Optimization of Cutting Parameters in Turning Operation of Mild Steel

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Optimization of Cutting Parameters in Turning Operation of Mild Steel

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International Review of Applied Engineering Research.

ISSN 2248-9967 Volume 4, Number 3 (2014), pp. 251-256

Optimization of Cutting Parameters in

Turning Operation of Mild Steel

Neeraj Saraswat1, Ashok Yadav 2, Anil Kumar3 and Bhanu Prakesh Srivastava4
1,2
Dayalbagh Education Institute, Agra-282110 INDIA.
3, 4
Sunder deep Engineering College, Ghaizabad.

Abstract

The main objective of today's manufacturing industries is to produce

low cost, high quality products in short time. The selection of optimal
cutting parameters is a very important issue for every machining
process in order to enhance the quality of machining products and
reduce the machining costs. Surface inspection is carried out by
manually inspecting the machined surfaces. As it is a post-process
operation, it becomes both time-consuming and laborious. In addition,
a number of defective parts can be found during the period of surface
inspection, which leads to additional production cost. In the present
work the cutting parameters (depth of cut, feed rate, spindle speed)
have been optimized in turning of mild steel of in turning operations on
mild steel and as a result of that the combination of the optimal levels
of the factors was obtained to get the lowest surface roughness. The
Analysis of Variance (ANOVA) and Signal-to-Noise ratio were used
to study the performance characteristics in turning operation. The
analysis also shows that the predicted values and calculated values are
very close, that clearly indicates that the developed model can be used
to predict the surface roughness in the turning operation of mild steel.

Keywords: Mild Steel, Cutting Parameters, Taguchi Method,

ANOVA, S/N Ratio.

1. Introduction
Machining is one of the most wide spread metal machining process in mechanical
manufacturing industry. The goal of changing the geometry of raw material in order to
form mechanical parts can be met by putting material together. Conventional
machining is one most important material removal methods. Machining is a part of the
252 Neeraj Saraswat et al

manufacture all most all metal products. In turning, higher values of cutting parameter
offered opportunities for increasing productivity but it also involves greater risk of
deterioration in surface quality and tool life. Turning operation is very important
material removal process in modern industry. At least one fifth of all applications in
metal cutting are turning operations.

2. Literature Review
Unfortunately, in most scenarios, time is limited and design of experiments (DOE)
methods tend to be lengthy and cumbersome when considering the complex factors
and noise that affect such an operation .. An excellent solution to this issue is an
approach known as Taguchi Parameter Design.
S. Thamizhmanii et al (2007) studied on Analyses of Surface Roughness using
Taguchi Method . They stated that depth of cut plays a very significant role in
producing lower surface roughness followed by feed and cutting speed has lower role
on surface roughness from the tests. Purpose of this research was to analyze the
optimum cutting conditions to get lower surface roughness in turning process.
A.K.Sehgal, Amit Agarwal et al (2009) studied on surface roughness
optimization based on taguchi design of experiment . They stated that the milling is
found by the Taguchi parameter design method to determine minimum surface
roughness with a relatively small number of experimental runs in an End Milling
Process.
Deepak pal et al. (2012) studied on optimization of grinding parameters for
minimum surface roughness by Taguchi parametric optimization technique . They
stated that optimum value of surface roughness is 1.7Ra. They selected work speed,
grinding wheel grades and hardness of material as their parameters with L9 orthogonal
array.

3. Experimental Setup
3.1 MATERIAL
The work piece material selected for investigation is the EN9 is an unalloyed medium
carbon steel. EN9 finds wide varieties of application such as, forming and molding
dies, rollers, blanking and forming tools, forging, die making industries. This steel can
be provide a greater strength and wear resistance. The size of the work piece used for
experiment is round bar with 50 mm diameter and 250 mm length.

Table 1: Chemical Composition of the work piece Material.

Element C Si Mn S P
Weight (%) 0.5 0.25 0.7 0.05 0.05
Optimization of Cutting Parameters in Turning Operation of Mild Steel 253

Table 2: Physical properties of work piece Materiel.

Density Coefficient of thermal expansion Per Modulus of
(Kg/m3) C from 200C elasticity(N/mm2)
7800 11.6 x10-6 206000

Table 3: Selection of Process Parameters Value.

S. No. Levels of process Process Parameters

parameters Cutting speed Feed Rate Depth of cut
(m/min.) (mm/rev.) (mm)
1 Low 58.9048 0.1 0.4
2 Medium 86.3938 0.2 0.6
3 High 113.8827 0.3 0.8

4. Results and Discussion

4.1. Optimization and Analysis by Taguchi Technique

Table 4: Average Surface Roughness based on Taguchi Technique:

(a) Effect of Cutting Speed on Mean Response, Ra and Noise Factor

254 Neeraj Saraswat et al

B) Effect of Feed Rate on Mean Response, Ra and Noise Factor

C) Effect of Depth of Cut on Mean Response, Ra and Noise Factor

Table 4.5: ANOVA Table for S/N

5. Conclusion
Taguchi method has been adopted for the design of experiments and results have been
by minimizing S/N ratio.Optimization of the surface roughness was done using
Taguchi method andPredictive equation was obtained. A confirmation test was then
performed which depicted that the selected parameters and predictive equation were
accurate to within the limits of the measurement instrument.
Optimization of Cutting Parameters in Turning Operation of Mild Steel 255

References
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