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Optimization of Machining Parameters On Surface Finish and MRR in Turning Process For en 31 Steel Using Taguchi Method

This document summarizes a study that used the Taguchi method to optimize machining parameters (speed, feed rate, depth of cut) for turning EN-31 steel. The objectives were to determine the influence of parameters on material removal rate (MRR) and surface roughness, and identify optimum settings. Experiments used an L9 orthogonal array. Results showed speed most influenced roughness while depth of cut most influenced MRR. Analysis of variance identified significant factors. Optimum settings were identified to minimize roughness.

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Naresh Kumar Reddy
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110 views17 pages

Optimization of Machining Parameters On Surface Finish and MRR in Turning Process For en 31 Steel Using Taguchi Method

This document summarizes a study that used the Taguchi method to optimize machining parameters (speed, feed rate, depth of cut) for turning EN-31 steel. The objectives were to determine the influence of parameters on material removal rate (MRR) and surface roughness, and identify optimum settings. Experiments used an L9 orthogonal array. Results showed speed most influenced roughness while depth of cut most influenced MRR. Analysis of variance identified significant factors. Optimum settings were identified to minimize roughness.

Uploaded by

Naresh Kumar Reddy
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Department of Mechanical Engineering

B. V. RAJU INSTITUTE OF TECHNOLOGY (AUTONOMOUS)


(NBA and NAAC Accredited, Approved By AICTE and Affiliated to JNTUH)

OPTIMIZATION OF MACHINING
PARAMETERS ON SURFACE FINISH
AND MRR IN TURNING PROCESS FOR
EN 31 STEEL USING TAGUCHI METHOD

Team no: A3
Guide
AKHILA REDDY (17215A0301)
Mr. P. Naresh Kumar Reddy
BHARATH RAJ (17215A0302)
Assistant Professor
SRIDEVI (16211A0307)
ABSTRACT
• This study investigated the optimization of CNC turning operation parameters for EN-
31 steel using the Taguchi method.
• In turning process parameters such as cutting tool geometry and materials, depth of
cut, feed rates, cutting speeds as well as the use of cutting fluids will impact the MRR
and machining properties like surface roughness.
• The controllable input parameters were Speed (RPM), Feed (mm/rev) and Depth of
Cut (mm).
• The properties of Surface Finish and Material Removal Rate were selected as the
quality targets or the response variables.
• The signal-to-noise ratio and the analysis of variance are employed to study the
performance characteristics on turning operation.
• The result shows that the cutting speed has more influential effect on surface
roughness of EN-31 steel followed by feed rate and has minimum effect of depth of
cut on the same. Whereas it has been seen that, in case of material removal rate, depth
of cut and feed rate have the more influential effect as compare to the cutting speed.
Objectives
The present study has the following proposed objectives:

 To illustrate the procedure adopted in using Taguchi method to a lathe


turning operation.

 To study the influence of machining parameters viz. speed, feed and depth of
cut, on the Material Removal Rate of machined material.

 To study the influence of machining parameters viz. speed, feed and depth of
cut, on the surface roughness of machined material.

 To determine optimum machining parameter settings for the chosen


tool/work combination to minimize surface roughness using Taguchi method.
Methodology
• Dr. Taguchi of Nippon Telephones and Telegraph Company, Japan has developed
a method based on ORTHOGONAL ARRAY experiments which gives much
reduced variance for the experiment with “optimum settings” of control
parameters.
• The DOE with optimization of control parameters to obtain BEST results is
achieved in the Taguchi Method.
• "Orthogonal Arrays" (OA) provide a set of well balanced (minimum) experiments
and Dr. Taguchi's Signal-to-Noise ratios (S/N), which are log functions of desired
output, serve as objective functions for optimization, help in data analysis and
prediction of optimum results.
STEPS IN TAGUCHI METHODOLOGY

Step-1: Identify the main function, side effects, and failure mode

Step-2: Identify the noise factors, testing conditions, and quality characteristics

Step-3: Identify the objective function to be optimized

Step-4: Identify the control factors and their levels

Step-5: Select the orthogonal array matrix experiment

Step-6: Conduct the matrix experiment

Step-7: Analyze the data, predict the optimum levels and performance

Step-8: Perform the verification experiment and plan the future action
A B C
1 1 1
1 2 2
1 3 3
2 1 2
2 2 3
2 3 1
3 1 3
3 2 1
3 3 2
Outcomes
Table 1.1 Experimental results for Surface roughness, MRR and S/N ratio
Cutting Feed rate Depth Roughne MRR SNRA1 MEAN1 SNRA2 FITS1
speed (mm/min) of cut ss (mm3/
(rpm) (mm) Ra (µm) sec)

1000 100 0.3 2.05 45.56 -6.23508 2.05 32.3735 1.50000

1000 150 0.5 1.25 58.80 -1.93820 1.25 35.3875 1.50000


1000 200 0.8 1.20 79.00 -1.58362 1.20 37.9525 1.50000
1500 100 0.5 1.00 75.00 0.00000 1.00 37.5012 1.09667
1500 150 0.8 0.80 57.58 1.93820 0.80 35.2054 1.09667
1500 200 0.3 1.49 48.54 -3.46373 1.49 33.7220 1.09667
2000 100 0.8 0.67 70.00 3.47850 0.67 36.9020 0.80667
2000 150 0.3 0.94 43.25 0.53744 0.94 32.7197 0.80667
2000 200 0.5 0.81 57.80 1.83030 0.81 35.2386 0.80667
Results/Discussion
Main Effects Plot for SN ratios Main Effects Plot for SN ratios
Data Means Data Means
CUTTING SPEED(rpm) FEED RATE(mm/min) DEPTH OF CUT(mm) CUTTING SPEED(rpm) FEED RATE(mm/min) DEPTH OF CUT(mm)
2 37

1
36
Mean of SN ratios

Mean of SN ratios
0

35
-1

-2
34

-3

33
-4
1000 1500 2000 100 150 200 0.3 0.5 0.8 1000 1500 2000 100 150 200 0.3 0.5 0.8

Signal-to-noise: Smaller is better Signal-to-noise: Larger is better

Fig: 1.1 Main effective plots for surface Fig: 1.2 Main effective plots for MRR
roughness (Ra)
Taguchi analysis: MRR vs A,B,C

Response Table for Signal to Noise Ratios


Larger is better
Level A B C
1 35.50 35.86 33.20
2 35.48 34.44 36.04
3 34.95 35.64 36.69
Delta 0.551.423.48
Rank 3 2 1
Taguchi analysis: Ra vs A,B,C

Response Table for Signal to Noise Ratios


Smaller is better
Level A B C
1 -3.25230 -0.91886 -3.05379
2 -0.50851 0.17915 -0.03597
3 1.94875 -1.07235 1.27769
Delta 5.20105 1.25150 4.33148
Rank 1 3 2
Results/Discussion
Table 1.2 Analysis of Variance for Surface roughness Ra
Source DF Seq SS Adj SS Adj MS F Percentage
contribution
Speed 2 0.71278 0.71278 0.35639 10.09 50.31
Feed rate 2 0.56725 0.56725 0.28363 8.03 40.04
Depth of cut 2 0.06580 0.06580 0.03290 0.93 4.64

Error 2 0.07067 0.07067 0.03534 4.98


total 8 1.41650
Results/Discussion
Table 1.3 ANOVA table of the regression model of Ra

source DF SS MS F P F,3,5,0.01=12.060

F>F,3,5,0.01
Regression 3 1.27285 0.42428 14.77 0.006 hence model is
adequate
Residual
5 0.14365 0.02873
error

Total 8 1.41650
Results/Discussion
Table 1.4 Analysis of Variance for MRR, using Adjusted SS for Tests
Source DF Seq SS Adj SS F P Percentage
contribution
Speed 2 16.23 8.11 0.42 0.705 1.7283
Feed rate 2 236.26 118.13 6.09 0.141 25.1600
Depth of 2 647.73 323.86 16.69 0.057 68.9786
cut
Error 2 38.82 19.4 4.1340
Total 8 939.03

Table 1.5 ANOVA table of regression model for MRR


source DF SS MS F P F,3,5,0.01=12.060
Regression 3 865.55 288.5 19.63 0.003 F>F,3,5,0.01 hence model is
2 adequate
Residual 5 73.48 14.70
error
Total 8 939.03
Results/Discussion
Interval Plot of ROUGHNESS,Ra vs C1
95% CI for the Mean

2.0

1.5
ROUGHNESS,Ra

1.0

0.5

1000 1500 2000


C1
The pooled standard deviation was used to calculate the intervals.

Fig: 1.3 main effective plots for ANNOVA


Results/Discussion
• Optimum condition for surface roughness and MRR

Factors Optimum Optimum Model Experime Model Experime


condition condition value of ntal value value of ntal value
for SR for MRR SR(Ra) for SR MRR of MRR
Speed 2000 1500 0.4038±.1 o.282 80.31±1.9 79.00
(rpm) 060 018(78.40
Feed rate 200 200 (0.2978- 82-
(mm/rev) 0.5098), 82.211)
0.244±.00
Depth of 0.8 0.8 0559
cut (0.2384-
(mm) 0.244559)
Conclusions
• It has been observed from ANNOVA table that cutting speed has been found has most
influencing process parameter for minimization of surface roughness.
• The F value found as 14.77 obtained from ANOVA table of the regression model of Ra
has more value than the tabulated value F, 3, 5, 0.01 as 12.06 which show that it lies
within the confidence interval of 99%. Hence the model is found adequate.
• It has been observed from ANNOVA table that depth of cut has been found has most
influencing process parameter for maximization of material removal rate MRR.
• The F value found as 19.63 obtained from ANOVA table of the regression model of
MRR has more value than the tabulated value F, 3, 5, 0.01 as 12.06 which show that it
lies within the confidence interval (CI) of 99%. Hence the model is adequate
• The optimization process parameters for surface roughness and MRR are obtained as
cutting speed 2000 rpm, feed rate 200 mm/rev, depth of cut 0.8 mm, and cutting speed
1500 rpm, feed rate 200 mm/rev and depth of cut 0.8 mm respectively.
THANK YOU!!!

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