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Optimisation of Machining Parameters for CNC

Milling of Fibre Reinforced Polymers
Chandra, Arunesh
Department of Mechanical Engineering, KIET Group of Institutions

Yadav, Abhishek
Department of Mechanical Engineering, KIET Group of Institutions

Singh, Shwetabh
Department of Mechanical Engineering, KIET Group of Institutions

Pawan Kumar Arora

Department of Mechanical Engineering, Galgotias College of Engineering and Technology

https://doi.org/10.5109/6792826

出版情報：Evergreen. 10 (2), pp.765-773, 2023-06. 九州大学グリーンテクノロジー研究教育センター

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 EVERGREEN Joint Journal of Novel Carbon Resource Sciences & Green Asia Strategy, Vol. 10, Issue 02, pp765-773, June 2023

Optimisation of Machining Parameters for CNC Milling

of Fibre Reinforced Polymers
Arunesh Chandra1,*, Abhishek Yadav1, Shwetabh Singh1, Pawan Kumar Arora2
1
Department of Mechanical Engineering, KIET Group of Institutions, Delhi-NCR, Ghaziabad-201 206
2
Department of Mechanical Engineering, Galgotias College of Engineering and Technology, Greater Noida,
India

*Author to whom correspondence should be addressed:

E-mail: [email protected]

(Received December 25, 2022; Revised April 26, 2023; accepted May 14, 2023).

Abstract: The objective of the presented work is to improve the machining parameters of fibre
reinforced polymer (FRP) using Taguchi's robust design technique. A large number of variables
impact the quality of the completed component throughout the machining process. The quality of
machined FRP components is greatly influenced by the surface roughness. Manufacturers can make
sure that the finished product fulfils the necessary quality requirements and is cost-effective by
optimizing machining settings to achieve the specified surface roughness. Optimizing machining
parameters for achieving the desired surface roughness can help reduce production costs by
minimizing waste, improving tool life, and reducing the need for post-processing operations. To
optimize the process, Three levels of each parameter were chosen for investigation for each such
adjustable process parameter. Machining was performed on a CNC milling machine using a carbide
end mill. Experiments were conducted utilising Taguchi's technique to generate an experiment design
(L9 orthogonal array). Analysis of variance was used to determine the impact of each parameter
(ANOVA). The recommended control factor values for the best possible surface finish of FRP are
1.64 m, 400 rpm spindle/cutting velocity, 1.5 mm depth of cut and 0.3 millimetre/revolution feed
rate. Surface roughness was shown to be most impacted by cutting speed, followed by feed rate and
depth of cut. To determine the relationship between process parameters and quality attributes,
regression analysis and response surface methodology was used.

Keywords: Fibre reinforced polymers (FRP); machining parameters; Taguchi; surface roughness;
optimization

1. Introduction damage, and surface roughness5). Because surface

roughness has such a big influence on dimensional
Fibre-reinforced polymers (FRP) have wide precision and material performance, a lot of effort has
applications in the current economy due to good corrosion been put into developing models that employ
resistance, lightweight, good dielectric strength, high experimental design to estimate surface roughness and
fracture toughness, low moisture absorption, thermal quantify machined surfaces6). Surface roughness affects
resistance and high specific stiffness therefore they have mechanical characteristics including fatigue, corrosion
wide application in the aerospace industry, automobile resistance, and creep, as well as functional aspects
industry, lightweight furniture and electrical insulators1). including light reflection, friction, electrical conductivity,
FRPs are also gaining popularity due to their superior wear, heat transfer and lubrication7). Various machining
mechanical qualities and affordable cost2,3). Recently, FRP operations are used in the manufacturing business to
has replaced stainless steel and other comparable remove material from FRP to generate a better product
materials because it has advantages such as a high based on their capacity to remove undesirable material
strength-to-weight ratio, stiffness-to-weight ratio, while preserving a good surface quality. End milling is
excellent damping, and low heat4). Although with wide one of the most widely used, simple and easy metal cutting
applications but FRP users face a number of machining techniques used for machining of components and parts
challenges, this is due to the fact that the technical basis frequently. Complicated shapes/forms can be machined
developed for conventional materials cannot be used with a high surface finish during milling operations8-10).
for such new materials since their ability to process differs CNC machine tools have been utilised to automate milling
from standard materials. Some issues connected with FRP in recent years because they increase; output while
machining include material heterogeneity, delamination requiring very less intervention from the operator side. As

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the demand for flexibility and agility has increased, new during the milling process. The CNC machine (JYOTI
CNC machines have grown more stable and robust, PX40 VMC) utilised in this investigation has the
making determining the right amounts of cutting parameters provided in Table 1 and represented in Fig.1.
parameters during CNC milling operations more
difficult11). Table 1. CNC milling machine specifications
Several machining parameters make up the machining Type of machine Vertical machine centre
process. For low (surface roughness of the surface, wear Machine JYOTI PX 40 VMC PX
of tool, cutting force, temperature, and so on) or high
(material removal rate) machining responses, the Series
optimization technique offers a preferable parameter Table size 915 x 460 mm
combination12). The most critical cutting parameters for Spindle motor capacity 8.25 kW
end milling machining were cutting speed, depth of cut,
Spindle speed (max) 6000 rpm
and feed rate13,14). As a result of improper parameter
selection, cutting tools wear down quickly, resulting in Feed rapid traverse 25 m/min
economic losses such as destroyed work-piece(s) and bad (X, Y & Z Axis)
surface quality15). For a specific application, achieving
Feed cutting 10 m/min
appropriate surface roughness during machining (milling)
is required, which is influenced by different cutting Accuracy (positioning) 0.01 mm
parameters and tool geometry16). The quality of machined Accuracy (repeatability) 0.005 mm
FRP components is greatly influenced by the surface
roughness. Manufacturers can make sure that the finished
product fulfils the necessary quality requirements and is
cost-effective by optimizing machining settings to achieve
the specified surface roughness. Optimizing machining
parameters for achieving the desired surface roughness
can help reduce production costs by minimizing waste,
improving tool life, and reducing the need for post-
processing operations. Optimization techniques such as
the Taguchi method and response surface methodology
(RSM) have been used to optimize machining parameters
for improving surface roughness in FRP composites. The
Taguchi method is a statistical design of experiments
technique that determines the optimal combination of
machining parameters based on the signal-to-noise ratio. Fig.1: Machining of FRP on CNC milling
RSM is a statistical method that models the relationship
between the machining parameters and surface roughness. 2.1 Work-piece and Tool
Regression analysis is computational models that learn
from historical data to predict surface roughness based on Tool with high hardness like solid carbide end mill of
machining parameters17,18). 40 mm flute length and 6 mm diameter is selected for
In present study all major machining parameters like machining as it has better thermal conductivity and
cutting speed, feed rate and depth of cut are taken into modulus of elasticity in comparison with most available
consideration. Based on the components and levels that other tool materials. Selected tool also helps to achieve
were explored can be achieved by the various design of better surface finish with a high level of dimensional
experiments techniques (DOE)19). In the present study, the accuracy.
DOE was built using Taguchi's L9 orthogonal array20). FRP (fibre reinforced polymer) used in this study is a
Taguchi's S/N ratio analysis and preference approach are sample of sheet used in construction sites which typically
used to reduce surface finish and optimise cutting consist of a polymer matrix that has been reinforced with
variables during milling. Surface roughness was glass fibres. The polymer matrix is typically an epoxy
monitored with the objective that smaller is better and the resin, the glass fibers used in FRP sheets for construction
influence of each parameter was carried out using analysis sites are typically made from E-glass, In addition to the
of variance (ANOVA). Finally, we conduct confirmation polymer matrix and glass fibers, FRP sheets for
tests to compare the experimental and calculated results. construction sites may also contain fillers or additives
such as calcium carbonate or silica. Test specimen of
2. Materials & methods FRP having length of 400 mm, width 300 mm and
thickness of 5 mm. Specimen sheet used in this study is
The experiment was carried out on a CNC machine, directly purchased from the market-place. Typically, E-
which requires mounting and fastening the workpiece on glass, a form of fibre-glass with exceptional fatigue,
the CNC machine bed to avoid vibrations and deflections impact, and chemical resistance, is used to make the glass

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 Optimisation of Machining Parameters for CNC Milling of Fibre Reinforced Polymers

fibres in FRP sheets for building sites. E-glass has a high each focusing on a distinct approach and set of parameters.
modulus of elasticity, strong tensile strength, compressive There are some outstanding instances of published
strength, and flexural strength. The FRP sheet's strength research that used the Taguchi technique for parameter
and stiffness are provided by the fibres, which are optimization. During milling with the maximum speed of
normally woven or stitched into a precise pattern. 200 rpm, the depth of cut is 1.25 mm, and feed is 0.48
millimetre/revolution16), 200 – 550 rpm, 0.6 – 1.8 mm
2.2 Design of experiments (DOE) depth of cut16). Overall, the selection of input parameters
Traditional experimental design methodologies are and levels for machining requires careful consideration.
inherently complex and difficult to execute; however, Here input parameters speed, feed and depth of cut are
Novel orthogonal array design using the principle of most relevant and are selected on the basis of early studies
Taguchi methodology was used to overcome this issue to and taking into consideration the machine and tool range
optimize the parameters with limited experiments21). It is of available CNC (JYOTI PX40 VMC) as well as
a set of experiments aimed to collect data in a controlled objective to minimize the surface roughness. Table 2
setting to learn more about process behaviour. The displays the many aspects and their levels that were
Taguchi robust design approach is used because it is a properly selected for the investigation.
useful tool for quickly finding key parts, producing a high-
quality system, and cutting down on experimental/cutting Table 2. Machining parameters and their levels
time22). The orthogonal array helps in reducing the amount S.No. Factor Levels
of experimental work by using design criteria with
1 2 3
controlled factors in the columns and standard level of
quantities in the row. Taguchi suggested the use of the 1 Speed (rpm): N 300 400 500
efficacy metric signal to noise ratio (S/N)23). The 2 Depth of cut (mm): D 1 1.5 1.75
(Taguchi) optimization process flow diagram used in this
study is depicted in Fig. 2. 3 Feed 0.3 0.45 0.6
(millimetre/revolution): F

3. Experimental setup
Table 3 shows the experiment plan, which considers
three different factors at three different levels, resulting in
the selection of the L9 orthogonal array (OA) with nine
experiments24). The above-mentioned OA completed all
nine runs (slots) (L9). Three input/control parameters,
used in this study: The factors and their values were
chosen based on a survey of the literature, and the reason
for their selection and levels is explained below.
(a) Speed: The rate at which the spindle and work piece
move is measured in RPM in this experiment for
optimization reasons.
(b) Feed rate: It is the pace of the cutting tool
progressing along its cutting path. The feed rate is given
in millimeters per rotation.
(c) Depth of cut: The distance between the work piece’s
uncut and cut surfaces, measured in millimeters,
As a response variable, surface roughness (Ra) was
Fig.2: Process flow diagram for optimization technique
used. The goal was to keep the surface area to a bare
minimum. Surface roughness is defined as the average
2.3 Implementation of the Taguchi difference in surface height compared to the reference
This approach comprises creating an experiment to do plane.
research in a controlled way, followed by testing to learn
more about the behaviour of a certain process. This
research aimed to determine how different machining
settings influenced FRP composite milling. Statistical
experiments based upon Taguchi techniques were used to
calculate surface-roughness under the influence of various
machining parameters. Several research on milling
process parameter optimization have been undertaken,

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 EVERGREEN Joint Journal of Novel Carbon Resource Sciences & Green Asia Strategy, Vol. 10, Issue 02, pp765-773, June 2023

Table 3. Selection of L9 orthogonal array the best possible S/N ratio26). As a result, the mean squared
Control factor deviation should be as low as possible, indicating a
Experiment minimal divergence from the desired feature's threshold.
N D F In an experiment, maximizing the S/N ratio is critical27).
number
(rpm) (mm) (millimetre/revolution) The higher the signal-to-noise ratio, the more valuable the
intended signal is. Table 3 shows the experimental
1 300 1.00 0.30
parameter combinations. In the present study experiment
2 300 1.50 0.45 was conducted with three repetitions for each combination
of input parameters therefore 27 slots are cut as shown in
3 300 1.75 0.60 fig. 3. This specific repetition will help to improve the
4 400 1.00 0.45 variability in the data of surface roughness (output
parameter) with desired level of precision.
5 400 1.50 0.60
6 400 1.75 0.30 Table 4. Result of surface roughness (μm)

7 500 1.00 0.60 Experiment 1st 2nd 3rd Average S/N

8 500 1.50 0.30
1 2.62 2.38 2.67 2.556 -8.15122
9 500 1.75 0.45
2 2.67 1.71 1.54 1.973 -5.90254
3.1 Measurements 3 2.63 1.74 2.85 2.406 -7.62591
Surface roughness is one of the metrics used to assess
4 2.67 2.27 2.11 2.350 -7.42136
the mach-inability of a work piece and is also a significant
consideration to find whether the surface is suitable for a 5 1.33 1.77 1.83 1.643 -4.31275
specific function as rough surfaces are normally more
vulnerable to corrosion and crack but it aids in adhesion25). 6 1.54 2.09 1.91 1.846 -5.32463
The surface roughness of the machined surfaces was 7 2.08 2.83 1.87 2.260 -7.08217
measured using a Mitutoyo SJ-201: surface roughness
tester, which has a measuring range of -200 µm to +150 8 2.05 2.40 2.89 2.446 -7.76913
µm. (Fig.3). Each experiment was repeated thrice to check 9 2.28 1.79 2.31 2.126 -6.55127
the accuracy of the reading collected. The roughness:
tester displays the mean roughness: value and the Average 2.178 -6.68233
measured roughness depths (Rz) in micrometers or
microns (Ra). Table 4 summarizes the experimental findings for
surface roughness and their S/N ratios for the nine (9) trial
situations. At a cutting velocity of 400 rpm, a depth of cut
of 1.50 mm, and a feed rate of 0.60 millimeter/revolution,
a minimum surface roughness (Ra) of 1.643 m was
attained in experiment 5. In general, a higher surface
quality was achieved by combining a moderate cutting
velocity, moderate depth of cut, and the highest feed rate.
The largest surface roughness (Ra) of 2.556 µm was
obtained with trial 1, at the lowest cutting velocity (300
rpm), depth of cut (1 mm) and feed rate (0.3
millimeter/revolution).
The lines connecting the quantities of components in
Fig. (4-5) are not horizontal, implying that each parameter
has a varied influence. The lowest and highest values of
the S/N ratio are recorded at speed level 2 (400 rpm),
Fig.3: Machined (slotted) work-piece three samples for each
depth level 2 (1.50 mm), and feed level 1 (0.3
experiment
millimeter/revolution). These control factor amounts are
optimal for reducing surface roughness. Fig.4 shows that
4. Results and Discussions when cutting velocity (A) increases from level 1 to level
Table 4 represents the results of experiments conducted 3, surface roughness reduces from 2.32 to 1.95 m and then
in this study and summarizes the values of data of surface increases to 2.29 m. Surface roughness was found to
roughness as well as its S/N ratio for various factors at decrease from 2.38 to 2.0 µm and further increase from
each level the purpose of each experiment was used to find 2.0 to 2.12 µm as the depth of cut (B) increases from level

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 Optimisation of Machining Parameters for CNC Milling of Fibre Reinforced Polymers

1 to level 3. Surface roughness increased; from 2.0 to 2.4

m as the feed (C) was increased from 0.3 to 0.6 4.1 ANOVA
millimeter/revolution, because at higher depths of cut, a
larger area: of the tool is in contact with the FRP, resulting In order to determine how input factors: affect output
in increased load on the tool and higher frequency variables, an analysis of variance (ANOVA) is used28).
vibration, resulting in increased surface roughness; The ANOVA values for the output factors that were
surface roughness also increased from 2.0 to 2.4 m as the assessed are displayed in Table 5 as well. In this study, the
feed (C) was increased from 0.3 to 0.6 aggregates of squares and variations are determined, and
millimeter/revolution. On the major impacts plot of the an F-test: is used to choose the essential components with
S/N ratio, Fig.5, the best combination of surface a 95% confidence level. When surface roughness was
roughness factor parameters is A2B2C1 which matches taken into account, cutting (spindle) speed (32.81%) was
the maximum values of S/N ratios and the smallest means the main parameter of concern, followed; by parameters
for all the control parameters. feed rate (31.22%) and depth of cut (28.96%).
sum of squares (Adj SS) of each factor
%contribution =
Total number of sum of squares

Table 5. ANOVA for surface roughness

Source DOF Adj. SS Adj. MS P- %
value Contribution
Spindle 2 0.024421 0.012210 0.017 32.81
speed
Depth 2 0.021551 0.010776 0.019 28.96
of cut
Feed 2 0.023231 0.011615 0.018 31.22
Fig.4: Main effects plot for means rate
Error 2 0.005215 0.002607 - 7.01

Total 8 0.074418 - -

4.2 Confirmation experiment

The major goal of this study's confirmation test is to
find the best process parameter (A2B2C1) for the
machined surfaces. The anticipated mean (µ) is the
expected value of the average result produced by the
experimental data. The parameter range must be specified
at a specific level of confidence, and the average value
Fig.5: Main effects plot for S/N ratio must be within a particular percentage of confidence29,30).
Table 6 shows the outcomes of three trials performed with
the best machining settings combination.

Table 6. Results of confirmation experiment

Surface roughness, Ra (µm)
Machining parameter Level
Experiment 1 Experiment 2 Experiment 3 Average
Cutting velocity (rpm) 400
Depth of cut (mm) 1.5 1.65 1.70 1.57 1.64
Feed (millimetre/revolution) 0.3

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 EVERGREEN Joint Journal of Novel Carbon Resource Sciences & Green Asia Strategy, Vol. 10, Issue 02, pp765-773, June 2023

The predicted confidence interval (95% confidence equation for surface roughness (Ra) may be represented in
level) was found to lie within the confidence interval real factor form:
validating the experimental results 1.37 < µSR < 1.66. The
anticipated best value is 1.57 µm, but the actual (average) Ra = 3.091 – 0.00017*cutting speed – 0.405*depth of cut
value is 1.64 µm. The confirmatory experiment's results – 0.599*feed rate
were found to be within the confidence interval,
Table 7 compares measured and projected Ra. The exact
suggesting that the experimental result was legitimate.
deviation and expected value are represented by the
deviation sequence (Δ). It is clear that most of the
4.3 Validation of the model through experiments
Ra values predicted by the first-order regressive model are
A first-order regression model was utilized to analyse near the experimental values; the average error is 1.03 per
the change in surface roughness (Ra) with different cent, which is comparable to reported values when
machining settings31,32). The MINITAB – 20 software and compared to published research work; hence, this model
the experimental data were used to construct the may be employed for future examination.
regression coefficient. The multiple linear regression

Table 7. Comparison between measured and predicted results of Ra

Experiment Measured Ra (µm) Predicted Ra (µm) Deviation for Ra (Δ) % Error

1 2.556 2.455 0.101 3.95

2 1.973 2.162 0.189 -9.58
3 2.406 1.972 0.434 18.03
4 2.350 2.348 0.002 0.085
5 1.643 2.056 0.413 -25.13
6 1.846 2.134 0.288 -11.37
7 2.260 2.242 0.018 0.796
8 2.446 2.219 0.227 9.28
9 2.126 2.028 0.098 4.61
Average error 0.197 -1.03%

As previously said, little research was done on the roughness. The dark green shaded zone indicates the
creation of a regression model for RSM-based possibility of low surface roughness at a medium cutting
performance predictions33). RSM is a powerful statistical velocity and depth of cut.
tool for optimizing machining parameters to improve
surface roughness in FRP composites. Several optimal
solutions exist for many engineering optimization
problems, one or more of which may be the absolute
minimum or maximum. Response surface plots are used
in statics to investigate the correlations between many
explanatory and one or more response variables34,35).
Because the model contains three variables, one of them
can be held constant at the plot's centre level, resulting in
three response surface plots. The interaction influence of
cutting velocity and depth of cut is demonstrated in Fig. 6.
The virtually circular part of the curve indicates that at a
medium cutting velocity and medium depth of cut, the
surface roughness value is much less than 1.8 µm, and it
performs better than any other combination of cutting
velocity and depth of cut. As a result, the milling operation Fig.6: Contour plot showing the effect of cutting speed (rpm)
should be done at a 1.5 mm depth of cut with a 400-rpm on the depth of cut (mm) on surface roughness (feed rate 0.45
cutting velocity to achieve the lowest possible surface millimetre/revolution)

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 Optimisation of Machining Parameters for CNC Milling of Fibre Reinforced Polymers

At a constant depth of cut of 1.375 mm, Fig. 7 shows

the effects of feed rate: and cutting speed on surface
roughness. The graph shows that a lower cutting speed and
feed rate will produce the minimum amount of surface
roughness: compared to other cutting velocity and feed
rate combinations, with a surface roughness value that is
lower and is obtained in the range of 1.8 to 2 µm. The dark
green shaded area indicates the possibility of minimum
surface roughness at an optimum range of cutting velocity
of (300 - 400) rpm and at a lower feed rate of (0.3 - 0.45)
millimeter/rev.

Fig.8: Contour plot showing the effect of depth of cut (mm)

on feed rate (mm/rev.) on surface roughness (cutting velocity
400 rpm)

4. Conclusions
For analyzing experimental data, the Taguchi approach
is a common and successful method. This methodology
may be used to enhance any process. The DOE-Taguchi
approach is used in this study to optimize machining
settings to reduce surface roughness. The experiment's
results reveal the optimal value of machining parameters,
as well as the related rank: speed – 400 rpm – rank 1, feed
Fig.7: Contour plot showing the effect of cutting speed (rpm) rate – 0.3 millimeter/revolution – rank 2, depth of cut –
on feed rate (mm/rev.) on surface roughness (depth of cut 1.375 1.5 mm – rank 3. The surface roughness is 1.64 µm as a
mm) result of these characteristics. The most significant
contributor to surface roughness is cutting velocity
The interaction implications of the depth of cut and feed (32.81%), followed by feed rate (31.22%) and depth of cut
rate are shown in Fig. 8. The curve is elliptical in shape (28.96%), according to ANOVA results. The surface
which infers that at a slower feed rate and higher depth of roughness of FRP diminishes at first and subsequently
cut, the surface roughness value is less than 1.8 µm and it grows when the spindle speed is increased. The surface
gives better performance than any other combination of roughness decreases initially, and then rises when the
cutting velocity and depth of cut. At 0.30 depth of cut is raised; however, when the feed rate is
millimeter/revolution and 1.5 mm depth of cut, the dark increased, the roughness of the surface of the FRP
green shaded area illustrates the potential of minimal decreases. The experimental data obtained in present
surface roughness. These obtained values of cutting study show close relation with the data obtained from the
velocity, depth of cut and feed rate justified the values predicted model.
predicted from the confirmation experiment and it
proposes that the best combination of cutting parameters
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