Manufacturing Engineering

IML401E
Homework #2
Case #2
GRUP 5
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APPLICATION OF TAGUCHI AND ANOVA METHODSIN

SELECTION OF PROCESS PARAMETERSFOR SURFACE
ROUGHNESS IN PRECISION TURNING OF TITANIUM
ADVANCES IN MANUFACTURING SCIENCE AND TECHNOLOGY Vol. 38, No. 2,
2014 DOI:10.2478/amst-2014-0008

1. INTRODUCTION

The objective of this study is the selection of cutting data (such as nc, f,
ap) and tool materials (PCD,ceramic, CBN and carbide cutting tools) in order
to improve the surface roughness in precision turningoperation of parts made
of pure titanium (GRADE 2). Machining parameters and tool materials
areconsidered as input parameters. The surface roughness is selected as the
process output measure ofperformance. A Taguchi approach is employed to
gather experimental data. Then, based on signal-tonoise(S/N) ratio, the best
sets of cutting parameters and tool materials specifications have been
determined.

2. Taguchi experiment: design and analysis

The Taguchi method uses a special design of orthogonal arrays to study the entire
parameter space with only a small number of experiments.Taguchi methods have
been widely utilized in engineering analysis and consist of a plan of experiments
with the objective of acquiring data in a controlled way, in order to obtain
information about the behavior of a given process The greatest advantage of this
method is saving of effort in conducting experiments; saving experimental time,
reducing costs, and discovering significant factors quickly.

3. Machining conditions and experimental design

The material used in this work was a pure titanium, Ti (Grade 2).The test sample was
prepared in the form of shaft, 28 mm diameter with separated parts.Turning tests
were carried out on a Masterturn 400 with different cutting speeds, feed, depth of
cut and cutting tools; in accordance with the Taguchiexperiment design. The lathe
equipped with variable spindle speed from 1 to 3000 rpm, and a 7.5 kW motor drive
was used for the tests.

4. Results and analysis of experiment

In the Taguchi method, the term signal represents the desirable value(mean)
for the output characteristics and the term noise represents theundesirable
value for the output characteristics. Taguchi uses the S/N ratio tomeasure the
quality characteristic deviating from the desired value. There areseveral S/N
ratios available, depending on the type of characteristics: lower isbetter (LB),
nominal is the best (NB), or higher is better (HB) [13]. Smaller isbetter S/N ratio
was used in this study, because lower parameters of surfaceroughness (Ra and
Rz) were desirable.Quality characteristics of the smaller is better is calculated
according to the following equation:
= 10 log10 [(1/n) S(yi2)] (1)

where n is the number of measurements in a trial/row and yi is the measured value

in a run/row. The S/N ratio values were listed in Table 6 for parameters of surface

roughness (Sa and Sz). Table 7 shows the response table for S/N ratio of Sa for
smaller is better obtained for different parameter levels.

From the S/N ratio analysis (Fig. 2 and 3) the optimal machining conditions
were 100 m/min cutting speed (level 2), 0.038 mm/rev feed rate (level 1),0.1 mm
depth of cut (level 3), PCD cutting tools (level 1) for parameter Sa.150 m/min cutting
speed (level 4), 0.048 mm/rev feed rate (level 2), 0.125 mm depth of cut (level 4),
PCD cutting tools (level 1) for parameter Sz. respectively.

5. Conclusion
Surface roughness is an important measure of performance in machining
operations. This study investigates the overall effects of turning parameters (cutting
speed. depth of cut and feed rate) and kind of cutting tool geometry specifications
on surface roughness of Ti (Grade 2) parts. To model the process. Taguchi method
has been employed for experimental tests. surface methodolog was used to
determine optimal values of input parameters to achieve the minimum surface
roughness; as the process output characteristics.
The optimal machining conditions were 100 m/min cutting speed (level 2), 0.038
mm/rev feed rate(level 1), 0.1 mm depth of cut (level 3), PCD cutting tools (level 1)
for parameter Sa. 150 m/min cutting speed (level 4), 0.048 mm/rev feed rate
(level2), 0.125 mm depth of cut (level 4), PCD cutting tools (level 1) for parameter
Sz, respectively.
In addition the effects (in percent) of each these parameters on the output have
been determined. It is shown that the kind of the cutting tool has the most
significant effect on the surface roughness