12 DCT 0.598 0.141 4.461 17.016
18 300 0.15 DCT 1.100 0.143 0.825 16.893

Table 4. S/N and signi¯cance response tables for Ra and Vb.

Ra (
m) Vb (mm)

Cutting speed Feed rate Cutting Cutting speed Feed rate Cutting
(m/min) (mm/rev) tools (CT) (m/min) (mm/rev) tools (CT)

Level A B C Level A B C

1 1.1753 4.9686 2.2603 1 20.76 18.35 18.41

2 3.2952 2.6904 2.4917 2 18.56 18.68 18.91
3 2.6575 0.5311 3 16.67 18.94
Delta 2.1200 5.4997 0.2314 Delta 4.09 0.59 0.50
Rank 2 1 3 Rank 1 2 3

5.2. Variance analysis
Analysis of variance (ANOVA) is performed in order
to determine the individual interactions and e®ects of
all control factors in an experimental design. Table 5
gives the ANOVA results revealing the e®ects on Ra
and Vb of the control factors of cutting speed, feed
rate and cutting tool at a con¯dence level of 95% and
a signi¯cance level of 5%. The F values of each control
factor were compared to determine the signi¯cance of
the control factors.32,33 In this study, the ANOVA
results revealed the most e®ective parameter on Ra to
be Factor B (feed rate) with an impact ratio of
72.84%. Factor A (cutting speed) was the most ef-
fective parameter after feed rate at 11.65%. Factor C
(cutting tool) was seen to be ine®ective. The most
e®ective parameter on Vb was cutting speed
(Factor A), found at 93.93%, whereas the e®ects of
the feed rate (Factor B, 1.43%) and the cutting tool
(Factor C, 2.08%) were very low.
The normal probability graph shows the deviation
of individual values compared to the regression model
equation. The clustered points around the line show
low deviation. Residual graphs for surface roughness
and tool wear are shown in Fig. 8. It is clear that the
normal probability graph shows an almost linear

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 Optimization of the Machining Parameters in Turning of Hardened Hot Work Tool Steel

Fig. 6. (Color online) Process parameter e®ects on average S/N ratio for Ra.

Fig. 7. (Color online) Process parameter e®ects on average S/N ratio for Vb.

response, indicating that the errors are normally
distributed.34,35
5.3. Regression analysis
Regression analysis is applied for modeling and
analysis in the case of di®erent variables having a
relationship between one dependent variable and one
or more independent variables.36–39
Regression analysis was used in this study to
calculate the equations for prediction of surface
roughness and °ank wear. Equation predictions were
formulated as linear and quadratic models. Table 6
shows the predicted quadratic and linear equations
for the output parameters. The R 2 values found via
the linear regression model equations were 76.70% for
Ra and 97.33% for Vb.
The predicted values in the quadratic regression
model compared with the experimental results can be
seen in Fig. 9. A very good correlation was found
between the predicted values and the experimental
results. In the equations realized by the quadratic

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E. Nas & N. Altan Ozbek

Table 5. ANOVA results for Ra and Vb.

Variance source Degree of freedom (DoF) Sum of squares (SS) Mean square (MS) F Ratio Contribution rate

Ra
A 2 0.12400 0.062000 4.54 11.65%
B 2 0.77505 0.387526 28.36 72.84%
C 1 0.00107 0.001068 0.08 0.10%
Error 12 0.16397 0.013665 15.41%
Total 17 1.06410 100%
Vb
A 2 0.009026 0.004513 219.86 93.93%
B 2 0.000137 0.000069 3.35 1.43%
C 1 0.000200 0.000200 9.74 2.08%
Error 12 0.000246 0.000021 2.56%
Total 17 0.009610 100%

Fig. 8. (Color online) Residual plots for the S/N ratios of surface rughness and °ank wear.

regression model, the R 2 value was determined as
97.33% for Ra and 98.48% for Vb. The predicted
values obtained by the quadratic regression model
were more intensive than those obtained via the lin-
ear regression model, thus demonstrating that the
quadratic regression model was successful in the
prediction of Ra and Vb.
5.4. Estimation of optimum surface
roughness and °ank wear
After statistical analysis of the output parameters
obtained from the experimental study, Eqs. (8)
and (9) were used, respectively, to estimate values for
optimum surface roughness and °ank wear.
Raopt ¼ TRa þ ðA2  TRa Þ þ ðB1  TRa Þ þ ðC2  TRa Þ;
ð8Þ
Vbopt ¼ TVb þ ðA1  TVb Þ þ ðB3  TVb Þ þ ðC2  TVb Þ:
ð9Þ
The TRa and TVb values were calculated by ¯nding
the average of the Ra and Vb values in Table 3. The
ideal levels of parameters for Ra and Vb were calcu-
lated by taking the signi¯cance values in Table 4.
These levels for Ra and Vb were A2B1C2 and A1B3C2,
respectively. From the calculations, the estimation
for Raopt was 0.489
m and for Vbopt was 0.085 mm.
The estimated values were compared with those of
the veri¯cation experiments to determine the con¯-
dence interval (CI). The CI for average surface
roughness was calculated using Eqs. (10) and (11).
Estimated values should fall within the CI33,40
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 
1 1
CI ¼ F;1;fe xVe x þ ; ð10Þ
neff r

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 Optimization of the Machining Parameters in Turning of Hardened Hot Work Tool Steel

Table 6. Equations for prediction of Ra and Vb.

Ra (
m)

U (linear) 0.186–0:001516 V þ 8:31 f

DCT (linear) 0.171–0:001516 V þ 8:31 f
R-sq 76.70%
U (quadratic) 3:54  0:0220 V  8:5 f þ 0:000047 V
V þ 94:4 f
f–0:0328V
f þ 0:00066Ct
V þ 1:58Ct
f
DCT (quadratic) 3:17  0:0220 V  8:5 f þ 0:000047V
V þ 94:4f
f  0:0328V
f þ 0:00066Ct
V þ 1:58Ct
f
R-sq 87.34%

Vb (mm)
U (linear) 0:00142 þ 0:000548V  0:1111f
DCT (linear) 0:00808 þ 0:000548V  0:1111f
R-sq 97.33%
U (quadratic) 0:1024 þ 0:000073V  0:819f þ 0:000000V
V þ 1:11f
f
þ 0:002167V
f  0:000023Ct
V  0:0667Ct  f
DCT (quadratic) 0.1096 þ 0:000073V (m/min)–0:819fðmm=revÞ þ 0:000000V
V þ 1:11f
f
þ 0:002167V
f  0:000023Ct
V  0:0667Ct
f
R-sq 98.48%

Fig. 9. (Color online) Quadratic regression model compared with experimental results for Ra and V.b

N By using Eqs. (10) and (11) the CIs were calcu-

neff ¼ ; ð11Þ
1 þ ½Tdof  lated as neff ¼ 3, CIRa ¼ 0:043 and CIVb ¼ 0:081. The
estimated optimal average surface roughness and
where F;1;fe represents the F ratio at a 95% con¯-
°ank wear with the con¯dence interval at 95% was
dence level (F table),  the signi¯cance level, fe the
found using Eq. (12):
degrees-of-freedom of error, Ve the error variance, neff
the e®ective number of replications and r the number ½ðTRa or TVb Þ  ½CI < ðRa or VbÞ
of replications of the con¯rmation experiments exp < ½ðTRa or TVb Þ þ ½CI: ð12Þ
(Eq. (10)); N represents the total number of experi-
The calculation results can be seen in Table 7.
ments and Tdof the total main factor degrees-of-free-
dom (Eq. (11)); F0.05,1,12 ¼ 4:747 (from F test
table), VeRa ¼ 0:000474 and VeVb ¼ 0:0002454 5.5. Gray relational analysis
(Table 6), R ¼ 3 (Eq. (10)). N ¼ 3, Tdof ¼ 5 and Surface roughness and °ank wear turning parameter
neff ¼ 3(Eq. (11)). optimization was performed via an analysis of the

1950177-11
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E. Nas & N. Altan Ozbek

Table 7. Estimated Ra and Vb optimal averages.

Estimated Ra Estimated Vb

[0.797–0.208] < Ra <[0.797+0.208] [0.119–0.025] < Vb <[0.119+0.025]

[0.589] < Ra < [1.005] [0.094] < Vb < [0.144]

Table 8. Gray associative grades and rankings for Ra and Vb.

Cutting speed Feed rate Cutting tools Gray relational

Exp no. (m/min) (mm/rev) (CT) Ra (
m) Vb (mm) grade Ranking

1 200 0.09 U 0.741 0.096 0.639 6

2 200 0.12 U 0.876 0.102 0.561 8
3 200 0.15 U 1.225 0.087 0.608 7
4 250 0.09 U 0.395 0.125 0.725 2
5 250 0.12 U 0.754 0.117 0.532 11
6 250 0.15 U 0.962 0.121 0.462 16
7 300 0.09 U 0.668 0.153 0.481 15
8 300 0.12 U 0.649 0.148 0.498 14
9 300 0.15 U 0.971 0.152 0.391 17
10 200 0.09 DCT 0.589 0.100 0.680 3
11 200 0.12 DCT 0.716 0.086 0.735 1
12 200 0.15 DCT 1.325 0.081 0.666 4
13 250 0.09 DCT 0.487 0.118 0.663 5
14 250 0.12 DCT 0.849 0.116 0.506 13
15 250 0.15 DCT 0.865 0.112 0.517 12
16 300 0.09 DCT 0.576 0.144 0.542 9
17 300 0.12 DCT 0.598 0.141 0.535 10
18 300 0.15 DCT 1.100 0.143 0.382 18

multiple performance characteristics.41 The gray re-
lational grade and ranking for each experiment are
given in Table 8. Furthermore, Fig. 10 shows the gray
relational degree graph for minimum Vb and Ra
values. Gray relational grades that are higher signify
that the corresponding experimental results are closer
to ideal normalized values, i.e. that better multiple
performance characteristics are indicated by higher
gray relational grades.42 Experiment 11 had the best
multiple performance characteristics among all the
experiments due to the fact that it had the highest
gray relational grades. Thus, the optimal factor set-
ting condition was A1B2C2. The optimum levels of
cutting parameters according to the analyses are
shown in Table 9.

Table 9. Optimum levels of cutting parameters according

to the analyses.

Optimum test
Analyze method Output parameters condition

Taguchi method Optimum Ra A2 B1 C2

Taguchi method Optimum Vb A1 B3 C2
Gray relational Optimum Ra and Vb A1 B2 C2
Fig. 10. (Color online) Gray correlation level for lowest Ra analysis
and Vb.

1950177-12
 Optimization of the Machining Parameters in Turning of Hardened Hot Work Tool Steel
6. Conclusions
This study used the gray-based Taguchi method for
the optimization of the parameters in the turning of
hardened DIN 1.2344 hot work tool steel. The
experiments were carried out using untreated and
deep cryogenically treated cutting tools. The ¯ndings
obtained in this study as a result of the analyses and
turning experiments included the following:
. Lower surface roughness values and less °ank wear
were obtained with the cryogenically treated tools.
. The surface roughness values rose greatly along
with the increasing feed rate.
. Flank wear increased with increasing cutting speed.
. When the feed rate was increased, the cutting tool
wear decreased.
. The optimum cutting parameters for the lowest Ra
values were A2B1C2 (cutting speed ¼ 250 m/min,
feed rate ¼ 0:09 mm/rev and tool type ¼ DCT).
The optimum cutting parameters for the lowest Vb
values were A1B3C2 (cutting speed ¼ 200 m/min,
feed rate ¼ 0:15 mm/rev and tool type ¼ DCT).
. Results of ANOVA showed the feed rate (Factor B),
at a 72.84% impact ratio, to be the parameter most
e®ective on surface roughness, whereas the cutting
speed (Factor A), at a 93.93% impact ratio, was
shown to be the parameter most e®ective on °ank
wear.
. Gray relational analysis revealed A1B2C2 (200
m/min cutting speed, 0.12 mm/rev feed rate and
the deep cryogenically treated tool) as the opti-
mum parameters for minimum average surface
roughness and minimum °ank wear.
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