Journal of Engineering Research xxx (xxxx) xxx

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Journal of Engineering Research

journal homepage: www.journals.elsevier.com/journal-of-engineering-research

Mathematical modeling and optimization of machining parameters in CNC

turning process of Inconel 718 using the Taguchi method
Fatlume Zhujani a, Georgi Todorov b, Konstantin Kamberov b, Fitore Abdullahu a, *
a
University of Pristina “Hasan Prishtina”, Faculty of Mechanical Engineering, Pristina, Kosovo
b
Technical University of Sofia, Faculty of Industrial Technology, Bulgaria

A R T I C L E I N F O A B S T R A C T

Keywords: To remain competitive, machining processes must be optimized to provide increased productivity and higher
Optimization quality products. The aim of most efforts in these machining processes is to establish the optimal parameters to
Desirability obtain the maximum material removal rate with minimum surface roughness which represents two of the main
Multi-objective
quality responses. This paper focuses on the optimization of process parameters in dry turning of Inconel 718, a
Composite
Modelling
nickel-based superalloy with PVD-coated carbide inserts based on single-objective optimization Taguchi tech­
Multiple nique, desirability function approach combined with response surface methodology (RSM), which is known as
Parameters the multi-objective Desirability Optimization Methodology (DOM). Taguchi’s orthogonal-array design L9 (33)
Regression and ANOVA analysis of variance are used to study the relationship between cutting parameters (cutting speed,
Surface roughness feed rate and depth of cut) and the dependent output variables i.e., the arithmetic mean deviation of the profile’s
MRR surface roughness (Ra) and material removal rate (MRR). A regression analysis was used to develop a mathe­
Turning matical model based on the first-order model to predict the Ra and MRR model. Using multiple regression
analysis, first order linear prediction model was obtained to find the correlation between surface roughness and
MRR with independent variables. In the range of parameters investigated, the obtained mathematical models
accurately represent the response index, and the results of the experiments demonstrate that the feed rate and the
depth of cut are the most important factors influencing Ra and MRR, respectively. Finally, confirmatory tests
proved that Taguchi’s method, desirability function approach combined with linear regression models was
successful in optimizing turning parameters for minimum surface roughness and maximum MRR.

Introduction machining parameters is a constant technical activity whose goals are to

Inconel 718 is an extensively used heat-resistant nickel-based super
alloy, primarily in the aerospace and aeronautical engineering in­
dustries. It is known as difficult to cut material because of its unusual
thermal and mechanical qualities. In order to increase the machinability
of Nickel-based alloys, research has been conducted from the past to the
present [31]. Inconel 718 is utilized in the fabrication of safety-critical
components where the condition of the machined surface is crucial.
Insufficient surface integrity might lead to part rejection or service
failure. Therefore, to reduce surface and subsurface damage caused by
tool wear, machining Inconel 718 requires not only low cutting speeds,
but also premature removal of cutting tools well before the end of their
useful life [3]. A low surface finish obtained from machining processes
significantly enhances corrosion resistance, fatigue strength, creep life,
and a variety of other functional properties [25]. The optimization of
lower production costs while producing the desired result quality. Sur­
face roughness (Ra) is a popular quality indicator and, in most circum­
stances, a technical requirement for mechanical items. Obtaining the
correct surface quality is critical for a part’s functional functionality. At
the same time, a higher material removal rate (MRR) is regarded as a
factor that has a direct impact on production costs and machining hour
rate [11]. As is known, numerous factors influence surface roughness in
actual machining, including cutting parameters, tool variables, and
workpiece variables. Cutting parameters include cutting speed, feed
rate, and cut depth, as well as tool variables such as tool material, nose
radius, rake angle, cutting edge geometry, tool vibration, tool overhang,
tool point angle, and so on. Workpiece variables include material
hardness and mechanical characteristics. Taking all of the parameters
that govern surface roughness for a specific manufacturing process is
extremely tough. It is quite difficult to choose the cutting parameters for

* Corresponding author.
E-mail address: fitore.abdullahu@uni-pr.edu (F. Abdullahu).

https://doi.org/10.1016/j.jer.2023.10.029
Received 7 June 2023; Received in revised form 27 July 2023; Accepted 20 October 2023
Available online 23 October 2023
2307-1877/© 2023 Published by Elsevier B.V. on behalf of Kuwait University. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).

Please cite this article as: Fatlume Zhujani et al., Journal of Engineering Research, https://doi.org/10.1016/j.jer.2023.10.029
F. Zhujani et al.
Fig. 1. General flowchart of the research process.
a turning operation in order to produce a good surface finish. This
research would assist the operator in determining the cutting parameters
[17]. To make a product with the necessary machining quality, the best
process parameters should be selected. To improve and assess process
parameters, some statistical methods such as the Taguchi technique,
Response Surface Methodology (RSM), Desirability Function Analysis
(DFA), ANOVA, and Grey Relational Analysis (GRA) have recently been
adopted [19]. Experimental investigation of material removal rate in
CNC turning using Taguchi method investigated the material removal
rate (MRR) in CNC turning of C34000 using the Taguchi approach and
the L27 array [12]. The optimal levels of process parameters for con­
current MRR optimization have been established. Confirmation experi­
ments were used to validate optimal outcomes. Material removal rate
was shown to be primarily affected by cutting speed and feed rate.
Cutting speed has been identified as a significant parameter of surface
roughness. The most frequently accepted strategy in the literature is to
increase the cutting speed to improve surface roughness [28]. [7] used
CVD coated carbide inserts to investigate the surface quality of Inconel
718 at various cutting speeds (60, 90, 190, and 225 m/min). Surface
roughness reduced with increasing cutting speeds, except at 225 m/min,
where surface degradation was observed. The researchers attributed this
2
Journal of Engineering Research xxx (xxxx) xxx
to high-speed notching. The Taguchi technique is particularly valuable
in engineering applications and academic studies of experimental design
because of the orthogonal array, which significantly decreases the
number of tests and strives to eliminate the influence of uncontrollable
elements on test results [27]. Roy, R. K. (2022) concludes that the very
purpose of Taguchi parameter design is to maximize or minimize the
performance of a natural process variable by modifying the controlled
factors [23].
Unfortunately, great difficulties develop during the machining of
these superalloys as a result of the poor heat transfer coefficient, high
hardness and very unfavorable working conditions, all of which hinder
efficiency by preventing the production of desirable quality of the
surface.
Depending on many input factors, including the lubrication envi­
ronment, the combination of cutting parameters and the qualities of the
cutting tools, the machinability of Ni-based superalloys can be improved
[2].
The shape of chips removed per unit of time improves as cutting
speed increases. Likewise, any increase in feed rate or depth of cut re­
sults in a larger chip section.
The relationship between cutting parameters and the response
F. Zhujani et al.
Fig. 2. CNC Lathe Machine GLS-200 M.
parameter material removal rate (MRR) is linear.
The shape of chips removed per unit of time improves as cutting
speed increases. Likewise, any increase in feed rate or depth of cut re­
sults in a larger chip section.
In both instances, the material removal rate (MRR) increases. Ac­
cording to Klocke and Kuchle (2011), the optimal cutting tool for
machining must possess hardness, durability, high material strength,
and chemical inertness.
It must be capable of withstanding cyclic mechanical and thermal
stresses while retaining its edge sharpness. Such a cutting instrument
does not exist in praxis [14].
Numerous studies on the machining performance of the laminated
Inconel 718 alloy, such as machinability, surface quality, tool wear
mechanism, and process optimization, have been conducted, but fewer
studies on moulded Inconel 718 have been published (Wassila Frifita1,
2020).
Taguchi’s signal-to-noise ratio and Composite Desirability Optimi­
sation (CDO) in conjunction with the desirability function approach of
linear RSM models for multi-objective factor optimization were used to
determine optimal cutting conditions (cutting speed, feed rate, and
depth of cut) for minimum surface roughness and maximum material
removal rate. Then, an analysis of variance (ANOVA) was employed to
determine the significant cutting parameters influencing the Ra and
MRR.
Considering the information presented above, this study can be
summed up in three points:
First, the effects of machining parameters on surface roughness and
material removal rate during CNC turning of Inconel 718 alloy with PVD
AlTiSiN-coated carbide inserts were studied. The investigations were
conducted using Taguchi’s L9 (33) orthogonal array.
Taguchi’s signal-to-noise ratio and Composite Desirability Optimi­
zation (CDO) in conjunction with the desirability function approach of
linear RSM models for multi-objective factor optimization were used to
determine optimal cutting conditions (cutting speed, feed rate, and
depth of cut) for minimum surface roughness and maximum material
removal rate. Then, an analysis of variance (ANOVA) was employed to
determine the significant cutting parameters influencing the Ra and
MRR.
Using regression analysis, a linear first-order mathematical models
were devised to estimate the outcome of varying amounts of input
parameters.
Finally, validation experiments were conducted to ensure that the
developed models were accurate.
Table 1
Chemical composition of Inconel 718.
C Si Mn Al Co Cr
0.03 0.06 0.07 0.49 0.25 19.3
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Experimental setup and procedure
The investigation utilized a process flow diagram and an experi­
mental setup, as illustrated in Fig. 1. The presented information illus­
trates the sequential manner in which the inquiry was conducted.
Machining conditions.
Machine tool: The experiments were conducted under dry cutting
conditions on CNC lathe machine - GOODWAY, Type GLS-200 M with a
power of 7.5 kW on the spindle and a maximum spindle speed of
4000 rpm., Fig. 2.
Workpiece material: The workpiece material used as test specimen is
Inconel 718 alloy (Batch heat treatment: Solution treated, 60 min at
980 C, water quenched), a molded round bar of test specimen ∅63.5 mm
diameter and 500 mm length and a hardness after heat treated of 411
HBW is used for the cutting turning tests. The Inconel 718 alloy is United
Kingdom-made and material is certified by Special Metals Wiggin
Limited, with certificate of inspection No. 433803 v 1, 28 Aug 2020,
according to standard EN 10204–3.1/ISO 9001/EN/AS/JISQ 9100. Its
chemical composition is shown in Table 1. The sample was then divided
into nine equal fields of 15 mm length and each of them was separated
by a slit 4 mm wide and 2 mm deep, so as to perform a series of nine
tests, according to Taguchi’s L9(33) orthogonal array design of experi­
ments and each time a new cutting edge was replaced to avoid the effect
of wear on it.Table 2.
Cutting inserts: Carbide tool inserts as per ISO specification
CCMT09T308N-SU Sumitomo grade AC5005S coated with PVD ultra
multi-layer thin layer AlTiSiN process are used for the finish turning
tests of the Inconel 718 alloy. The inserts are rigidly attached to a
toolholder SCLCR 2020 K89, Fig. 3.
Surface roughness measurement: The Mitutoyo 2D SJ-310 surface
roughness tester was used to measure the arithmetic mean of the profile
deviation (Ra) of the machined surface based on EN-ISO 4287–1998
norms. Fig. 4 shows the surface tester used for experimentation.
Due to the small size of the workpiece, the measurements could not
be taken directly on the machine without first disassembling the setup.
After disassembling the workpiece, this prompted the calculation of the
arithmetic mean roughness (Ra). Therefore, in order to reduce any un­
certainty, each time four measurements were taken. Their mean is
regarded as the measured roughness value. The average roughness
values are then evaluated. The profilometer was set to a cut-off length of
λc = 0.8 mm, a 2CR filter, a transverse velocity of 1 mm/s and a trans­
verse length of 4 mm. The surface roughness (Ra) was measured by
placing the stylus perpendicular to the feed rate marks on the machined
surface towards the end of the cut and the surface roughness measure­
ment values are shown in Table 4.
Calculation of material removal rate: In turning process, the
material-removal rate (MRR) is the volume of material removed per unit
time, measured in mm3 per minute. It was derived from the expression
presented by Kalpakjian and Schmid (2009) [29], for each experimental
run: MMR = (v * f * d*1000) in mm3/min, where, the main cutting
parameters are; cutting speed v (m/min), feed rate f (mm/rev), and
depth of cut d (mm).
Selection of factors and their levels
The system is examined in order to select a suitable quality charac­
teristic that is a continuous and monotonous function, easy to measure,
and a direct indicator of energy transfer in the system. The SNR is chosen
as the objective function based on the nature of the quality feature.
Control factors levels, and noise factors are determined. A product’s
Fe Mo Nb Ni Ti Se
17.3 3.3 5.28 52.9 0.96 ≤3
F. Zhujani et al. Journal of Engineering Research xxx (xxxx) xxx

Table 2
Mechanical properties of Inconel 718.
Tensile strength Yield strength Young modulus Density (kg/ Melting point Hardness Hardness after heat treated Thermal conductivity
(MPa) (MPa) (MPa) m3) (˚c) (HBW) (HBW) (W/mK)

1197 1248 205 × 103 819 1290 245 411 11.20

processing parameter zones, according to the recommendations of the

tool manufacturer and the existing database were not completely satis­
factory. Therefore, for the material of the workpiece used in this
research and the inserts of the applied cutting tools, were performed
extensive preliminary tests, which determined the limit values of the
processing parameters, i.e. the range of the input variables. Finally, the
machining parameters to be studied such as cutting speed, feed rate and
depth of cut and the attribution of their levels are shown in Table 3.
Fig. 3. a) Toolholder SCLCR 2020 K89 – Techno Takim, b) Cutting insert
CCMT 09T308N. Experimental design and optimization

The Taguchi method and experimental

A Taguchi design, also known as an orthogonal array, is a technique
for designing experiments that typically requires a fraction of the total
factorial combination [5,30]. As a result, each factor may be evaluated
independently of the others, thus the effect of one element does not
affect the evaluation of another [24]. By minimizing the impact of
variables that cannot be controlled, orthogonal arrays can significantly
reduce the number of tests. Additionally, it offers a straightforward,
effective, and systematic method for specifying the optimal machining
settings during the manufacturing process.
The Taguchi technique determines the difference between the
experimental values and the intended values using a loss function. The
signal-to-noise (S/N) ratio is then created using this loss function.
Here, the signal data (S) contains the desirable influence on the test
results, whereas the noise data (N) contains the undesired influence on
Fig. 4. Surface roughness measurements with Mitutoyo SJ-310. the test results. As a result, the highest S/N ratio yields the best per­
formance. There are three distinct approaches to calculating S/N ratios.
These are the smaller the-better, the nominal-is-best, and the larger-the-
Table 4
better approaches.
Coded Experimental matrix layout using an L9 orthogonal array for Ra, and In the present study, the smaller-the-better and the larger the-better
MRR. option of the S/N quality characteristic was utilized to obtain the best
combination for the surface roughness and material removal rate with
` Cutting speed Feed rate Depth of cut Ra MRR
(m/min) (mm/rev) (mm) (µm) (mm3/min) respect to the desired low Ra and high MRR. The smaller-the-better and
the larger-the-better approaches is expressed as follows [15]:
1 1 1 1 0.23 1420
2 1 2 2 0.30 3680
Smaller-the-better (minimize):
3 1 3 3 0.32 7500 ( )
4 2 1 2 0.24 3408 1∑ n
S/NRa = − 10log y2i (1)
5 2 2 3 0.28 6624 n i=1
6 2 3 1 0.31 3000
7 3 1 3 0.20 5964 Larger-the-better (maximize);
8 3 2 1 0.23 2576 ( )
9 3 3 2 0.28 7000 1∑ n
1
S/NMRR = − 10log (2)
n i=1 y2i

Table 3 where yi represents the responses of the machining characteristic for an

Machining parameters and their levels. n-time trial condition. The negative sign in Eq. (1) and Eq. (2) is only for
Cutting parameters Notation Unit Levels showing the smaller-the-better and larger-the-better quality
1 2 3
characteristic.

Cutting speed v m/min 100 120 140

Experimental work
Fed rate f mm/rev 0.071 0.092 0.125
Depth of cut d mm 0.2 0.4 0.6
Based on the selected parameters and their levels as are shown in
Table 3., the experimental tests were conducted on the GOODWAY CNC
robustness is ensured by using testing circumstances that capture the lathe, the 3D design of the workpiece model was created in SolidWorks
effect of numerous noise causes. Furthermore, the Signal to Noise Ratio CAD software, and then AZ-CAM software was used to calculate the
(SNR) must be defined in such a way that it incorporates not only the cutting path of tests based on Taguchi’s experimental design. Nine
average level of the response, but also the observed variance in its level separate trials were carried out, with the standard orthogonal array L9
due to noise factors [21]. The guidelines for the selection of the (33), and the workpiece that was produced after machining was

4
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Table 5 parameters on surface roughness and material removal rate. Main effect
Experiment results and STN ratio for Ra and MRR. plots were created using Minitab-18 software as illustrated in Figs. 5 and
Exp. Cutting Feed Depth Ra S/N MRR S/N 6, respectively.
No. speed rate of cut (µm) Ratio (mm3/ Ratio
(m/min) (mm/ (mm) (dB) min) (dB) Analysis and assessment of experimental results
rev)

1 100 0.071 0.2 0.23 12.77 1420 63.05 Analysis of the signal-to-noise (S/N) ratio
2 100 0.092 0.4 0.30 10.46 3680 71.32
3 100 0.125 0.6 0.32 9.90 7500 77.50
4 120 0.071 0.4 0.24 12.40 3408 70.65
The S/N response tables were created using the Taguchi technique
5 120 0.092 0.6 0.28 11.06 6624 76.42 which was used to analyze process parameters such as cutting speed,
6 120 0.125 0.2 0.31 10.17 3000 69.54 feed rate and depth of cut, as can be seen in Tables 6and 7.
7 140 0.071 0.6 0.20 13.98 5964 75.51
8 140 0.092 0.2 0.23 12.77 2576 68.22
9 140 0.125 0.4 0.28 11.06 7000 76.90
Table 6
Response table for surface roughness (Ra).
inspected for surface finish parameter (Ra) and material removal rate Control Factors
(MRR) as shown in the Table 4. S/N ratio Means
The Taguchi technique was used to evaluate the surface roughness
v f d v f d
(Ra) and material removal rate (MRR) using an orthogonal array for
each combination of the test parameters, and signal-to-noise (S/N) ratios Level 1 11.04 13.05 11.90 0.2833 0.2233 0.2567
Level 2 11.21 11.43 11.30 0.2767 0.2700 0.2733
were used to optimize the process parameters. Table 5 displays the S/N Level 3 12.60 10.38 11.64 0.2367 0.3033 0.2667
ratios estimated from the experimental results using Eqs. (1) and (2). Delta 1.56 2.67 0.60 0.0467 0.0800 0.0167
The data was then examined further to determine the effect of cutting Rank 2 1 3 2 1 3

Fig. 5. Main effects plots for Ra: a) for S/N ratio and b) for Means.

Fig. 6. Effect of process parameters for MRR: a) on S/N ratio b) on average S/N ratio.

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Table 7 Table 10
Response table for material removal rate (MRR). Regression statistics and coefficients for linear regression of Ra.
Control Factors Regression statistics Coefficients

S/N ratio Means Multiple R 0.949038 Intercept 0.257

R-sq 0.900673 Cutting speed -0.00117
v f d v f d
R-sq (adj) 0.841077 Feed rate 1.439
Level 1 70.62 69.74 66.94 4200 3597 2332 Standard error 0.01669 Depth of cut 0.025
Level 2 72.20 71.99 72.96 4344 4293 4696
Level 3 73.54 74.65 76.48 5180 5833 6696
Delta 2.92 4.91 9.54 980 2236 4364 utilized to evaluate the error variance and identify the significant pro­
Rank 3 2 1 3 2 1 cess parameters that mostly affects the performance characteristics, i.e.
surface roughness and material removal rate. Using the statistical soft­
ware MINITAB 18, the results of ANOVA are derived and presented in
Table 8 Tables 8 and 9. Fisher’s ratio (F-value) is utilized in ANOVA to deter­
Analysis of variance for means of Ra. mine whether the parameter substantially affects the selected surface
Source DF SS MS F P Contribution (%) roughness and material removal rate. If the value of the calculated F-stat
v 2 0,003822 0,001911 43,00 0023 27.26
test is greater than the critical F- stat at α = 0.05, derived from the null
f 2 0,009689 0,004844 109,00 0009 69.10 hypothesis i.e. Fα(1/2)= 18.513, a statistically significant relationship
d 2 0,000422 0,000211 4,75 0174 3.01 can be inferred between the factors and the outcome variable. Alter­
Error 2 0,000089 0,000044 0.63 natively, the related probability P-value of less than 0.05 implies that the
Total 8 0,014022 100
parameters are statistically significant at a 95% confidence level [26].
The ANOVA findings presented in Table 8 indicate that the feed rate
variable exerts the most substantial influence on the overall variance in
Table 9 surface roughness, accounting for 69.1% of the total variance. The
Analysis of variance for means of MRR. cutting speed variable follows with a contribution of 27.26%, while the
Source DF SS MS F P Contribution (%) depth of cut variable exhibits a relatively lower level of significance,
v 2 1680032 840016 1.70 0.370 4.29 contributing only 3.01% to the total variance. The percentage of error
f 2 7855712 3927856 7.94 0.112 20.06 for Ra and MRR were found to be 0.63% and 2.53%, respectively,
d 2 28632992 14316496 28.96 0.033 73.12 indicating a significant level of accuracy.
Error 2 988800 494400 2.53 The analysis of Table 8 reveals that the P-values for the cutting speed
Total 8 39157536 100
(0.023) and feed rate (0.009) are both less than the significance level
α = 0.05, indicating a confidence level of 95%. Therefore, it can be
They show the S/N ratio at each control factor level and how it concluded that these two factors significantly affect the surface rough­
changes as the settings of each control factor are adjusted from one level ness. Conversely, the depth of cut, with a P-value of 0.174, is deemed
to another [9]. insignificant, as it exceeds the aforementioned significance level. This
Surface roughness as a function of various process parameters i.e. finding aligns with the corresponding F-value of 0.54, which is lower
cutting speed, feed rate and depth of cut is shown in Fig. 5 This occurs than the F-statistic derived from the null hypothesis (Fα,1,
because higher cutting temperatures in the machining zone result in ferr=F0.05,1,2)= 18.513).
thermal softening of the workpiece and reduction of materials scattered The examination of Table 9 reveals that the depth of cut, along with
on the machined surface [6]. Increasing the feed rate results in a higher its corresponding P-value of 0.033, falls below the established signifi­
Ra value. This is due to the fact that as the feed rate increases, the cance level of α = 0.05. This suggests that the depth of cut plays a crucial
workpiece presents more resistance to the tool, causing more built up role in determining the material removal rate. By contrast, the cutting
edge (BUE) to form on the tool’s lateral face, which in turn causes sur­ speed (0.37) and feed rate (0.12) exhibit P-values that exceed the
face degradation and an increase in the Ra value [13,18]. established significance level (0.05), thereby suggesting that they lack
In addition, Fig. 5 reveals that as the depth of incision increases, the statistical significance. The aforementioned discovery aligns with the
surface roughness increases to a certain point and then decreases. corresponding F-value of 1.7 and 7.94, which is comparatively lower
From Fig. 6 it can be seen that the increase of each of the cutting than the Fα-statistic obtained from the null hypothesis (Fα,1,
parameters (v, f, and d) results in the increase of material removal rate ferr=F0.05,1,2)= 18.513). The preceding analysis indicates that both the
(MMR). Response graphs (see Figs. 5 and 6, respectively) help visualize F-critical value and P-value converge to the same conclusion, namely
the impact of each control component. that a significant association exists between the dependent variables and
The magnitude of the effect of each control element may be seen in a minimum of two independent variables.
the graphs depicting the effects of the S/N ratio Figs. 5 and 6), namely in
the slope of the line connecting the levels. Development and analysis of regression models
It has been demonstrated that the feed rate, in particular, has the
greatest influence on the surface roughness (rank 1), followed by the In many scientific researches, regression analysis has been used to
cutting speed which has less influence (rank 2), as well as the depth of establish the relationship between independent variables and experi­
cut (rank 3) with least impact, as indicated by the gentle slope of the mental results.
lines. Mathematical predictive models for Ra and MRR as a function of
Furthermore, it has been established that the depth of cut, specif­
ically, has the most influence on material removal rate (rank 1), fol­ Table 11
lowed by feed rate (rank 2), and the cutting speed (rank 3) with the least Regression statistics and coefficients for linear regression of MRR.
impact, as indicated by the gentle slope of the lines. Regression statistics Coefficients

Multiple R 0.98 Intercept -6749

Analysis of variance (ANOVA) R-sq 0.96 Cutting speed 24.5
R-sq (adj) 0.94 Feed rate 41876
Analysis of variance (ANOVA) is a computational technique that Standard error 520.34 Depth of cut 10910

6
F. Zhujani et al.
Fig. 7. Normal probability charts for surface roughness.
Fig. 8. Normal probability charts for surface roughness.
cutting speed (v), feed (f) and depth of cut (d) were developed using the
Minitab 18.0 software tool, and regression statistics are shown in the
corresponding Tables 10 and 11.
For Ra and MRR, the regression analysis yielded the prediction
equations indicated in Eqs. (3) and (4).
Ra = 0⋅2574 – 0⋅001167*v + 1⋅439*f + 0⋅025*d (3)
MRR = − 6749 + 24⋅5*v + 41876*f + 10910*d (4)
Multiple R values were around 0.949 and 0.983 for Ra and MRR. This
suggests that the fitted regression model explained more than 94%,
respectively 98% of the variation in surface roughness and material
removal rate.
The anticipated R-squared shows how accurately a regression model
forecasts how fresh observations will respond. From the literature it is
suggested that R-sq be between 0.8 and 1 [8].
The determination coefficient in this study R-sq is 0.90 respectively
0.96 for Ra and MRR, which is strong enough to demonstrate the
7
Journal of Engineering Research xxx (xxxx) xxx
projected model’s high importance.
A graphical technique was used to examine the contents of the
model’s residual. The residuals were examined to determine the suffi­
ciency of the models. The statistical validity of the models was tested by
inspecting certain diagnostic charts of the model.
In normal plots of residuals, the residuals could be considered to
follow a straight line, meaning that the errors were distributed regularly,
as illustrated in Figs. 7 and 8. This provides evidence that the models
developed were significant and accurate.
Single - objective optimization for surface roughnes and material
removal rate
Single-objective optimization (SOO) can be described as only one
objective function which the goal is to identify the optimal solution that
maximizes or minimizes it [4].
By applying the Taguchi Method, the desirability function approach
F. Zhujani et al. Journal of Engineering Research xxx (xxxx) xxx

Table 12 in the graph Fig. 5.b, as well as the levels with the highest points Fig. 6.b.
Optimum conditions for surface roughness and material removal rate. Therefore, it was determined that the optimal predicted process
Ra (µm) MRR (mm3/min) parameters for achieving low surface roughness using the Taguchi
method are v = 140 m/min, f = 0.071 mm/rev, and d = 0.2 mm, with
Parameter Notation Best Value Best Value
level level the corresponding level values bolded in response Table 6. This optimal
combination predicted for surface roughness is represented as (v3-f1-d1),
Cutting speed (m/ v 3 140 3 140
min)
as seen in Table 12.
Feed rate (mm/rev) f 1 0.071 3 0.125 As illustrated in Fig. 6, the Taguchi approach was utilized to deter­
Depth of cut (mm) d 1 0.2 3 0.6 mine the optimal parametric combination for achieving the highest
material removal rate. The results indicate that the optimal combination
was characterized by factor v at level 3 (v=140 m/min, S/N = 73.54 dB,
combined with linear regression models (3) and (4) are used for mini­
mean: 5180 mm3/min dB), factor f at level 3 (f=0.125 mm/rev., S/
mizing the surface roughness and maximizing the material removal rate.
N = –74.65 dB, mean: 5833 dB), and factor d at level 3 (d=0.6 mm, S/
Optimum cutting conditions for better surface quality and higher
N = 76.48 dB, mean: 6696 dB), as presented in Table 7. The predicted
material removal rate are determined by obtaining a main effects plot
optimal combination for material removal rate was (v3-f1-d1), as shown
for S/N ratios and mean data means using Minitab-18 statistical soft­
in Table12.
ware, as seen in Fig. 5.a, b and 6.a, b.
After evaluation of single objective optimization presented in Fig. 9 it
A higher S/N ratio always indicates superior performance, regardless
seen the values obtained for minimum surface roughness (Ramin) and
of the category of performance attributes being measured. Hence, the
maximum material removal rate (MRRmax) are as follows:
best setting for the process parameters is the one that yields the largest
signal-to-noise ratio [1].
- Surface roughness: cutting speed (level 3), feed rate (level 1) and
These graphs show the relative effect of each parameter on the S/N
depth of cut (level 1). The minimum value is predicted at 0.2012
ratio and (the overall slope of the line), as well as the levels to be chosen
(µm), expected to be reached with cutting speed v= 140 m/min, feed
for the optimal cutoff parameters (the levels with the highest points in
rate f= 0.071 mm/rev and depth of cut d= 0.2 mm, and optimal of
the graphs Fig. 5.a and 6.a, respectively the levels with the lowest points
d= 0.9897 mm, and

Fig. 9. Single-objective optimization of Ra and MRR.

8
F. Zhujani et al. Journal of Engineering Research xxx (xxxx) xxx

Fig. 10. Multi-objective optimization.

- Material removal rate: cutting speed, feed rate and depth of cut all of
them are in (level 3),
- -The maximum value is predicted at 8461.0661 (mm3/min) for
optimal desirability function (D=1), as seen in Table 12.
Multi - objective optimization for surface roughnes and material
removal rate
The purpose of multi-objective optimization is to identify a collection
of solutions that balance the tradeoffs between many objective functions
that each reflect a separate goal [16] . Many researchers concentrated on
improving various machining processes for single characteristic criteria.
Selecting the best parameter for numerous response criteria is really
challenging. To solve this problem, significant improvements in the
optimization of cutting parameters have been reported, with the use of
several techniques, including the Composite Desirability Optimization
(CDO) technique coupled with the RSM linear models desirability
function approach for multiple response factors optimization [22] .
Combining the individual desirability values from each response yields
the overall composite desirability (D) [10].
Surface roughness (Ra) and material removal rate (MRR), as two
opposite quality criteria of the turning process, whichare the major
factors in determining productivity in the manufacturing industry
worldwide, thought to be optimized simultaneously.
A composite desirability value (D) of turning parameters is derived
from multi-criteria, namely surface roughness and material removal
rate, utilizing individual desirability values from the desirability func­
tion analysis presented in Fig. 9. The researcher using Minitab Release
18, Response Optimizer and selecting the desirability function for
Ramin, and MRRmax found the optimal values of cutting factors and the
obtained values shown in Fig. 10.
As illustrated in Fig. 10, the best combination of cutting factor levels
for achieving the minimum surface roughness and maximum material
removal rate correspond to experimental trial number 7 with respective
optimal levels (v3,f1and d3) and respective multi-objective Composite
Desirability Function (D=0.8441), the desirability Ramin function
(y = 0,2112; d=0.906) as well as desirability MRRmax function
(y = 6199.77; d=0.876). From the above analysis it can be concluded

Table 13
Conformation results for Taguchi method and linear regression.
Level Quality attribute Taguchi method Linear regression

Exp. Pred. Error (%) Exp. Pred. Error (%)

Surface roughness -Ra (µm)

v3f1d1 Single optimum 0.19 0.186 2.15 0.19 0.201 5.79
v3f1d3 Multi-objective optimum 0.20 0.196 2 0.20 0.211 5.5
v2f2d2 (Random) 0.28 0.289 3.21 0.28 0.283 1.07
v1f3d1 (Random) 0.31 0.312 0.64 0.31 0.326 5.16
Material removal rate – MRR (mm3/min)
v3f3d3 Single optimum 10500 8560 18.48 10500 8461 19.42
v3f1d3 Multi-objective optimum 5964 6324 6.04 5964 6200 3.95
v2f2d2 (Random) 4416 4040 9.30 4416 4408 0.19
v1f2d3 (Random) 5520 6040 8.60 5520 6100 9.50

9
F. Zhujani et al.
that in the case of multi-objective optimization dhe surface roughness
the optimal parameter Ra approximately increases with five percent,
while material removal rate(MRR) decreases approximately 27%.
Experimental validation
The Taguchi technique, response optimizer predictive results and
predictive regression equations underwent confirmation testing of the
process parameters at optimal and random levels. The comparison of
test results with expected values derived from the Taguchi method,
response optimizer and regression equations (Eqs. (3), (4)) is presented
in Table 13. The experimental results and the predicted values are
extremely similar. Error values must be under 20% for statistical anal­
ysis to be considered reliable [20].
As can be seen from Table 13, the error percentages of the optimal
predictive levels based on the Taguchi method and the regression
analysis for surface roughness have almost the same range. As illustrated
in Table 13, the error percentages of single and multi-objective optimal
predictive levels based on Taguchi method and regression analysis for
surface roughness have almost the same range. While the percentage of
errors of the optimal optimization levels of a single-objective is 3–4
times greater than the errors of multi-objective optimization.
Although the error rate at the optimal level of single-objective
optimization is three to four times higher than the error rate of multi-
objective optimization, it is still below the allowable level of 20%.
Therefore, the results of the confirmation tests indicate that optimiza­
tion was successful.
Conclusion
The present investigation employed the Taguchi methodology to
ascertain the optimal machining parameters for the turning process of
Inconel 718 alloy utilizing PVD coated carbide inserts in the absence of
any cutting fluid. The statistical analysis of the experimental outcomes
was conducted through the use of ANOVA. It is possible to draw the
following conclusions:
• The study determined the optimal levels of control factors for the
purpose of minimizing surface roughness and maximizing of material
removal rate, utilizing S/N rates.
• The investigation established that the parameters yielding the most
desirable outcomes in terms of surface roughness and material
removal rate were identified at v3f1d1 (cutting speed of 140 mm/
min, feed rate of 0.071 mm/rev, and depth of cut of 0.2 mm) and
v3f3d3 (cutting speed of 140 mm/min, feed rate of 0.125 mm/rev,
and depth of cut of 0.6 mm), respectively.
• The statistical analyses revealed that the feed rate had the highest
level of significance in relation to surface roughness, accounting for
69.10% of the variance. Similarly, the depth of cut was identified as
the most significant parameter for material removal rate, contrib­
uting to 73% of the variance.
• The obtained multiple R values for Ra and MRR were approximately
0.949 and 0.983, respectively. The aforementioned findings indicate
that the regression model that was fitted had an explanatory power
of over 94% and 98% for the surface roughness and metal removal
rate, respectively.
• The findings indicate that the Taguchi method is a dependable
approach for minimizing machining time and production expenses in
the CNC turning process of Inconel 718 alloy.
Recommanditaion for future research
Based on the results and the analysis of the experimental data, these
recommendations for further work is being proposed in the following
areas:
10
Journal of Engineering Research xxx (xxxx) xxx
• In addition to the linear regression models of the first order, as
another alternative for the prediction of machinability responses can
be used the second order or higher models as well as exponential.
• Further research could explore additional methods for multi-
objective optimization such as extended Taguchi approach using
Hybrid GRA-PCA.
• Subsequent investigations may explore additional variables,
including the configuration of the cutting tool, the composition of
CVD coatings, alternative materials for cutting inserts, the nose
radius, and the implementation of lubrication. These factors have
been shown to impact the surface roughness.
Declaration of Competing Interest
The authors declare the following financial interests/personal re­
lationships which may be considered as potential competing interests:
Fitore Abdullahu reports administrative support, article publishing
charges, equipment, drugs, or supplies, statistical analysis, travel, and
writing assistance were provided by University of Prishtina. Fitore
Abdullahu reports a relationship with University of Prishtina that in­
cludes: employment. Fitore Abdullahu has patent Prof.asc pending to
Professor. It is good for me that readers can download and cited my
paper.
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