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Journal of Mechanical
Engineering
and Technology (IJMET),
ISSN 0976
INTERNATIONAL
JOURNAL
OF MECHANICAL
ENGINEERING
6340(Print), ISSN 0976 6359(Online)
Volume
4,
Issue
4,
July
August
(2013)
IAEME
AND TECHNOLOGY (IJMET)
ISSN 0976 6340 (Print)
ISSN 0976 6359 (Online)
Volume 4, Issue 4, July - August (2013), pp. 188-196
IAEME: www.iaeme.com/ijmet.asp
Journal Impact Factor (2013): 5.7731 (Calculated by GISI)
www.jifactor.com
IJMET
IAEME
ABSTRACT
Quality is inversely proportion to variability. In the other words as variability reduces,
Quality improves. This approach has been used in this work. In the present work variability in the
dimension of the manufactured part has been reduced. Reduction in the surface roughness as well as
tolerance is the basic aim of this work. The increase of consumer needs for quality metal cutting
related products (more precise tolerances and better product surface finish) has driven the metal
cutting industry to continuously improve quality control of metal cutting processes. Within these
metal cutting processes the turning process is one of the most fundamental cutting processes used in
the manufacturing industry. Surface finish and dimensional tolerance, are used to determine and
evaluate the quality of a product, are two of the major quality attributes of a turned product. The
project work has been carried out at Neeraj Industries, Badli Industrial Area, Delhi in which the
optimization of input parameter has been done for improvement of quality of the product in turning
operation on CNC machine. Feed Rate, Spindle speed & Depth of cut are taken as the input variables
and the dimensional tolerances and the surface roughness are taken as quality output. In the reduction
of variation of performance characteristics and quality measures, Taguchi approach is very useful in
the design of experiments. In the present work L9 Array has been used in design of experiment for
optimization of input parameters. This project attempts to introduce and thus verifies experimentally
as to how the Taguchi parameter design could be used in identifying the significant processing
parameters and optimizing the surface roughness of the turning operation.
There are two purposes of this research .The first is to demonstrate a systematic approach of
using Taguchi parameter design of process control of individual CNC turning machine.The second is
to demonstrate the use of Taguchi parameter design in order to identify the optimum surface
roughness and dimensional tolerance performance with a particular combination of cutting
parameters in a CNC turning operation.The present work shows that the spindle speed is key factor
for minimizing the dimensional variation and feed rate is most effective input parameter for
minimizing the surface roughness.
188
190
191
(Equation:4.1)
where, n is the number of experiments for each experimental set and yi expresses the quality
characteristic at the ith experiment. On the contrary, the larger quality characteristic will have better
result when considering the larger-the-better quality; therefore, by taking the inverse of quality
characteristic into Eq. (4.1), the related S/N ratio can also be deduced and shown in Eq. (4.2).
(Equation:4.2)
In this study, the overall relational rating using GRA for multiple precision CNC machining
objectives is introduced to the Taguchi experiment as the S/N ratio. Therefore, it is judged as the
quality of larger the best. In addition to the S/N ratio, a statistical analysis of variance (ANOVA)
[Wang and Lan, 2008] is to be employed to indicate the impact of process parameters. In this way,
the optimal levels of process parameters can be estimated.
EXPERIMENTAL SET UP
The precision diameter turning operation of Aluminium alloy (9.64 x 12 mm) work piece on
an STORM-A50 CNC lathe is arranged for the research. The TOSHIBA WTJNR2020K16 tool
holder with MITSUBISHI NX2525 insert is utilized as the cutting tool. The relevant specification for
the coupling of the JMG
CONSTRUCTION OF ORTHOGONAL ARRAY
In this study, three turning parameters (Cutting Speed, Feed Rate, and Depth of Cut) with
three different levels (Table 4.1) are experimentally constructed for the machining operation. In
Table 4.1, the three levels of cutting depth, feed rate and speed are identified from the machining
handbook suggested by the tool manufacturer. The orthogonal array is then selected to perform the
nine sets of machining experiments. The parameter levels for the experiments are illustrated in
Table 4.2.
PARAMETER TABLES AND LEVELS
TABLE 4.1. PROCESS LEVELS AND PARAMETER DESIGNATION
Parameter Designation
A
Process Parameters
Cutting speed(rpm)
Feed rate(mm/rev)
Depth of cut(mm)
192
Level 1
1000
A3
0.02
B3
0.25
C3
Level 2
1300
A2
0.03
B2
0.30
C2
Level 3
1600
A1
0.04
B1
0.35
C1
B(Cutting Depth)
C(Feed Rate)
Level 1
Level 1
Level 1
Level 1
Level 2
Level 2
Level 1
Level 3
Level 3
Level 2
Level 1
Level 2
Level 2
Level 2
Level 3
Level 2
Level 3
Level 1
Level 3
Level 1
Level 3
Level 3
Level 2
Level 1
Level 3
Level 3
Level 2
OBSERVATIONS AND RESULTS: As discussed in section 4.1 & 4.2 three levels of each input
parameters Speed, Feed rate and depth of cut are taken and the experimental layout of three
parameters using the L9 orthogonal array is formed as shown in Table 5.1.
TABLE-5.1 EXPERIMENTAL LAYOUT USING AN L-9 ORTHOGONAL ARRAY
Exp.No.
A
Speed (r.p.m.)
1600
0.04
0.35
1600
0.03
0.3
1600
0.02
0.25
1300
0.04
0.25
1300
0.03
0.35
1300
0.02
0.3
1000
0.04
0.3
1000
0.03
0.25
1000
0.02
0.35
Nine experiments are conduced for the above mentioned nine sets of parameters (speed, feed
rate & depth of cut) and in each experiment 20 numbers of pieces are made and are checked with air
gauge for dimensional tolerance and for surface roughness the pieces are tested in spectro-testing lab.
The average value of dimensional tolerance and surface roughness in microns are listed in table 5.2.
193
Results
DIMENSIONAL
TOLERANCE (X)*
SURFACE
(MICRONS)
ROUGHNESS
(Y)** (MICRONS)
SPEED
(A)(R.P.M)
FEED (B)
(MM/REV)
DEPTH OF
CUT (C)
(MM)
1600
0.04
0.35
1.192263
1.6
1600
0.03
0.3
1.311
1.74
1600
0.02
0.25
1.157
1.66
1300
0.04
0.25
1.564
1.38
1300
0.03
0.35
1.72
1.7
1300
0.02
0.3
2.10862
1.33
1000
0.04
0.3
1.28565
1.43
8
9
1000
1000
0.03
0.02
0.25
0.35
1.3048
1.85
1.75
1.35
* These Dimensional variations were obtained by Air Gauge in the company premises itself
using 20 samples per reading.
** These Surface roughness values were obtained using the RA values obtained from the Lab
Reports of Spectro Test Labs which is an ISO-9001:2000 and ISO-14001:2004 certified
organisation and works in accordance to Protocol: IS-3073-1967. A sample of 3 pieces per
reading was supplied to the aforesaid lab for testing purpose.
ANALYSIS OF RESULTS
In the Taguchi method the results of the experiments are analyzed to achieve one or more of
the following three objectives:
a) To establish the best or the optimum condition for a product or a process.
b) To estimate the contribution of individual factors.
c) To estimate the response under the optimum conditions.
Studying the main effects of each of the factors identifies the optimum condition. The process
involves minor arithmetic manipulation of the numerical result and usually can be done with the help
of a simple calculator. The main effects indicate the general trend of the influence of the factors.
Knowing the characteristic i.e. whether a higher or lower value produces the preferred result, the
levels of the factors, which are expected to produce the best results, can be predicted.
The knowledge of the contribution of individual factors is the key to deciding the nature of
the control to be established on a production process. The analysis of variance (ANOVA) is the
statistical treatment most commonly applied to the results of the experiment to determine the percent
contribution of each factor. Study of the ANOVA table for a given analysis helps to determine which
of the factors need control and which do not.
In this study, an L9 orthogonal array with four columns and nine rows was used. This array
has eight degree of freedom and it can handle three design parameters. Each parameter is assigned to
a column, nine parameters combination being available. Therefore only nine parameters are required
to study the entire parameter space using the L9 orthogonal array.
194
2.
3.
4.
5.
6.
9.
10.
11.
12.
13.
14.
15.
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Production Technology and Management (IJPTM), Volume 1, Issue 1, 2010, pp. 13 - 31,
ISSN Print: 0976- 6383, ISSN Online: 0976 6391.
Prof. (Dr). Rachayya.R.Arakerimath and Prof (Dr).V.A.Raikar, Productivity Improvement
by Sa and Ga Based Multi-Objective Optimization in CNC Machining International Journal
of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 1, 2012, pp. 100 - 109,
ISSN Print: 0976 6340, ISSN Online: 0976 6359.
Ajeet Kumar Rai, Shalini Yadav, Richa Dubey and Vivek Sachan, Application of Taguchi
Method in the Optimization of Boring Parameters, International Journal of Advanced
Research in Engineering & Technology (IJARET), Volume 4, Issue 4, 2013, pp. 191 - 199,
ISSN Print: 0976-6480, ISSN Online: 0976-6499.
Prabhat Kumar Sinha, Vijay Kumar, Piyush Pandey and Manas Tiwari, Static Analysis of
Thin Beams by Interpolation Method Approach To Matlab, International Journal of
Mechanical Engineering & Technology (IJMET), Volume 4, Issue 4, 2013, pp. 254 - 271,
ISSN Print: 0976 6340, ISSN Online: 0976 6359.
196