Final Thesis - 1 PDF

PROJECT REPORT
ON
EXPERIMENTAL ANALYSIS OF BORING OPERATION FOR STUDYING PROCESS

PARAMETERS
Submitted to
SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT

NAGPUR (M.S.)
in partial fulfilment of the Bachelor’s Degree in
MECHANICAL ENGINEERING
Submitted by
Mr. ANURAG SARDA (34) Mr. ARYABHAT DARNAL (36)
Mr. CHAITANYA SAKHARE (39) Mr. PRASAD RATHI (61)
Mr. RHITURAJ BHALERAO (70)
Under the Guidance of
Prof. PRANJALI S DEOLE

Guide
2014-2015
DEPARTMENT OF MECHANICAL ENGINEERING
NAGPUR – 440013
PROJECT REPORT
ON

PARAMETERS
Submitted to

NAGPUR (M.S.)
in partial fulfilment of the Bachelor’s Degree in
MECHANICAL ENGINEERING
Submitted by
Under the Guidance of
Guide
2014-2015
DEPARTMENT OF MECHANICAL ENGINEERING
NAGPUR – 440013
NAGPUR – 440013
CERTIFICATE
This is to certify that this is a bonafide record of project work entitled

PARAMETERS
Carried out by
of the Final Year B.E. MECHANICAL ENGINEERING
during the academic year 2014-2015 in partial fulfilment
of requirement for the award of Degree of
BACHELOR OF ENGINEERING
offered by the RASHTRASANT TUKADOJI MAHARAJ NAGPUR UNIVERSITY, NAGPUR

(Maharashtra)

Guide
Dr. K. N. Agrawal Dr. Rajesh S. Pande
H. O. D. Principal
ACKNOWLEDGEMENT
Apart from the efforts of the team, the success of any project depends largely on the
encouragement and guidelines of many others. We take this opportunity to express our gratitude
to the people who have been instrumental in the successful completion of this Project.
Firstly we would like to thank PROF. PRANJALI S DEOLE, Project Guide, Dr. K. N.
AGRAWAL, HOD, Mechanical Engineering Department and Dr. Rajesh S. Pande,
Principal, SRCOEM. We can’t say thank you enough for their tremendous support and help.
We feel motivated and encouraged every time we meet them. Without their encouragement and
guidance this report would not have materialized.
We would express our heartfelt gratitude to Mr. Prakash Chokhandre, Lab Assistant,
RPS Lab for standing with us on each step we took in our project and Mr. Vijay Tayade,
Workshop Assistant for always getting us out of the difficulties which we faced in the
workshop.
We would express our special gratitude to Prof. Dr. Gajendra R Potey, Workshop
Superintendent, Prof. Prashant B Shiwalkar, Assistant Professor, Mechanical Engineering
Department, Prof. Roshan U Patil, Assistant Professor, Mechanical Engineering
Department, Mr. Amit Zanwar, Industrialist, Nagpur and Mr. Prashant Kadam,
Businessman, Nagpur for helping us at those moments when we were stuck up in our work and
were heading no way.
We feel indebted to Department of Chemistry, SRCOEM; Mr. Jamdar, M/s Kinetic

Gears, Nagpur and Mr. Bishnu Dutt Darnal & his team, M/s Mahindra & Mahindra Ltd,
Nagpur, Mr. Siddharth A Singh, student, RCOEM for providing us access to their
equipments to enable us to execute very important parts of our project.
The guidance and support received from all the faculty members of Mechanical
Department and Workshop of SRCOEM who contributed to this project was vital for the success
of the report. We are grateful for their constant support and help.
We also express our deepest gratitude to all the Suppliers who provided us with all the
material which we required to carry out our project work.
Lastly, we thank all our friends, family members and all others who helped us directly or
indirectly in our project. Without your constant support and motivation, it would have been
difficult for us to do our project.
Projectees
ANURAG SARDA
ARYABHAT DARNAL
CHAITANYA SAKHARE
PRASAD RATHI
RHITURAJ BHALERAO
DECLARATION
We the students of final year Mechanical engineering solemnly declare that, the report of the
Project work entitled EXPERIMENTAL ANALYSIS OF BORING OPERATION FOR
STUDYING PROCESS PARAMETERS is based on our own work carried out during the
course of study under the supervision of PROF. PRANJALI S DEOLE. We assert that the
statements made and conclusions drawn are an outcome of our research work. We further certify
that
i. The work contained in the Project is original and has been done by us under the
general supervision of our Guide.
ii. We have not reproduced this report or its any appreciable part from any other
literature in contravention of the academic thesis.
iii. We have conformed to the norms and guidelines given in the concerned Ordinance of
the SRCOEM, Nagpur.
Date:
Submitted by,

ABSTRACT
Boring operation is one of the most common operations done in any manufacturing industry. A
concern in the manufacturing industry today is the vibrations induced by metal cutting, e.g.
turning, milling and boring operations. Turning operations, and especially boring operations, are
associated with serious vibration-related problems. In machining, Boring is the process of
enlarging a hole that has already been drilled (or cast), by means of a single-point cutting tool.
Boring is used to achieve greater accuracy of the diameter of a hole.
In our Research Project, we are analyzing and studying the various process parameters involved
in the boring operation performed on CNC machine. The various parameters are spindle speed,
feed, depth of cut and work piece material. We have acquired the sound signal and vibration
signals using microphone and accelerometer via data acquisition system on computer during the
boring operation. The main aim of our research is to find out which process parameters
contribute the highest towards surface roughness of the work piece and the wear of the insert on
the boring bar. We are following Taguchi method for varying each parameter for each
experimental run. We have used L9 orthogonal array for the four process parameter. We have
used EN8, EN9 and EN 31 material for our experiment because of their wide applications.
INDEX
DESCRIPTION PAGE NO
List of Figures i
List of Tables iii
List of Graphs iv
1. Introduction 1
1.1 Types Of Boring Operation 3
1.2 Numeric Control (NC) Machines 4
1.3 CNC Lathe Machine 5
1.4 Operations Performed On CNC Machines 5
1.4.1 External Operations 5
1.4.2 Internal Operations 8
2. Literature Review 10
3.Aim And Objective 33
3.1 Approach 34
4. Methodology 35
4.1 Design Of Experiment 36
4.2 Introduction To Taguchi Method 39
4.2.1 Steps In Taguchi Methodology 42
4.3 Selection Of An Orthogonal Array 44
4.3.1 Selection Of Input And Output Factors 44
4.3.2 Selection Of Levels Of Factors 45
4.4 ANOVA Terms, Notations And Development 51
5. Experimental Set Up 57
5.1 CNC Machine 58
5.2 Tools Used In CNC Lathe Machine 59
5.3 CNC Programming 62
5.4 CNC Program For Boring Used For Experimentation 66
5.5 Work Pieces 67
5.5.1 Cross Reference Of Standards For Equivalent Grades Of Steel 69
5.6 Sensors 73
5.7 Sensor Mounting 74
5.8 Data Acquisition System (DAQ) 76
5.9 Surface Measurement Tester 77
5.10 Analytical Balance 79
5.11 Labview & Minitab Software 80
6. Observations 85
7. Calculations 89
7.1 ANOVA Calculations For First Run 90
7.1.1 ANOVA Calculations For Surface Roughness 90
7.1.2 ANOVA Calculations For Sound Signal (Pressure) 95
7.1.3 ANOVA Calculations For Vibration Signal (Pressure) 99
7.1.4 ANOVA Calculations For Vibration Signal (Frequency) 103
7.2 ANOVA Calculations For Second Run 107
7.2.1 ANOVA Calculations For Surface Roughness 107
7.2.2 ANOVA Calculations For Sound Signal 112
7.2.3 ANOVA Calculations For Vibration Signal (Pressure) 116
7.2.4 ANOVA Calculations For Vibration Signal (Frequency) 120
7.3 ANOVA Calculations For Tool Wear 124
8. Result and Discussion 128
8.1 Comparison Of Result Of 2 Runs 129
8.2 Discussion 130
9. Conclusion and Future Scope 131
10. References 133
Annexure 137
1: Project Group Members 138
2: Project Group Photo 139
List of Figures
Figure Description
Figure 1.1 Boring operation
Figure 1.2 Types of Boring Operation
Figure 1.3 Turning operation
Figure 1.4 Facing operation
Figure 1.5 Grooving operation
Figure 1.6 Cut-off parting operation
Figure 1.7 Thread cutting operation
Figure 1.8 Drilling operation
Figure 1.10 Reaming operation
Figure 1.11 Tapping operation
Figure 4.1 P-Diagram for STATIC Problems
Figure 4.2 P-Diagram for DYNAMIC Problems
Figure 4.3 Steps 1, 2 for generating orthogonal array
Figure 4.4 Steps 3, 4 for generating orthogonal array
Figure 5.1 CNC Machine
Figure 5.2 Turning Tool
Figure 5.3 Boring Tool
Figure 5.4 Inserts
Figure 5.5 Work piece
Figure 5.6 Work piece
Figure 5.7 ICP Accelerometer
Figure 5.8 G.R.A.S Microphone
Figure 5.9 Fibre glass tape
Figure 5.10 Sensor Mountings on Boring Bar
Figure 5.11 DAQ System
Figure 5.12 Terminologies
SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | i

Figure 5.13 Surface Roughness Tester - MITUTOYO
SJ201-P
Figure 5.14 Working principle
Figure 5.15 Terminologies
Figure 5.16 Analytical balance
Figure 5.17 Virtual Interface and Block Diagram
(LABVIEW Software) for acquisition of sound
signals through microphone
Figure 5.18 Virtual Interface and Block Diagram
(LABVIEW Software) for acquisition of
vibration signals through accelerometer
Figure 5.19 Acquisition of sound signals through
microphone in LABVIEW Software
Figure 5.20 Recorded Sound Log data in Excel Sheet
Figure 5.21 Acquisition of vibration signals through
accelerometer in LABVIEW Software
Figure 5.22 Recorded Vibration Log data and Frequency in
Excel Sheet
Figure 5.23 Complete Experimental Setup
SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | ii

List of Tables
Table Description
Table 4.1 Levels of Experiment
Table 4.2 Allotment priority
Table 4.3 L9 Orthogonal Array
Table 5.1 Notations
Table 5.2 Chemical Composition of EN 8
Table 5.5(a-i) Cross Reference of Standards for Equivalent
Grades Of Steel
Table 5.6 Specifications
Table 6.1 Observation table for first run
Table 6.2 Observation table for second run
Table 6.3 Observation table for tool wear
Table 7.1.1 ANOVA table for Surface Roughness
Table 7.1.2 ANOVA table for Sound signal
Table 7.1.3 ANOVA table for Vibration Signal
(Pressure)
(Frequency)
Table 7.2.2 ANOVA table for Sound Signal
(Frequency)
Table 7.3 ANOVA table for Tool Wear
Table 8.1 Comparison Table
SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | iii

List of Graphs
Graph Description
Graph 7.1 Residual plots for Surface Roughness
Graph 7.2 Interaction plots for Surface Roughness
Graph 7.3 Main effect plots for Surface Roughness
Graph 7.4 Main effect plots for SN ratios
Graph 7.5 Residual plots for Sound Signal
Graph 7.6 Interaction plots for Sound Signal
Graph 7.7 Main effect plots for Sound Signal
Graph 7.8 Residual plots for Vibration Signal
(Pressure)
Graph 7.9 Interaction plots for Vibration Signal
(Pressure)
Graph 7.10 Main effect plots for Vibration Signal
(Pressure)
(Frequency)
(Frequency)
Graph 7.13 Main effect plots for Vibration Signal
(Frequency)
Graph 7.16 Main Effect plot for Surface Roughness
Graph 7.20 Main Effect plot for Sound Signal
(Pressure)
(Pressure)
Graph 7.23 Main Effect plot for Vibration Signal
(Pressure)
(frequency)
(frequency)
Graph 7.26 Main Effect plot for Vibration Signal
(frequency)
Graph 7.27 Residual plots for Tool Wear
Graph 7.28 Interaction plots for Tool Wear
Graph 7.29 Main Effect plot for Tool Wear
SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | iv

CHAPTER 1:
INTRODUCTION
SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 1

CHAPTER 1 INTRODUCTION
Boring is an operation used to enlarge and finish the surface of a cylindrical hole by the action of
a rotating boring bar (cutting tool) or by the action of a stationary tool pressed (fed) against the
surface as the part is rotated defined as a precision machining process for generating internal
cylindrical forms by removing metal with single-point or multiple-edge tools. Boring operations
involving rotating tools are applied to machine holes that have been made through methods such
as pre-machining, casting, forging, extrusion, flame-cutting, etc. Roughing operations are
performed to open up the existing hole to within large tolerances and usually to prepare for
finishing, which makes the hole to within tolerance and surface finish limits. Typically, boring
operations are performed in machining centres and vertical boring machines. The rotating tool is
fed axially through the hole. Most holes are through-holes, often in prismatic or round
components. External boring operations can be accomplished using specially adapted boring
tools. Because of the limitations on tooling design imposed by the fact that the work piece
mostly surrounds the tool, boring is inherently somewhat more challenging than turning, in terms
of decreased tool holding rigidity, increased clearance angle requirements (limiting the amount
of support that can be given to the cutting edge), and difficulty of inspection of the resulting
surface (size, form, surface roughness). These are the reasons why boring is viewed as an area of
machining practice in its own right, separate from turning, with its own tips, tricks, challenges,
and body of expertise, despite the fact that they are in some ways identical.

1.1 TYPES OF BORING OPERATION
Boring operations are divided into following types:
1. Single-edge cuts
2. Multi-edge cuts
3. Step-boring
4. Reaming
Figure 1.2 – Types of Boring operation
Single-edge boring is usually applied for finishing operations and for roughing and finishing in
materials where chip control is demanding. A single-edge boring tool may also be a solution
when machine power is a limiting factor.
Multi-edge boring, involving two or three cutting edges, is employed for roughing operations
where metal removal rate is the first priority. High productivity levels can be maintained by
allowing two or three inserts, set at the same axial height, each to machine at the recommended
feed per tooth. This results in a high feed per revolution through the hole.
Step-boring is performed in roughing by a boring tool having the inserts set at different axial
heights and diameters. This also improves chip control in demanding materials with the different
depths of cut of up to 1.0 or 1.5 times the cutting edge length. Depths of cut of 0.5 times the
cutting edge length can be divided into smaller cuts, providing smaller chips.

Reaming is a light finishing operation performed with a multi edge tool giving high-precision
holes. Very good surface finish and close dimensional tolerance are achieved at high penetration
rates. The pre-machined hole needs to be within close limits and the radial depth of cut is small.
1.2 NUMERIC CONTROL (NC) MACHINES
Numerical control (NC) is the automation of machine tools that are operated by precisely
programmed commands encoded on a storage medium, as opposed to controlled manually via
hand wheels or levers, or mechanically automated via cams alone. Most NC today is computer
numerical control (CNC), in which computers play an integral part of the control.
In modern CNC systems, end-to-end component design is highly automated using computer-
aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs
produce a computer file that is interpreted to extract the commands needed to operate a particular
machine via a post processor, and then loaded into the CNC machines for production. Since any
particular component might require the use of a number of different tools – drills, saws, etc.,
modern machines often combine multiple tools into a single "cell". In other installations, a
number of different machines are used with an external controller and human or robotic
operators that move the component from machine to machine. In either case, the series of steps
needed to produce any part is highly automated and produces a part that closely matches the
original CAD design.
Motion is controlled along multiple axes, normally at least two (X and Y), [1] and a tool spindle
that moves in the Z (depth). The position of the tool is driven by motors through a series of step-
down gears in order to provide highly accurate movements, or in modern designs, direct-
drive stepper motor or servo motors. Open-loop control works as long as the forces are kept
small enough and speeds are not too great. On commercial metalworking machines closed loop
controls are standard and required in order to provide the accuracy, speed, and repeatability
demanded.
As the controller hardware evolved, the mills themselves also evolved. One change has been to
enclose the entire mechanism in a large box as a safety measure, often with additional safety
interlocks to ensure the operator is far enough from the working piece for safe operation. Most
new CNC systems built today are completely electronically controlled.

CNC-like systems are now used for any process that can be described as a series of movements
and operations. These include laser cutting, welding, friction stir welding, ultrasonic welding,
flame and plasma cutting, bending, spinning, hole-punching, pinning, gluing, fabric cutting,
sewing, tape and fiber placement, routing, picking and placing (PnP), and sawing.
1.3 CNC LATHE MACHINE
Lathes are machines that cut work pieces while they are rotated. CNC lathes are able to make
fast, precision cuts, generally using indexable tools and drills. They are particularly effective for
complicated programs to make parts that would be more difficult to make on manual lathes.
CNC lathes have similar control specifications to CNC mills and can often read G-code as well
as the manufacturer's proprietary programming language. CNC lathes generally have 2 axes (X
and Z), but newer models have more axes allowing for more advanced jobs to be machined.
1.4 OPERATIONS PERFORMED ON CNC MACHINES
1.4.1 External operations
1. Turning:- A single-point turning tool moves axially, along the side of the work piece,
removing material to form different features, including steps, tapers, chamfers, and
contours. These features are typically machined at a small radial depth of cut and
multiple passes are made until the end diameter is reached.
Fig 1.3 Turning operation

2. Facing:- A single-point turning tool moves radially, along the end of the work piece,
removing a thin layer of material to provide a smooth flat surface. The depth of the face,
typically very small, may be machined in a single pass or may be reached by machining
at a smaller axial depth of cut and making multiple passes.
Fig 1.4 Facing operation
3. Grooving:- A single-point turning tool moves radially, into the side of the work piece,
cutting a groove equal in width to the cutting tool. Multiple cuts can be made to form
grooves larger than the tool width and special form tools can be used to create grooves of
varying geometries.
Fig 1.5 Grooving operation

4. Cut off (parting):- Similar to grooving, a single-point cut-off tool moves radially, into
the side of the work piece, and continues until the centre or inner diameter of the work
piece is reached, thus parting or cutting off a section of the work piece.
Fig 1.6 Cut-off parting operation
5. Thread cutting:- A single-point threading tool, typically with a 60 degree pointed nose,
moves axially, along the side of the work piece, cutting threads into the outer surface.
The threads can be cut to a specified length and pitch and may require multiple passes to
be formed.
Fig 1.7 Thread cutting operation

1.4.2 Internal operations
1. Drilling:- A drill enters the work piece axially through the end and cuts a hole with a
diameter equal to that of the tool.
Fig 1.8 Drilling operation
2. Boring:- A boring tool enters the work piece axially and cuts along an internal surface to
form different features, such as steps, tapers, chamfers, and contours. The boring tool is a
single-point cutting tool, which can be set to cut the desired diameter by using an
adjustable boring head. Boring is commonly performed after drilling a hole in order to
enlarge the diameter or obtain more precise dimensions.
Fig 1.9 Boring operation

3. Reaming:- A reamer enters the work piece axially through the end and enlarges an
existing hole to the diameter of the tool. Reaming removes a minimal amount of material
and is often performed after drilling to obtain both a more accurate diameter and a
smoother internal finish.
Fig 1.10 Reaming operation
4. Tapping: - A tap enters the work piece axially through the end and cuts internal threads
into an existing hole. The existing hole is typically drilled by the required tap drill size
that will accommodate the desired tap.
Fig 1.11 Tapping operation

CHAPTER 2:
LITERATURE
REVIEW

CHAPTER 2 LITERATURE REVIEW
The analysis made by Sandip Kanase & Vishwas Jadhav stated that impact damping had a
significant effect in improving surface finish in boring operation. In their paper a creative
approach of passive vibration damping is presented to absorb the vibrations created in boring
operation. Due to larger overhang, requires because of deep-hole drilling vibrations generated
which will affect the surface finish of the machined surface. An impact damper concept is used
to minimize the effect of vibrations and subsequently results into good surface finish. Numbers
of experiments were conducted to analyze the effect of vibration on surface finish. Boring bar of
20 mm × 20 mm cross-section and 200 mm long of WIDAX make is used. The work piece
material used for study was EN9. The boring operations were carried out on CNC turning centre
of ACE make. The work piece was mounted using a pneumatic chuck in CNC turning centre and
the clamping pressure was set as 10 bar. The machining parameters like feed, depth of cut,
clamping pressure, etc. were selected based on the manufacturers recommendations and were
kept constant for all the samples used. Only the cutting speed, passive damper position on boring
bar and overhang length was changed. In their study an innovative method was proposed to
reduce tool chatter and enhance surface finish in boring operation. The results proved that
particle damping technique has vast potential in the reduction of tool chatter. Boring bars with
impact damping are also relatively cheaper than other damped boring bars. It was therefore
concluded that impact damping has a good effect in improving surface finish in boring operation.
[1]
M. S. H. Bhuiyan, I. A. Choudhury, and Y. Nukman published their work in July 2012 on the
Tool Condition Monitoring using Acoustic Emission and Vibration Signature in Turning. The
various sensors used to monitor tool condition usually sense the cutting tool state in terms of
electric/magnetic/optical signal by responding to the change of process dynamics during
machining. The redistribution of energy that is released from the localized sources, i.e. stress and
strain developed in machining, generates the transient elastic wave inside the work material and
cutting tool known as, the acoustic emission (AE). The changes in cutting condition produce
vibration in the system and thus affect the cutting tool state. Therefore, investigating the tool
condition using the acoustic emission and vibration signature would be an effective approach. In
this study, an acoustic emission sensor and a triaxial accelerometer have been placed on the

shank of the cutting tool holder to monitor the cutting tool condition in machining. The acoustic
emission sensor assesses the internal change whereas the vibration sensor demonstrates the
external effect on tool state. RMS signals and Fast Fourier transform (FFT) are used to illustrate
the output of sensors by them. For this particular investigation, the experiment shows that the AE
and vibration components can effectively respond to the tool state and the different occurrences
in turning. The AERMS represents the rate of tool wear progression whereas the feed directional
vibration component (VX) corresponds to the surface roughness in turning. The vibration
components, Vx, Vy and Vz change with feed rate, depth of cut and cutting speed respectively.
The amplitude of vibration components decreases with the increase of cutting speed, and
increases with the increase of feed rate and depth of cut; which support the nature of tool wear in
turning. Even though the maximum intensity of signal frequency fluctuates at the different state
of tool wear and at different cutting conditions, the frequency of vibration components always
lies within a band of 0 Hz – 41 kHz, and the AE varies between 56 kHz and 581 kHz. [2]
Gaurav Vohra, Palwinder Singh, Harsimran Singh Sodhi states the importance of work
optimization of the boring parameters for a CNC turning centre such as speed, feed rate and
depth of cut is done for aluminium to achieve the highest possible Material removal rate and at
the same time minimum surface roughness by using the Taguchi method. Further the results are
signified by using the analysis of variances and optimised solution is suggested for the process.
A polynomial network using a self-organizing adaptive modelling method was applied to
construct the relationships between the feature of the surface image and the actual surface
roughness under a variation of turning operations for predicting surface roughness with
reasonable accuracy if the image of the turned surface and turning conditions were given. The
influence of cutting condition (cutting velocity and feed) and cutting time on turning metal
matrix composites was studied. He used taguchi method and (ANOVA) to do the analysis. The
objective of the study was to stabiles correlation between cutting velocity feed and cutting time
with tools wear the power required to perform the machining operation and the surface
roughness in work. This method is a systematic application of designing and analysis of
experiments. Through this method, parameters affecting experiments can be investigated as
controlling and non controlling (noise factors). Secondly, this method can be used to investigate
the parameters for three levels. After experimentation work results were analysed and figures
were plotted between various parameters. ANOVA analysis were carried out to study the average

effect of S/N ratio and average value on various parameters that were selected and optimization
of work piece material was selected. Surface Roughness (Ra) and Metal Removal Rate (M.R.R)
was calculated. The analysis of variance was conducted to study the influence of spindle speed
and depth of cut on surface roughness and to test the statistical significance of differences
between the means for surface roughness for different levels of spindle speed and depth of cut
Firstly data has been checked for its normality by probability plot. By taking cutting Speed of
108.68 m/min ,feed 0.10mm/rev and Depth of cut 1.035 mm, we will achieve material removal
rate of 70.28 (mm³/sec), and we will achieve surface roughness of 1.7979 μm. So the composite
desirability will become 100%. [3]
Krishankant, Jatin Taneja, Mohit Bector, Rajesh Kumar’s study stated the Application of
Taguchi Method for Optimizing Turning Process by the effects of Machining Parameters to
improve the quality of manufactured goods, and engineering development of designs for
studying variation. They used the E24 steel as the work piece material for carrying out the
turning process. The bars used were of diameter 44mm and length 60mm. There were three
machining parameters i.e. Spindle speed, Feed rate, Depth of cut. Different experiments were
done by varying one parameter and keeping other two fixed so maximum value of each
parameter was obtained. Taguchi orthogonal array was designed with three levels of turning
parameters with the help of software Minitab 15. L9 (33) orthogonal array was generated using
the Taguchi design. Taguchi method stresses the importance of studying the response variation
using the signal–to–noise (S/N) ratio, resulting in minimization of quality characteristic variation
due to uncontrollable parameter. The metal removal rate was considered as the quality
characteristic with the concept of "the larger-the-better". The S/N ratio for the larger-the-better
where n is the number of measurements in a trial/row. The best value for the optimization was
found to be spindle speed of 340rpm, 0.418mm/rev of feed rate and 1mm of depth of cut. The
main effects plot for S/N ratio for the 3 process parameters, Spindle speed, feed and the depth of
cut were studied with the help of the Minitab software. Thus the turning of EN24 steel was done
in order to optimize the turning process parameters for maximizing the material removal rate. [4]
Show-Shyan Lin, Ming-Tsan Chuang and Jeong-Lian Wen investigated the optimization of
computer numerical control (CNC) boring operation parameters for aluminium alloy 6061T6
using the Taguchi method and grey relational analysis (GRA) method. He used the L9 orthogonal

array of Taguchi method and performed nine experimental runs. The experimental control
factors in this study are cutting speed (m/min), Feed rate (mm/rev), Cut Depth (mm) and also the
levels used were three. The output or quality targets selected were the surface properties of
roughness average and roughness maximum as well as the roundness. An optimal parameter
combination of the CNC boring operation was obtained via GRA. The effect of each controllable
factor on individual quality characteristics is analyzed by using the grey relational grade matrix.
From this study they concluded that the feed rate has the most influence on the roughness
average and roughness maximum, and the cutting speed is the most influential factor to the
roundness. Additionally, the analysis of variance (ANOVA) was also applied to identify the most
significant factor; the feed rate is the most significant controlled factor for the CNC boring
operations according to the weighted sum grade of the roughness average, roughness maximum
and roundness. [5]
The experimental analysis made by A.M.Badadhe, L.G.Navale confirms the importance of

Taguchi parameter design technique for optimizing machining parameters. In their work an
attempt was made to select the combination of optimum cutting parameters which will result in
better surface finish. Machining with optimum cutting parameters will result in minimum
machining time and hence increasing the productivity. Four parameters viz. spindle speed, feed,
depth of cut and length to diameter (L/D) ratio of boring bar has been taken as control factors.
The cutting trials were performed as per Taguchi 3 4 (L9) orthogonal array method to deal with
the response from multi-variables. AISI 1041 (EN9) carbon steel cylinders with 100 mm outside
diameter, 85 mm inside diameter and 75 mm length were used as work piece material which was
cut by using standard boring bars of various sizes each having a tungsten carbide inserts of same
insert radius. The Analysis of Variance (ANOVA) was carried out to find the significant factors
and their individual contribution in the response function i.e. surface roughness. Four parameters
i.e. spindle speed, feed, depth of cut and length to diameter (L/D) ratio of boring bar was taken as
control factors. The experimentation was carried out with the help of an ordinary lathe machine.
Their study presented an efficient method for determining the optimal turning operation
parameters for surface roughness under varying conditions through the use of the Taguchi
parameter design process. The study showed that the control factors had varying effects on the
response variable. The use of the Taguchi parameter design technique was considered successful
as an efficient method to optimize machining parameters in a boring operation which will tend to

reduce the machining time and enhance the productivity. Four parameters i.e. spindle speed,
feed, depth of cut and length to diameter (L/D) ratio of boring bar has been taken as control
factors. [6]
Harsimran Singh Sodhi, Dhiraj Prakash Dhiman, Ramesh Kumar Gupta and Raminder Singh
Bhatia’s study in 2012 proved that speed is the prime factor for improving the surface finish. In
their paper Taguchi parameter optimization methodology was applied to optimize cutting
parameters in boring. The boring parameters evaluated were cutting speed, feed rate, and depth
of cut, of the material each at three levels. The results of analysis show that feed rate and cutting
speeds have present significant contribution on the surface roughness and depth of cut have less
significant contribution on the surface roughness. The study has been performed on mild steel
hollow bars having dimensions of 42 mm diameter and 70 mm length, on CNC boring machine
by using carbide tool of 0.6 mm nose radius. The best value for the Surface Roughness was at
Speed 120m/min, feed rate 0.10 rev/min and Depth of cut 1.0 mm. For solving machining
optimization problems, various conventional techniques had been used so far, but they are not
robust and have problems when applied to the Boring process, which involves a number of
variables and constraints. To overcome the above problems, Taguchi method was used in this
work. Since Taguchi method is experimental method it is realistic in nature. For the Taguchi
matrix three categories of S/N ratios were used. The three categories were: Nominal–is–best,
lower–the –better and higher–the–better. Experiments were performed on the combinations of
variables. According to this study the prime factor affecting surface finish is speed. [7]
Houng Sun, S.M Wu and K.F Eman studied the feasibility of single pass boring operation in
1983. They developed a model for spindle deflection for boring operation. The diametric errors
in conventional, by pass and newly proposed method were compared. The single pass boring
process provides a significant increase in productivity while maintaining the required
dimensional accuracy and surface finish. They used the conventional full factorial statistical
method having 2 levels of the experiment and 4 factors. The 4 factors were spindle speed m/min,
in feed rate mm/rev, overhang length mm and depth of cut mm. They proved that the spindle
deflection and its 90% confidence interval can be used to design/predict the productivity and
quality of the process. The optimal single pass boring process which has been proposed based on
the model, is about 15.5% more efficient than the conventional multi pass boring process. To

achieve a desired diametric tolerance and surface quality, the single pass boring process must be
controlled by properly changing the in feed rate. For work hardening materials, the single pass
boring process may only be the feasible choice. [8]
An experimental study was carried out by D.V.V. Krishan Prasad to find out the Influence of
Cutting Parameters on Turning Process Using ANOVA Analysis in the year 2013. In a turning
process surface roughness depend on machining parameters and tool geometry. In his work
considering three machining parameters and two tool geometrical parameters 243 experiments
were conducted for full factorial design. Using ANOVA analysis the influence of these
parameters on surface roughness was studied. The study aimed at finding the optimum
parameters in order to get the minimum surface roughness and to analyze the effect of machining
parameters and rake angles on the surface finish. The Turning operation was carried out at 3
levels of the back rake, side rake; speed feed and depth of cut. In this work mild steel was
selected as the specimen, since it is mostly used structural steel. From the experimentation it was
observed that minimum surface roughness was obtained at a speed of 550 rpm, feed of 0.1
mm/rev, depth of cut of 1mm, side rake angle of 18º and back rake angle of 14º the surface finish
is 1.465μm. It was also observed that feed was the significant parameter influencing surface
roughness and side rake angle was having very less effect on surface roughness. [9]
An online PDF lecture titled General full factorial design with k factors of Hongwei Zhang was
made to explain the Full Factorial Method. He firstly explained the basic model. Then the
analysis of the model was done. Nextly, the method was explained using Case Study with
multiple parameters and observation table and graphs were plotted Apart from it Observation
method was explained using an example. Ranking Method and Range Methods were also
explained individually in brief. [10]
Fundamentals of Design of Experiment, an e-book penned by V.K.Gupta and Rajendar Parsad to

explain Design of Experiment. Three basic techniques fundamental to designing an experiment
are replication, local control (blocking), and randomization. Whereas the first two help to
increase precision in the experiment, the last one is used to decrease bias. These techniques were
discussed briefly. It was explained that the data generated through designed experiments exhibit
a lot of variability. Even experimental units (plots) subjected to same treatment give rise to

different observations thus creating variability. The statistical methodologies, in particular the
theory of linear estimation, enables us to partition this variability into two major components.
The first major component comprises of that part of the total variability to which we can assign
causes or reasons while the second component comprises of that part of the total variability to
which we cannot assign any cause or reason. This variability arises because of some factors
unidentified as a source of variation. Howsoever careful planning is made for the
experimentation, this component is always present and is known as experimental error. The
observations obtained from experimental units identically treated are useful for the estimation of
this experimental error. Ideally one should select a design that will give experimental error as
small as possible. Analysis of covariance is an analytical procedure and is very effective in
controlling the experimental error although it has nothing to do with the designing of the
experiment. The analysis of variance technique that essentially consists of partitioning the total
variation in an experiment into components ascribable to different sources of variation due to the
controlled factors and error. The variability in the experimental material enables us to form the
blocks supposed to comprise of experimental units that are homogeneous. The experimental
error can be controlled in two ways. One way of controlling the error is through the choice of an
appropriate design by controlling the variability among the experimental units. The other way is
through sound analytical techniques. There is some variability present in the data that has not
been taken care of or could not be taken care of through the designing of an experiment. Such
type of variability can be controlled at the time of analysis of data. The entire concept was
explained using examples. [11]
The study carried out by T.Alwarsamy, S.Vetrivel and S. Nadarajan was done to make
Theoretical Cutting Force Prediction and Analysis of Boring Process Using Mathcad. It was
done in 2011. Boring is a process in which pre-drilled holes or holes in cast, forged or extruded
components are enlarged or finished with a cutting tool mounted on a boring bar. The process is
mostly used in applications where close dimensional tolerances and good surface finish are
required. In this research work based on the theoretical cutting force model, values of force
components have been obtained by using the combination of work piece and tool signature. The
cutting forces are theoretically resolved in the tangential force (Ft), feed force (Ff), radial force
(Fr) directions. The study of cutting forces of boring process is therefore a prerequisite for
selecting appropriate cutting conditions. A predictive cutting force model was been developed

and influence of cutting parameters on force components had been depicted as graphs using
mathematical tool MathCAD 8 professional software. In this paper a new analytical cutting force
model was obtained from the information related to the work piece and tool signature for a
boring operation. The cutting forces are theoretically resolved in the tangential force (Ft), feed
force (Ff), radial force (Fr) directions. When the cutting force decreases with increasing in
cutting speed. In all machining concept depth of cut increases obviously increasing Cutting force
hastily, hence theoretically proved. In future the experimental values would be adopted and
would be compared with the actual results obtained. [12]
Analyses of surface roughness by turning process using Taguchi method were done by S.
Thamizhmanii, S. Saparudin, S. Hasan in 2006. The purpose of this study was focused on the
analysis of optimum cutting conditions to get lowest surface roughness in turning SCM 440 alloy
steel by Taguchi method. The experiment was designed using Taguchi method and 18
experiments were designed by this process and experiments conducted. The results were
analyzed using analysis of variance (ANOVA) method. Taguchi method had shown that the
depth of cut has significant role to play in producing lower surface roughness followed by feed.
The Cutting speed has lesser role on surface roughness from the tests. The vibrations of the
machine tool, tool chattering are the other factors which may had contributed to poor surface
roughness to the results and such factors were ignored for analyses. The results obtained by this
method are useful to other researches for similar type of study and may be eye opening for
further research on tool vibrations, cutting forces etc. It was found out that the depth of cut was
the only significant factor which contributed to the surface roughness. i.e. 14.467 % contributed
by the depth of cut on surface roughness. The second factor which contributed to surface
roughness was the feed having 9.764 %. The Validation experiment confirmed that the error
occurred was less than 1.0% between equation and actual value. It was recommended from the
results that depth of cut of 1 to 1.5 mm can be used to get lowest surface roughness. Taguchi
Method gives systematic simple approach and efficient method for the optimum operating
conditions. This research gave how to use Taguchi’s parameter design to obtain optimum
condition with lowest cost, minimum number of experiments and industrial engineers can use
this method. The research can be extended by using tool nose radius, lubricant, material
hardness, etc as parameters. [13]

A study on Tool Condition Monitoring In Various Machining Operations & Use of Acoustic
Signature Analysis was carried out by Pranjali R. Dongre, Shital S. Chiddarwar & Dr. V. S.
Deshpande in 2013. Tool wear and failure monitoring has raised quite a lot of interest among
researchers and has consequently been studied. The reason for the interest is that tool condition
monitoring is considered important for because unmanned production is possible only if there is
a method available for tool wear monitoring and tool breakage detection .Also tool wear
influences the quality of the surface finish and the dimensions of the parts that are manufactured.
Hence the economical tool life cannot be benefited from without a means for tool wear
monitoring because of variations in tool life. Today tool changes are made based on conservative
estimates of tool life which does not take into account sudden failures and at the same time leads
to an unnecessarily high number of changes because the full lifetime of tools is not taken into
account and consequently valuable production time is lost. As a consequence of the above,
automated production control is not really possible without a means for tool wear monitoring.
There are various methods that are used for tool condition monitoring but only few of these are
universally successful due to the complex nature of the machining processes. Tool wear
monitoring plays a critical role in detecting the dimensional accuracy of work piece and
guaranteeing automatic cutting process. It is essential to develop simple, reliable and effective
tool wear conditions. Developing a real time tool wear monitoring system has been an intensive
research topic for almost two decades and two main monitoring schemes exist. There are various
direct and indirect methods of tool wear monitoring that are most promising and hence are
widely used in order to monitor tool condition. This paper reviewed the tool condition
monitoring systems for various applications such as milling; drilling, turning, grinding etc. It will
also provide a comprehensive survey of the current work approaching to TCM and also proposes
new prospects for using Acoustic emissions for monitoring of tool conditions. This paper
represented a review of recent tool condition monitoring methods and use of acoustic emission
signal for tool wear monitoring. Due to the recent developments in the technology the process
capabilities are becoming more and more accurate, effective and accessible to the machine tool
user as well. The condition monitoring methods are reviewed for different machining operations
such as drilling, milling, turning, and boring etc. The major points that are highlighted were; A
system, by using sensors must be developed and implemented to translate the physical
parameters to system degradation and it should ideally be sensitive to source signal; The
condition monitoring systems should be used for decision making for a tool to avoid waste of

manufacturing resources and to improve the quality of products; Systems should be developed
for condition monitoring for varying cutting conditions; The effect on machine performance,
complexity and cost have to be taken under consideration while developing an effective tool
condition monitoring system.; Development of condition monitoring systems for machine tool
operators who are not required to know about methods such as wavelet transform, neural
networks, and signal extractions etc without the intervention of the operators is a main challenge
for the researchers. The use of Acoustic Emission signal in monitoring the condition of a cutting
tool is reviewed. It has been observed that despite AE signal being complex and stochastic in
nature it is more reliable and accurate because of its high frequency content and the use of AE
Signal is increasing day by day. The major points were; AE signals are referred as indirect
signals that are believed to be influenced by tool wear progression; Frequency level of AE signal
is higher than that of machine vibrations environmental distractions does not affect it; AE signals
are easier to extract than the other signals and are real time with high sensitivity; It is one of the
most effective methods of tool condition monitoring which does not require any modifications in
the tool or machine tool. Overall the important issue with these monitoring techniques was the
proper integration of the machining operations and use of monitoring systems to result in an
effective production system. We have highlighted a number of issues that has to be considered
while designing a proper tool condition monitoring system. A systematic approach of
experiments is needed while designing. Use of AE signals is still an area untouched in most of
the machining operations. [14]
An experimental study on Application of Taguchi methods and ANOVA in optimization of

process parameters for metal removal rate in electrochemical machining of Al/5%SiC
composites was carried out by Rama Rao. S, Padmanabhan. G. Metal matrix composites
(MMCs) are now gaining their usage in aerospace, automotive and biomedical industries because
of their inherent properties like high strength to weight ratio, low wear rate etc. To machine these
types of materials conventional machining methods are unsuitable because of high tool wear and
tooling cost. Electrochemical Machining (ECM) is one of the important non-traditional
machining processes, which is used for machining of electrically conducting, difficult-to-
machine materials and intricate profiles. In the present work LM6 Al/5%SiC composites, which
are fabricated by stir casting route, were machined by ECM process. The influence of the various
process parameters, i.e. voltage, feed rate and electrolyte concentration on the predominant

machining criteria, i.e. the metal removal rate (MRR) was studied. The settings of the process
parameters were determined by using Taguchi’s experimental design method. Orthogonal arrays
of Taguchi, the signal-to-noise (S/N) ratio, the analysis of variance (ANOVA), and regression
analyses are employed to find the optimal process parameter levels and to analyze the effect of
these parameters on metal removal rate values. Confirmation test with the optimal levels of
machining parameters was carried out in order to illustrate the effectiveness of the Taguchi
optimization method. This study had discussed an application of the Taguchi method for
investigating the effects of process parameters on the metal removal rate value in the
electrochemical machining of LM6 Al/5%SiC composites. In the ECM process, the parameters
were selected taking into consideration of manufacturer and industrial requirements. From the
analysis of the results in the ECM process using the conceptual signal-to-noise (S/N) ratio
approach, regression analysis, analysis of variance (ANOVA), and Taguchi’s optimization
method, it was concluded that Statistically designed experiments based on Taguchi methods
were performed using L9 orthogonal arrays to analyze the metal removal rate as response
variable. Conceptual S/N ratio and ANOVA approaches for data analysis drew similar
conclusions; Statistical results (at a 95% confidence level) show that the voltage (A), feed rate
(B), and electrolyte concentration (C) affects the metal removal rate by 34.04%, 58.09% and
7.57% in the electrochemical machining of LM6 Al/5%SiC composites, respectively; The
maximum metal removal rate is calculated as 0.131 g/min by Taguchi’s optimization method; In
this study, the analysis of the confirmation experiment for metal removal rate has shown that
Taguchi parameter design can successfully verify the optimum cutting parameters (A3B3C3),
which are voltage=20 V (A3) feed rate= 0.3 mm/rev (B3) and electrolyte concentration=30 g/lit
(C3); Metal removal rate increases with voltage, feed rate and electrolyte concentration in
electrochemical machining of LM6 Al/5%SiC composites. [15]
Pardeep Kumar, J. S. Oberoi, Charnjeet Singh and Hitesh Dhiman carried out a study on
Analysis and Optimization of Parameters Affecting Surface Roughness in Boring Process in
2014. This investigation applied a full factorial orthogonal table, integrating response surface
methodology (RSM) to optimize parameters of a finish boring process using a computer
numerical control (CNC) machine VA-50 for the finishing operation of engine crank case tappet
bore. The main scope of this research work was to study the effects of various operational
parameters like cutting speed, feed rate and cutting allowance on Surface roughness (Ra) of

engine crankcase tappet bore. It was found that with the increases of cutting speed and feed the
Surface roughness decreases approximately 49.83% was observed. The result of the experiment
then was analyzed using DESIGN EXPERT (DOE) 9.0 software. This was done by using the
FULL FACTORIAL technique with optimal (custom) design and ANOVA analysis. After
analyzing and comparing the results of experimental study on cutting parameters and subsequent
values of responses, it was been observed that the existing parameters for finish tappet bore was
cutting speed 137 m/min, feed 0.1 mm/rev, and cutting allowance was 0.5 mm, whereas for the
same dimensions the optimum cutting parameters was cutting speed 160 m/min, feed 0.3
mm/rev, and cutting allowance was 0.3 mm. On examining the average values of surface
roughness (Ra), its value with existing parameters was measured as 4.60 μm. On the other hand,
the surface roughness obtained with optimum parameter is about 3.02 μm which showed the
49.83% reduction in surface roughness or improvement in surface finish. [16]
A study on Analysis of Sound Signal Characteristics Associated with Adhesive Wear in

Machining was done by Ming-Chyuan Lu and Elijah Kannatey-Asibu. Audible sound generated
from the cutting process was analyzed as a source for monitoring tool wear during turning,
assuming adhesive wear as the predominant wear mechanism. The analysis incorporated the
dynamics of the cutting process. In modeling the interaction on the flank surface, the asperities
on the surfaces were represented as a trapezoidal series function. The effect of changing asperity
height, size, and the spacing between two asperities was investigated and compared with
experimental data. Asperities on the surfaces of the cutting tool and work piece were modeled as
trapezoids, and the interaction between the asperities considered the source of system excitation
that generated sound signals. It was shown that a change in the asperity form led to a change in
energy distribution of the signal frequencies. Based on the simple assumption of the interaction,
the asperity height decreased as tool wear increased. Under these circumstances, the dominant
and harmonic peaks moved to higher frequencies and the amplitudes of the higher frequency
harmonic peaks increase compared with the amplitudes of the dominant lower frequency peak.
These results agreed qualitatively with the frequency characteristics of experimental data
obtained with sharp and worn tools. [17]
A genetic algorithmic approach for optimization of surface roughness prediction model was
researched upon by P.V.S. Suresh, P. Venkateswara Rao and S.G. Deshmukh during 1999-2002.

Due to the widespread use of highly automated machine tools in the industry, manufacturing
requires reliable models and methods for the prediction of output performance of machining
processes. The prediction of optimal machining conditions for good surface finish and
dimensional accuracy plays a very important role in process planning. Their work dealt with the
study and development of a surface roughness prediction model for machining mild steel, using
Response Surface Methodology (RSM). The experimentation was carried out with TiN-coated
tungsten carbide (CNMG) cutting tools, for machining mild steel work-pieces covering a wide
range of machining conditions. A second order mathematical model, in terms of machining
parameters, was developed for surface roughness prediction using RSM. This model gave the
factor effects of the individual process parameters. An attempt was also made to optimize the
surface roughness prediction model using Genetic Algorithms (GA) to optimize the objective
function. The GA program gave minimum and maximum values of surface roughness and their
respective optimal machining conditions. The two-stage effort of obtaining a surface roughness
model by surface response methodology, and optimization of this model by Genetic Algorithms,
has resulted in a fairly useful method of obtaining process parameters in order to attain the
required surface quality. This had validated the trends available in the literature, and extended
the data range to the present operating conditions, apart from improving the accuracy and
modeling by involving the most recent modeling method. The application of the GA approach to
obtain optimal machining conditions will be quite useful at the Computer aided process planning
(CAPP) stages in the production of high quality goods with tight tolerances by a variety of
machining operations, and in adaptive control of automated machine tools. [18]
An experimental research was done by Dr. S.S.Mahapatra, Amar Patnaik, Prabina Ku. Patnaik
on Parametric Analysis and Optimization of Cutting Parameters for Turning Operations based on
Taguchi Method. Surface quality is one of the specified customer requirements for machined
parts. There are many parameters that have an effect on surface roughness, but those are difficult
to quantify adequately. In finish turning operation many parameters such as cutting speed, feed
rate, and depth of cut are known to have a large impact on surface quality. In order to enable
manufacturers to maximize their gains from utilizing hard turning, an accurate model of the
process must be constructed. Several statistical modeling techniques have been used to generate
models including regression and Taguchi methods. In this study, an attempt has been made to
generate a surface roughness prediction model and optimize the process parameters Genetic

algorithms (GA). Future directions and implications for manufacturers in regard to generation of
an robust and efficient machining process model was discussed. The results outlined in this study
led to conclusions for turning of S45C after conducting the experiments and analyzing the
resulting data. Cutting velocity (0.001) and feed rate (0.000) had greater influence on the surface
roughness followed by feed rate. Cutting velocity (0.000) and Feed rate (0.000) had greater
influence on the tool life. The interaction between cutting velocity / feed rate (0.000) had a
significant effect on surface roughness. Similarly, for tool life, the interaction between cutting
velocity / feed rate and cutting velocity / depth of cut had greater significant effect. The
confirmation tests showed that the error associated with surface roughness (maximum value
10.448 % and minimum 3.291%) was lesser than the error associated with tool life (maximum
value 12.83 % and minimum 10.92 %). Using experimental data, a multiple linear regression
model was developed and it proved to be effective in optimizing the cutting conditions in turning
operations. The search for optimal turning conditions was based on mathematical formulation of
the multi-objective optimization problem, and the contribution of each machining parameter is
studied. The algorithm was tested to find optimal values of parameters with varying weighting
factors for different objectives. It was concluded from this preliminary study that the turning
were carried out on an engine lathe using tungsten carbide with the grade of P-10 for the
machining of S45C steel bar is a very difficult operation, and much more work remains to be
done to establish effective turning operation for such materials through improvement of tooling
and process parameters. In this study, the Taguchi method gave effective methodology in order
to find out the effective performance output and machining conditions. [19]
An experimental study on Optimization of Process Parameters in Turning Operation of AISI-

1016 Alloy Steels with CBN Using Taguchi Method And ANOVA was carried out by K.Mani
lavanya, R.K.Suresh, A.Sushil Kumar Priya and V.Diwakar Reddy in 2013. This study
investigated the parameters affecting the roughness of surfaces produced in the turning process
for the material AISI-1016 Steel. Design of experiments was conducted for the analysis of the
influence of the turning parameters such as cutting speed, feed rate and depth of cut on the
surface roughness. The results of the machining experiments for AISI-1016 were used to
characterize the main factors affecting surface roughness by the Analysis of Variance (ANOVA)
method. The feed rate was found to be the most significant parameter influencing the surface
roughness in the turning process. Following were the conclusions drawn based on the test

conducted on AISI 1016 alloy during turning operation with Cubic Boron Nitride; From the
results obtained a Regression Model was developed for Surface Roughness from these equations
prediction of value of Surface Roughness could be done if the values of Cutting Speed, Feed and
Depth of Cut were known; From ANOVA Table and Response Table for Signal to noise ratios,
based on the ranking it was concluded that Speed has a greater influence on the Surface
Roughness followed by Feed; Depth of Cut had least influence on Surface Roughness; The
validation experiment confirmed that the error occurred was less than that 2.0% between
equation and actual value; The optimal settings of process parameters for optimal Surface
Roughness were: Speed(740), Feed (0.05) and DOC (1.0). This research gave how Taguchi’s
parameter designed to obtain optimum condition with lowest cost, minimum number of
experiments and Industrial Engineers can use this method. The research can be extended for
other materials using Tool Nose Radius, Lubricant Material Hardness etc as parameters. [20]
H.M.Somashekara and Dr. N. Lakshmana Swamy performed a study on Optimizing Surface

Roughness In Turning Operation Using Taguchi Technique And ANOVA in 2012. The objective
of the study was to obtain an optimal setting of Turning parameters (Cutting speed, Feed and
Depth of Cut) which results in an optimal value of Surface Roughness while machining Al 6351-
T6 alloy with Uncoated Carbide Inserts. Several statistical modelling techniques have been used
to generate models including Genetic Algorithm, Response Surface Methodology. In their study,
an attempt had been made to generate a model to predict Surface Roughness using Regression
Technique. Also an attempt had been made to optimize the process parameters using Taguchi
Technique. S/N ratio and ANOVA analysis were also performed to obtain significant factors
influencing Surface Roughness. with Uncoated Carbide Insert. From the results obtained a
Regression Model had been developed for Surface Roughness. From that equation they could
predict the value of Surface Roughness if the values of Cutting Speed, Feed and Depth of Cut
were known. It was concluded that Speed had a greater influence on the Surface Roughness
followed by Feed. Depth of Cut had least influence on Surface Roughness. The validation
experiment confirmed that the error occurred was less than 2.0 % between equation and actual
value. The optimal settings of process parameters for optimal Surface Roughness were: Speed
(500 rpm), Feed (0.7 mm/rev), and DOC (0.8 mm). This study gave them how to use Taguchi’s
parameter design to obtain optimum condition with lowest cost, minimum number of

experiments and Industrial Engineers can use this method. The research can be extended for
other materials using Tool Nose Radius, Lubricant, Material Hardness etc as parameters. [21]
K. Lipin and Dr. P. Govindan conducted a study to give A Review on Multi Objective
Optimization of Drilling Parameters Using Taguchi Methods. In their study, a comprehensive
and in-depth review on optimization of drilling parameters using Taguchi methods was carried
out. The quality and productivity aspects were equally important in the analysis of drilling
parameters. Taguchi methods are widely used for design of experiments and analysis of
experimental data for optimization of processing conditions. The research contributions were
classified into methodology for investigation and analysis, input processing conditions and
response variables. It was observed that the optimal speed for a machine tool was influenced by
several processing parameters such as hardness, composition, stiffness of work/tool and tool life.
Furthermore, it was evident that surfaces finish necessary and power available significantly
controls the feed. The roughness of drilled surfaces depended severely on the input conditions,
material of the workpiece or tool and condition of the machine tool. The grey relational analysis
was the most accurate and effective tool for analysis of data for a CNC drilling process. This
study indicated that Taguchi method followed by grey relational analysis was the most efficient
combination for the following: design of experiments, analysis of experimental data and for the
subsequent multi-objective optimization in drilling process. The conclusions drawn were many.
Taguchi method was been used to determine the main effects, significant factors and optimum
machining conditions to obtain better performance characteristics. The multiple performance
characteristics such as tool life, cutting force, surface roughness and the overall productivity
could be improved by useful tool of Taguchi method. The optimum speed for a particular setup
was affected by many factors, including Composition, hardness & thermal conductivity (k) of
material, Depth of hole, Efficiency of cutting fluid type, condition and stiffness of drilling
machines, Stiffness of workpiece, fixture and tooling (shorter was better), Quality of holes
desired, Life of tool before regrind or replacement. Feed used depended on the finish required,
Power available, Condition of machine and its drive etc. Surface roughness was determined by
several factors which included cutting parameters such as cutting speed, feed, depth of cut, Tool
geometry, The material of the cutting tool, Machining condition etc. Grey relational analysis was
widely used for measuring the degree of relationship between sequences by grey relational grade.

Grey relational analysis was applied by several researchers to optimize control parameters
having multi-responses through grey relational grade. [22]
A research with Application of Taguchi Method for Surface Roughness and Roundness Error in
Drilling of AISI 316 Stainless Steel was done by Adem Çiçek, Turgay Kıvak, Gürcan Samtaş. In
this study, the effects of deep cryogenic treatment and drilling parameters on surface roughness
and roundness error were investigated in drilling of AISI 316 austenitic stainless steel with M35
HSS twist drills. In addition, optimal control factors for the hole quality were determined by
using Taguchi technique. Two cutting tools, cutting speeds and feed rates were considered as
control factors, and L8(23) orthogonal array was determined for experimental trials. Multiple
regression analysis was employed to derive the predictive equations of the surface roughness and
roundness error achieved via experimental design. Minimum surface roughness and roundness
error were obtained with treated drills at 14 m/min cutting speed and 0.08 mm/rev feed rate.
Confirmation experiments showed that Taguchi method precisely optimized the drilling
parameters in drilling of stainless steel. In this study, the optimization of drilling parameters were
carried out by the Taguchi method to obtain optimum surface roughness and roundness error
values in the drilling of AISI 316 austenitic stainless steel with untreated and treated drills. In the
performed experimental trials using Taguchi orthogonal arrays, it was found that the cutting
speed (78.11%) had a significant effect on the surface roughness and that the cutting speed
(35.352%) and feed rate (35.352%) had significant effects on the roundness error. The quality
losses (52.36%) of the surface roughness obtained at optimal combinations (Ct = CT, V = 14
m/min, f = 0.08 mm/rev) were nearly equal to half of the ones obtained from experimental
combinations. Similarly, the quality losses of the roundness error obtained at optimal
combinations became 51.76%. Optimal surface roughness and roundness error values were
calculated as 1.77 μm and 5.60 μm using optimal parameters, respectively. The Taguchi method
was successfully applied to determine the optimal combinations of drilling parameters and to
minimize machining costs and time in drilling of AISI 316 stainless steel. Further research works
could consider more factors such as drilling depth, lubricant, tip and helix angle and cryogenic
treatments at different soaking time (i.e. 4, 8, 12, 36, 48 h, and so on) and at different cryogenic
temperatures (–70, –125, –150 °C and so on) affecting surface roughness and roundness error.
[23]

S S Panda, S S Mohapatra studied Parametric optimisation of multi response drilling process
using Grey based Taguchi method. In their work, optimization technique such as Grey based
Taguchi methods were used to predict surface roughness of drilled holes and drill flank wear into
a single characteristic response. Experiments were conducted in a radial drilling machine with
five input parameters using L27 orthogonal array. Minimum flank wear and average surface
roughness was the required objective parameter. It had been observed that combined response
affected by almost all input parameters, but drill diameter was most significant and feed was
least significant input parameter influencing the combined responses. Results of this study
illustrated that Grey Relational Analysis procedure wass simple and straight forward. It was a
linear predictor model. The purposed method could able to predict four different testing sample
within an error of ±12% error band line. This method was reliable and could able to implement
that have more than two responses. [24]
Srinivas Athreya, Dr Y.D.Venkatesh studied the Application Of Taguchi Method For

Optimization Of Process Parameters In Improving The Surface Roughness Of Lathe Facing
Operation. Taguchi Method is a statistical approach to optimize the process parameters and
improve the quality of components that are manufactured. The objective of this study was to
illustrate the procedure adopted in using Taguchi Method to a lathe facing operation. The
orthogonal array, signal-to-noise ratio, and the analysis of variance were employed to study the
performance characteristics on facing operation. In this analysis, three factors namely speed; feed
and depth of cut were considered. Accordingly, a suitable orthogonal array was selected and
experiments were conducted. After conducting the experiments the surface roughness was
measured and Signal to Noise ratio was calculated. With the help of graphs, optimum parameter
values were obtained and the confirmation experiments were carried out. These results were
compared with the results of full factorial method. The study illustrated the application of the
parameter design (Taguchi method) in the optimization of facing operation. Taguchi’s Method of
parameter design can be performed with lesser number of experimentations as compared to that
of full factorial analysis and yields similar results. Taguchi’s method can be applied for
analyzing any other kind of problems. It was found that the parameter design of the Taguchi
method provided a simple, systematic, and efficient methodology for optimizing the process
parameters. [25]

Application of Taguchi Method for Optimizing Turning Process by the effects of Machining
Parameters was experimentally researched upon by Krishankant, Jatin Taneja, Mohit Bector,
Rajesh Kumar in 2012. This study was on an optimization of turning process by the effects of
machining parameters applying Taguchi methods to improve the quality of manufactured goods,
and engineering development of designs for studying variation. EN24 steel was used as the work
piece material for carrying out the experimentation to optimize the Material Removal Rate. The
bars used were of diameter 44mm and length 60mm. There were three machining parameters i.e.
Spindle speed, Feed rate, Depth of cut. Different experiments were done by varying one
parameter and keeping other two fixed so maximum value of each parameter was obtained.
Operating range was found by experimenting with top spindle speed and taking the lower levels
of other parameters. Taguchi orthogonal array was designed with three levels of turning
parameters with the help of software Minitab 15. In the first run nine experiments were
performed and material removal rate (MRR) was calculated. When experiments were repeated in
second run again MRR was calculated. Taguchi method stresses the importance of studying the
response variation using the signal–to–noise (S/N) ratio, resulting in minimization of quality
characteristic variation due to uncontrollable parameter. The metal removal rate was considered
as the quality characteristic with the concept of "the larger-the-better". The S/N ratio for the
larger-the-better where n is the number of measurements in a trial/row, in this case, n=1 and y is
the measured value in a run/row. The S/N ratio values were calculated by taking into
consideration with the help of software Minitab 15. The MRR values measured from the
experiments and their optimum value for maximum material removal rate. Every day scientists
are developing new materials and for each new material, we need economical and efficient
machining. It was also predicted that Taguchi method is a good method for optimization of
various machining parameters as it reduces the number of experiments. In this research the
turning of EN24 steel was done in order to optimize the turning process parameters for
maximizing the material removal rate. The effect of spindle speed on the metal removal rate
values was increasing with increase in spindle speed upto 347 RPM beyond that it was
decreasing. So the optimum spindle speed was level 2 i.e. 347 RPM. The effect of feed rate on
the metal removal rate values was increasing with increase in feed rate. So the optimum feed rate
was level 3 i.e. 0.458 mm/rev. The effect of depth of cut on the metal removal rate values was
increasing with increase in depth of cut. So the optimum depth of cut was level 3 i.e. 0.458
mm/rev. [26]

A research work was carried out by M. Szafarczyk and J. Chrzanowski on Tool Probe for
Measuring Dimensional Wear and X Co-ordinate of Turning Edge. Automatic supervision of
tool wear is vital for any machining process. The cutting edge of a tool is an element of the
machining system which should be frequently replaced – in most cases of turning after about ten
minutes of work. An original method of direct measurement of turning tool wear at the tip of the
cutting edge, made automatically on an NC lathe by a probe, which at the same time allows for
determining the X co-ordinate of the cutting edge. In the initial solution, this measurement,
patented by one of the researchers, was carried out using a special probe with two touch-trigger
sensors or one touch-trigger sensor and a displacement sensor. The improved probe has only one
displacement sensor. The new solution had not only simplified the probe but also made tool wear
measurement more accurate. Tool wear measurements are divided into direct and indirect
methods. The direct methods are based on the changes of tool geometry. It means that they are
based on geometrical features of the cutting edge. The indirect methods use the effects caused by
tool edge wear and not the wear parameters themselves. The direct methods are more reliable but
are difficult to implement. The indirect methods are simpler to implement but their results are
burdened with uncertainty resulting from inaccuracy of the model connecting wear with the
measured quantity. The results of performed tests show that the developed probes are suitable
both for the tool orientation and for the measurement of turning tool wear. The probe with only
one displacement sensor was even more accurate than the previously tested two-sensor probe.
The measurement accuracy was within the repeatability limits of the linear displacement sensor.
The smaller distance between the touching elements of the probe was important - the LVDT
sensor tip and the stop tooth may touch the cutting insert. It eliminates errors resulting from e.g.:
non-uniform thermal expansion of the holder and the insert. [27]
Raghu N. Kacker, Eric S. Lagergren, and James J. Filliben worked to prove that Taguchi’s
Orthogonal Arrays Are Classical Designs of Experiments in 1991. Taguchi's catalog of
orthogonal arrays is based on the mathematical theory of factorial designs and difference sets
developed by R. C. Bose and his associates. These arrays evolved as extensions of factorial
designs and latin squares. Their work described the structure and constructions of Taguchi's
orthogonal arrays. It also illustrated their fractional factorial nature, and pointed out that
Taguchi's catalog could be expanded to include orthogonal arrays developed since 1960. As per
their work, Taguchi's catalog of orthogonal arrays was primarily based on two papers: Bose, and

Bose and Bush. The Bose paper laid the mathematical foundation of fractional factorials and
orthogonal arrays. The Bose and Bush paper describes a method of constructing mixed-element
orthogonal arrays from difference matrices. The difference matrices used by Taguchi to construct
OAj8(2'x3'), OA32(2'x4'), OA36(2"x3'2),OA36(2^x3'^) and OA5o(2'x5") were permuted
versions of the difference matrices developed by Bose and Bush, Seiden and Masuyama. The
extensions of the Bose, and the Bose and Bush, methods needed to construct OA36(2'' X3'^),
OA36(2'X3'^), and OA54(2' x3") appear to be Taguchi's contributions. The researchers had
shown that Taguchi's OAi2(2") is a permuted version of the Plackett and Burman plan of 12
runs, but there was no reason to believe that Taguchi permuted the Plackett and Burman plan to
construct his OAi2(2"). Although the original Japanese version of Taguchi's catalog of
orthogonal arrays was developed before 1960, it continues to be very useful. These arrays could
be modified to generate many types of multifactor experiments and many other orthogonal arrays
could be derived from Taguchi's catalog through established mathematical procedures.
Nevertheless, the catalog can now be expanded to include arrays developed after 1960. For
example, Taguchi's catalog can be expanded to include OA24(4'x2'"), OA4o(4'x2'*) and
OA4s(4^x2'*') first developed by Dey and Ramakrishna and Chacko, Dey, and Ramakrishna,
and then re-constructed through a unified procedure by Cheng. It was the researchers' intent to
develop an expanded and revised version of Taguchi's catalog of orthogonal arrays. [28]
Metalcutting Tecnical Guide(F) Boring issued by Sandvik Corporation serves as a great

reference for understanding Boring process in great detail. It explains in minute details the whole
theoretical part associated with boring operation, its types, its geometry etc. The book also has
separate chapter dedicated to help in Selection of optimum Boring Tool as per requirement.
Various types of Boring Tools are finely explained in the book. The book is well illustrated will
diagrams and photographs and serves a great reference to the reader. [29]
Rajesh S. Raool’s work in his M.Tech. Dissertation on Experimental Optimization of Process

Parameters of Corrugation Process highlighted his project work. The dissertation explained the
Design of experiment and Taguchi Method and also composed of ANOVA Method for the
calculation purposes. L9 orthogonal array was used in the experimental work. The various
calculations were properly explained in it. [30]

A Module on Design for Reliability and Quality has been published by IIT Bombay. It explains
the concept of Robust Design clearly. The Taguchi Method has been explained in detail in it. The
whole concept has been properly described with the help of examples with all calculation neatly
and clearly done. This Module serves as an excellent reference for a person doing ANOVA
Calculations and is working upon any experiment involving the Taguchi Method. [31]

CHAPTER 3:
AIM AND
OBJECTIVE

CHAPTER 3 AIM AND OBJECTIVE
In machining, boring is the process of enlarging a hole that has already been drilled (or cast), by
means of a single-point cutting tool (or of a boring head containing several such tools), for
example as in boring a cannon barrel. Boring is used to achieve greater accuracy of the diameter
of a hole, and can be used to cut a tapered hole. But the Boring operation is associated with
serious vibration-related problems which affects the performance of the boring bar resulting in
higher dimension tolerances and poor surface finish. The vibration is affected by the process
parameters involved in the boring operation like Speed, depth of cut and feed. To reduce the
problem of vibration and ensure that the desired shape and tolerance are achieved, extra care
must be taken with production planning and in the preparations for the machining of a work-
piece. To study the various process parameters of the boring operation in a CNC machine
affecting the noise and vibration in the operation and analyse the result in order to reduce the
noise and vibration is therefore an important step toward solving the problem.
3.1 APPROACH
1. Design of experiment: A specific method i.e Taguchi method was selected for the
performance of the experiment of boring operation. According to the method, we have to
perform the experiment several times and record the data.
2. Performance of the experiment: The performance of the experiment will be done on the
CNC lathe machine in the college workshop for which CNC programming is studied. The
boring operation will be done with 3 work pieces of different materials and variances in
the data of those materials will be examined.
3. Analysis: Once the experiment of the boring operation is done with the 3 different
materials, the data recorded will be analysed in the MINITAB and LABVIEW software.
MINITAB is often used in conjunction with the implementation of six sigma and other
statistics-based process improvement methods. LABVIEW is software with modular,
reconfigurable features to overcome the ever-increasing complexity involved in
delivering measurement and control systems on time and under budget.
4. Result: Based on the analysis of the data, the optimum solution will be provided.

CHAPTER 4:
METHODOLOGY

CHAPTER 4 METHODOLOGY
4.1 DESIGN OF EXPERIMENT
An effective way to improve performance is to optimize the engineering designs of products or

processes by experimental means. A structured and economical way to study projects whose
performance depends on many factors is to apply the experimental method known as "Design of
Experiments". Design of Experiments (DoE) is a powerful statistical technique introduced by R.
A. Fisher in England in the 1920's to study the effect of multiple variables simultaneously. As a
researcher in Electronic Control Laboratory in Japan, Dr. Genechi Taguchi carried out significant
research with DOE techniques in the late 1940's. He spent considerable effort to make this
experimental technique more user-friendly (easy to apply) and applied it to improve the quality
of manufactured products. Dr. Taguchi's standardized version of DoE, popularly known as the
Taguchi method or Taguchi approach, was introduced in the USA in the early 1980's. Today it is
one of the most effective quality building tools used by engineers in all types of manufacturing
activities. The DoE using Taguchi approach can economically satisfy the needs of problem
solving and product/process design optimization projects.
DoE can be highly effective when one wish to:
a) Optimize product and process designs, study the effects of multiple factors (i.e. -
variables, parameters, ingredients, etc.) on the performance, and solve production
problems by objectively laying out the investigative experiments. (Overall application
goals).
b) To study Influence of individual factors on the performance and determine which factor
has more influence, which ones have less. One can also find out which factor should
have tighter tolerance and which tolerance should be relaxed.
Further, the experimental data will allow determining:
1. How to substitute a less expensive part to get the same performance improvement
proposed
2. How one can determine which factor is causing most variations in the result
3. How one can set up process such that it is insensitive to the uncontrollable factors
4. Which factors have more influence on the mean performance
5. How the uncontrollable factors affect the performance

Every experimenter has to plan and conduct experiments to obtain enough and relevant data so
that he can infer the science behind the observed phenomenon. The various methods available
are:
i. Trial-and-error approach
Performing a series of experiments each of which gives some understanding requires

making measurements after every experiment so that analysis of observed data will allow
him to decide what to do next - "Which parameters should be varied and by how much".
Many a times such series does not progress much as negative results may discourage or
will not allow a selection of parameters which ought to be changed in the next
experiment. Therefore, such experimentation usually ends well before the number of
experimental runs reaches a double digit. The data is insufficient to draw any significant
conclusions and the main problem (of understanding the science) still remains unsolved.
ii. TAGUCHI approach
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. Thus the
marriage of Design of Experiment 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.

Advantages of DOE Using Taguchi Approach
The application of DOE requires careful planning, prudent layout of the experiment, and expert
analysis of results. Thus, DoE using the Taguchi approach has become a much more attractive
tool to practicing engineers and scientists. Based on years of research and applications Dr.
Genechi Taguchi has standardized the methods for each of these DoE application steps described
below.
1. Experiment planning and problem formulation - Experiment planning guidelines are

consistent with modern work disciplines of working as teams. Consensus decisions about
experimental objectives and factors make the projects more successful.
2. Experiment layout -High emphasis is put on cost and size of experiments... Size of the
experiment for a given number of factors and levels is standardized. Approach and
priority for column assignments are established. Clear guidelines are available to deal
with factors and interactions (interaction tables). Uncontrollable factors are formally
treated to reduce variation. Discrete prescriptions for setting up test conditions under
uncontrollable factors are described. Guidelines for carrying out the experiments and
number of samples to be tested are defined.
3. Data analysis -Steps for analysis are standardized. Standard practice for determination of
the optimum is recommended. Guidelines for test of significance and pooling are defined.
4. Interpretation of results - Clear guidelines about meaning of error term. Discrete
indicator about confirmation of results (Confidence interval).
5. Overall advantage - DoE using Taguchi approach attempts to improve quality which is
defined as the consistency of performance. Consistency is achieved when variation is
reduced. The prime motivation behind the Taguchi experiment design technique is to
achieve reduced variation (also known as ROBUST DESIGN). This technique, therefore,
is focused to attain the desired quality objectives in all steps. The classical DoE does not
specifically address quality.

4.2 INTRODUCTION TO TAGUCHI METHOD
Taguchi Method treats optimization problems in two categories:
a) Static problems
Generally, a process to be optimized has several control factors which directly decide the target
or desired value of the output. The optimization then involves determining the best control factor
levels so that the output is at the target value. Such a problem is called as a "STATIC
PROBLEM".
This is best explained using a P-Diagram which is shown below ("P" stands for Process or
Product). Noise is shown to be present in the process but should have no effect on the output!
This is the primary aim of the Taguchi experiments - to minimize variations in output even
though noise is present in the process. The process is then said to have become ROBUST.
Fig 4.1
Static problem (batch process optimization):

There are 3 Signal-to-Noise ratios of common interest for optimization of Static Problems.
I) SMALLER-THE-BETTER:
n = -10 Log10 [mean of sum of squares of measured data]
This is usually the chosen S/N ratio for all undesirable characteristics like “defects “etc. for
which the ideal value is zero. Also, when an ideal value is finite and its maximum or minimum
value is defined then the difference between measured data and ideal value is expected to be as
small as possible. The generic form of S/N ratio then becomes,
n = -10 Log10 [mean of sum of squares of {measured - ideal}]

II) LARGER-THE-BETTER:
n = -10 Log10 [mean of sum squares of reciprocal of measured data]
This case has been converted to SMALLER-THE-BETTER by taking the reciprocals of
measured data and then taking the S/N ratio as in the smaller-the-better case.
III) NOMINAL-THE-BEST:
Square of mean
n = 10 Log10 -------------------
Variance
This case arises when a specified value is MOST desired, meaning that neither a smaller nor a
larger value is desirable. Ex- Most parts in mechanical fittings have dimensions which are
nominal-the-best type.
b) Dynamic problems
If the product to be optimized has a signal input that directly decides the output, the optimization
involves determining the best control factor levels so that the "input signal / output" ratio is
closest to the desired relationship. Such a problem is called as a "DYNAMIC PROBLEM".
This is best explained by a P-Diagram which is shown below. Again, the primary aim of the
Taguchi experiments - to minimize variations in output even though noise is present in the
process- is achieved by getting improved linearity in the input/output relationship.
Fig 4.2

Dynamic problem (technology development):
In dynamic problems, we come across many applications where the output is supposed to follow
input signal in a predetermined manner. Generally, linear relationship between input and output
is desirable.
For example: Accelerator pedal in cars, volume control in audio amplifiers and document copier
(with magnification or reduction)
There are 2 characteristics of common interest in "follow-the-leader" or "Transformations" type
of applications,
(i) Slope of the I/O characteristics
(ii) Linearity of the I/O characteristics (minimum deviation from the best-fit straight line)
The Signal-to-Noise ratio for these 2 characteristics has been defined as:
I) SENSITIVITY (SLOPE):
The slope of I/O characteristics should be at the specified value (usually 1). It is often treated as
Larger-The-Better when the output is a desirable characteristics (as in the case of Sensors, where
the slope indicates the sensitivity).
n = 10 Log10 [square of slope or beta of the I/O characteristics]
On the other hand, when the output is an undesired characteristics, it can be treated as Smaller-
the-Better.
n = -10 Log10 [square of slope or beta of the I/O characteristics]
(II) LINEARITY (LARGER-THE-BETTER) :

Most dynamic characteristics are required to have direct proportionality between the input and
output. These applications are therefore called as "TRANSFORMATIONS". The straight line
relationship between I/O must be truly linear i.e. with as little deviations from the straight line as
possible.
Square of slope or beta
n = 10 Log10 ----------------------------
Variance
Variance in this case is the mean of the sum of squares of deviations of measured data points
from the best-fit straight line (linear regression).

4.2.1 Steps in Taguchi Methodology
Taguchi method is a scientifically disciplined mechanism for evaluating and implementing

improvements in products, processes, materials, equipment, and facilities. These improvements
are aimed at improving the desired characteristics and simultaneously reducing the number of
defects by studying the key variables controlling the process and optimizing the procedures or
design to yield the best results.
The method is applicable over a wide range of engineering fields that include processes that
manufacture raw materials, sub systems, products for professional and consumer markets. In
fact, the method can be applied to any process be it engineering fabrication, computer-aided-
design, banking and service sectors etc. Taguchi method is useful for 'tuning' a given process for
'best' results.
Taguchi proposed a standard 8-step procedure for applying his method for optimizing any
process,
8-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

Every experimenter develops a nominal process/product that has the desired functionality as
demanded by users. Beginning with these nominal processes, he wishes to optimize the
processes/products by varying the control factors at his disposal, such that the results are reliable
and repeatable (i.e. show less variations).
In Taguchi Method, the word "optimization" implies "determination of BEST levels of control
factors". In turn, the BEST levels of control factors are those that maximize the Signal-to-Noise
ratios. The Signal-to-Noise ratios are log functions of desired output characteristics. The
experiments, that are conducted to determine the BEST levels, are based on "Orthogonal
Arrays", are balanced with respect to all control factors and yet are minimum in number. This in
turn implies that the resources (materials and time) required for the experiments are also
minimum.
Taguchi method divides all problems into 2 categories - STATIC or DYNAMIC. While the
Dynamic problems have a SIGNAL factor, the Static problems do not have any signal factor. In
Static problems, the optimization is achieved by using 3 Signal-to-Noise ratios - smaller-the-
better, LARGER-THE-BETTER and nominal-the-best. In Dynamic problems, the optimization
is achieved by using 2 Signal-to-Noise ratios - Slope and Linearity.
Taguchi Method is a process/product optimization method that is based on 8-steps of planning,

conducting and evaluating results of matrix experiments to determine the best levels of control
factors. The primary goal is to keep the variance in the output very low even in the presence of
noise inputs. Thus, the processes/products are made ROBUST against all variations.
The method of 'Statistical Design of Experiments’ helps to scientifically plan the experiment
with appropriate combination of the parameters. In this method, the desired values of the
parameters are decided and priority at the beginning of the experiments and the output from the
experiments are then analyzed. In the conventional 'full factorial design' approach, the total
number of experiments to be conducted will be equal to the number of operating levels 'a' raised
to the power of the number of variables 'p' i.e. ap. In the present analysis of boring operation, the
number of experiments to be conducted would be huge since the numbers of factors, as well as,
the levels are large. Normally Taguchi’s orthogonal array is preferred in such cases.

Taguchi has tabulated 18 basic orthogonal arrays which are called "Standard Orthogonal
Arrays". In this Experimentation, we are using L9 (34) orthogonal array. An array's name, for
example, L9 (34) indicates 9 number of rows, 4 columns and 3 number of levels in each column.
The number of columns of an array indicates the maximum number of factors or parameters,
which can be considered using that array. Number of rows represents the number of experiments
to be carried out. In order that an array is a viable choice, the number of rows must be at least
equal to the degree of freedom required for the case study. The degree of freedom of a factor is
equal to the number of levels of a factor minus one and for an interaction among factors; it is
equal to multiplication of degree of freedom of individual factors. Usually, the smallest possible
orthogonal array that meets the requirement of the case study is selected for the experiment i.e.
L9.
Normally, most of the designs do not take into consideration the effect of interaction among the
parameters. However, in real life situations such as the boring, consideration of interaction
effects is essential. Taguchi's orthogonal arrays have the advantage of considering the interaction
effects.
Hence to reduce the number of experiments, to reduce cost and time involved in the
experimentation, to study the interaction effects between different parameters in the present
work, it was decided to do the experimentation systematically by using Taguchi Orthogonal
array.
4.3 SELECTION OF AN ORTHOGONAL ARRAY
Selection of an orthogonal array depends on the selection of the number of factors, their
operating levels and their interactions. These aspects may be discussed before selecting an array.
4.3.1 Selection of Input and Output Factors

The input factors set for the boring operation are as follows:
a) Spindle speed - The rotational speed of the spindle and the work piece in revolutions per
minute (RPM). The spindle speed is equal to the cutting speed divided by the
circumference of the work piece where the cut is being made. In order to maintain a
constant cutting speed, the spindle speed must vary based on the diameter of the cut. If
the spindle speed is held constant, then the cutting speed will vary.

b) Feed rate - The speed of the cutting tool's movement relative to the work piece as the
tool makes a cut. The feed rate is measured in mm per revolution.
c) Depth of cut - The depth of the tool along the radius of the work piece as it makes a cut,
as in a turning or boring operation. A large depth of cut will require a low feed rate, or
else it will result in a high load on the tool and reduce the tool life. Therefore, a feature is
often machined in several steps as the tool moves over at the depth of cut.
d) L/D ratio of Boring bar – The ratio of the length of the boring bar to the diameter of the
boring bar can be varied by changing the length or diameter. It is a controllable factor.
L/D ratio was kept constant during the operation. (L/D ratio – 6)
e) Work piece material – The work piece material used for the boring operation were
EN31, EN 8 AND EN 9.
The output factors set for the boring operation are as follows:
a) Surface Roughness – The surface roughness of the work piece was obtained after the
machining was measured. The unit of the surface roughness is Ra.
b) Tool wear – Tool wear was calculated by the measuring the weight of the insert before
and after the machining.
c) Sound and Vibration – The sound and the vibration data from the vibration and
microphone sensors was acquired during the operation.
4.3.2 Selection of Levels of Factors

The nature of variation of response with respect to a particular factor helps in deciding the level
of the factor. If the variation is linear, a factor with two levels is chosen. However, the levels
shall be decided carefully if the variation is non-linear in nature. The nature of variation, linear or
non-linear, is judged by the previous machining experience. In the present case of boring
experiments, the levels of the factors are decided to be THREE for all the four factors.
Values of Factors at the Respective Levels

The range of values of the factors is decided based on the preliminary set of experiments which
satisfy the desired responses. For instance, a range of spindle speed between 150rpm and 200rpm
is chosen. The individual values of these factors to be assigned at each level are, in general, equi
spaced for the sake of simplicity. Table 4 summarizes the levels assigned to various factors for
the different parameters used for boring operation.
Sr. No. Factor name Factor symbol / Levels
unit
1 2 3
1 Spindle speed s , rpm 150 200 250
2 Depth of Cut d , mm 0.2 0.3 0.4
3 Feed f, mm 0.08 0.09 0.1
4 W/p material - EN31 EN 9 EN 8
Table 4.1 Levels of Experiment
Allotment of Priorities to the Factors
As per the general rules of Design of Experiments, the first priority goes to a factor which is
most important or exhibits maximum effect on the response, but if some factor is difficult to
change during conduct of experiments, first priority should be given to such a factor.
The priority for the remaining factors can be assigned depending on their effect on the response.
Depth of cut is the most important factor from this point of view. Hence it was given second
priority. The factors with their respective priority are listed below and henceforth shall be
referred to by the numbers designated to them.
Factor number as Name of the factor

per priority
1 Spindle Speed
2 Depth of cut
3 Feed
4 Work piece material
Table 4.2 Allotment

priority

Orthogonal Array Plan for experiments
The array depicted by L9 (34) from Taguchi's Standard Orthogonal Array has been chosen for
boring process. The reasons for the choice of the array are listed in the following:
1) The array gives minimum number of experiments to be performed with factor level
chosen as per the requirement.
2) It does not have any mixed levels.
3) It considers the necessary interaction effects.
Generation of Final Orthogonal Array
The final orthogonal array is generated by allotting the factors to the columns. The allotment is
done considering factor priorities and their interaction. The array is generated by using
MINITAB software.

Fig 4.3 Steps 1, 2 for generating orthogonal array

Fig 4.4 Steps 3, 4 for generating orthogonal array

Fig 4.5 L9 Orthogonal array

4.4 ANOVA TERMS, NOTATIONS AND DEVELOPMENT
In the analysis of variance many quantities such as degrees of freedom, sums of square, mean
square etc. are computed and organized in a standard tabular format. These quantities and their
interrelationships are defined below and their mathematical development is presented.
1. Total number of trials [n] : - It is the addition of all the experimental trials performed at
different levels to determine the effect of different factors on the response.
n  n1  n2  ...  nt
2. Degrees of freedom [DOF, f] :- It is a measure of the amount of information that can be

uniquely determined from a given set of data. DOF for data concerning a factor equals
one less than the number of levels. Thus a 3 level factor has 2 DOF. The concept of DOF
can be extended to the experiment. An experiment with n trial and r repetitions of each
trial has n X r trial runs. The total DOF becomes:
ft  n  r 1
Similarly, the DOF for a sum of squares term is equal to the number of terms used to
compute the sum of squares and the DOF of the error term is given by
fe  ft  f A  f B  fC
3. Sum of Squares [St]: - The sum of squares is a measure of the deviation of the
experimental data from the mean value of the data. Summing each squared deviation
emphasizes the total deviation. Thus
n
S t   (Yi  Y ) 2
i 1
where Y is the average value of Yi.
Y represents the response or output.
4. Variance [V]:- Variance measures the distribution of the data about the mean of the data.
Since the data is representative of only a part of all possible data. DOF rather than the
number of observations is used in the calculation. It is the ratio of sum of squares to the
degrees of freedom.

St
Variance =
f
5. Variance Ratio [F]:- The variance ratio commonly called the F statistic, is the ratio of
variance due to the effect of a factor and variance due to the error term. It is named after
Sir Ronald A. Fisher. This ratio is used to measure the significance of the factor under
investigation with respect to the variance of all the factors included in the error term. The
F value obtained in the analysis is compared with a value from standard F-tables for a
given statistical level of significance. The tables for various significance levels and
different degrees of freedom are available in most handbooks of statistics. To use the
tables enter the DOF of the numerator to determine the column and the DOF of the
denominator for the row. The intersection is the F value. When the computed F value is
less than the value determined from the F tables at the selected level of significance, the
factor does not contribute to the sum of the squares within the confidence level.
V
F 
Ve
6. Pure sum of squares:- When the product of error variance and degrees of freedom is
subtracted from the sum of squares expression, the remainder is called the pure sum of
squares.
7. Percent Contribution [P]:- The percent contribution for any factor is obtained by
dividing the pure sum of squares for that factor by S t and multiplying the result by 100.
8. Confidence Intervals (C.I.): - The calculations shown in the ANOVA table are only
estimates of the population parameters. These statistics are dependent upon the size of the
sample being investigated. In statistics, it is therefore customary to represent the values of
a statistical parameter as a range within which it is likely to fall, for a given level of
confidence. This range is termed as the confidence interval (C.I.). If the estimate of the
mean value of a set of observations is denoted by E(m), then the CI for the mean is given
by:

F ( f1 , f 2 )  Ve
CI (m)  E (m)  where,
ne
F ( f1 , f 2 ) = Variance ratio for DOF f1 and f 2 at the level of significance.
f1 = DOF of mean (which always equals 1)
f 2 = DOF of error term.
Ve = Variance of error term.
ne = number of equivalent replications and is given by:

(Number of trials)
=
[DOF of mean (always 1) + DOF of the factors used in the estimate]
9. Pooling: When the contribution of a factor is small, the sum of squares for that factor is
combined with the error Se. This process of disregarding the contribution of a selected
factor and subsequently adjusting the contributions of the other factor is known as
Pooling. Pooling is usually accomplished by starting with the smallest sum of squares and
continuing with the ones having successively larger effects. Pooling is recommended
when a factor is determined to be insignificant by performing test of significance against
the error term at a desired confidence level. A general guideline for when to pool is
obtained by comparing error DOF with the total factor DOF. No matter the effect on the
results, insignificant factors should always be pooled. The larger DOF for the error term
as a result of pooling increases the confidence level of the significant factors.
10. S/N Ratio: The change in the quality characteristics of a process under investigation, in
response to a factor introduced in the experiment design is the “signal” of the desired
effect. However, when an experiment is conducted, there are numerous external factors
not designed into the experiment which influence the outcome. These external factors are
called the noise factors and their effect on the outcome of the quality characteristic under
test is termed “the noise”. The signal to noise ratio (S/N ratio) measures the sensitivity of
the quality characteristic being investigated in a controlled manner, to those external

influencing factors (noise factors) not under control. The aim of any experiment is always
to determine the highest possible S/N ratio for the result. A high value of S/N implies that
the signal is much higher than the random effects of the noise factors. Process operation
consistent with highest S/N , always yields the optimum quality with minimum variance.
The S/N analysis is designed to measure quality characteristics. From the quality point of
view, there are three possible categories of quality characteristics. They are:
1. Smaller is better.
2. Nominal is best.
3. Bigger is better.
i. Smaller-the-better
This is expressed as
n= - 10Log10 [mean of sum of squares of measured data]
This is usually the chosen S/N ratio for all the undesirable characteristics like “defects” for which
the ideal value is zero. When an ideal value is finite and its maximum or minimum value is
defined then the difference between the measured data and the ideal value is expected to be as
small as possible. Thus, the generic form of S/N ratio becomes,
n= - 10Log10 [mean of sum of squares of (measured – ideal)]
ii. Larger-the-better
n= - 10Log10 [mean of sum of squares of reciprocal of measured data]
This is often converted to smaller-the-better by taking the reciprocal of the measured data and
next, taking the S/N ratio as in the smaller-the-better case.
iii. Nominal-the-best
n= - 10Log10 [Square of mean/Variance]
This case arises when a specified value is the most desired, meaning that neither a smaller
nor a larger value is desired.

Advantages of S/N ratio over average
To analyze the results of experiments involving multiple runs, use of the S/N ratio over standard
analysis (use average of results) is preferred. Analysis using the S/N ratio will offer the following
two main advantages:
1. It provides guidance to a selection of the optimum level based on least variation around
the target and also on the average value closest to the target.
2. It offers objective comparison of two sets of experimental data with respect to variation
around the target and the deviation of the average from the target value.
Use of the S/N ratio of the results, instead of the average values, introduces some minor
changes in the analysis. Whenever an experiment involves repeated observations at each
of the trial conditions, the S/N ratio has been found to provide a practical way to measure
and control the combined influence of deviation of the population mean from the target
and the variation around the mean.
11. R-square
R-squared is a statistical measure of how close the data are to the fitted regression line. It is also
known as the coefficient of determination, or the coefficient of multiple determinations for
multiple regressions.
The definition of R-squared is fairly straight-forward; it is the percentage of the response

variable variation that is explained by a linear model. Or:
R-squared = Explained variation / Total variation
1. R-squared is always between 0 and 100%.0% indicates that the model explains none of
the variability of the response data around its mean.
2. 100% indicates that the model explains all the variability of the response data around its
mean.
In general, the higher the R-squared, the better the model provides a decent fit to the data.

12. Residuals
Residuals of a observed value is the difference between the observed value and estimated
function value.
Residual=Observed value – Fitted value
13. Regression Equation
Linear regression calculates an equation that minimizes the distance between the fitted
line and all of the data points. Technically, ordinary least squares (OLS) regression
minimizes the sum of the squared residuals.
In general, a model fits the data well if the differences between the observed values and
the model's predicted values are small and unbiased.

CHAPTER 5:
EXPERIMENTAL
SET UP

CHAPTER 5 EXPERIMENTAL SET UP
The following apparatus was used for the experimentation.
5.1 CNC MACHINE

The specifications of the CNC lathe machine which was used for the experimentation purpose is
given below:
• 2 axis slant bed lathe

• Max. Turning diameter = 165mm
• Max turning length =235 mm
• Distance between the centers = 380 mm
• Dimensions of machine : L=2300mm, H= 1900mm, W=1600mm
• 8 Station CNC Turret - 4 Rectangular and 4 Circular
The CNC lathe machine can be used for turning, facing, drilling, boring, threading and other
operations.
Fig 5.1 CNC Machine

5.2 TOOLS USED IN CNC LATHE MACHINE
a) Turning tool
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes
a helical tool path by moving more or less linearly while the work piece rotates. The tool's axes
of movement may be literally a straight line, or they may be along some set of curves or angles,
but they are essentially linear (in the nonmathematical sense). Usually the term "turning" is
reserved for the generation of external surfaces by this cutting action, whereas this same essential
cutting action when applied to internal surfaces (that is, holes, of one kind or another) is called
"boring". Thus the phrase "turning and boring" categorizes the larger family of (essentially
similar) processes. The cutting of faces on the work piece (that is, surfaces perpendicular to its
rotating axis), whether with a turning or boring tool, is called "facing", and may be lumped into
either category as a subset.
Insert
Tool Holder
Shim
Fig 5.2 Turning Tool

b) Boring tool
A boring tool is usually a modular tool, consisting of a basic holder, adaptor and a cutting unit in
the form of a cartridge, slide or fine boring unit. A fine boring head holds a boring bar which is
easily adjustable and a reamer has a tool shank with a close pitch head with brazed blades. The
tools are adjustable within a specific diameter range.
Boring Bar
Insert
Figure 5.3 – Boring Tool
Dimple Bars:
 The minimum cutting diameter is from Φ10. 5°, 7°, 11° positive inserts.
 Excellent vibration resistance due to a light dimple head.
 L/d is 3 to 5 times the diameter (Carbide shank is 7 to 8 times the diameter).
F Type Boring Bars:

 The minimum cutting diameter is from Φ5.8. 11° positive insert.
 Screw-on type and Clamp-on type.
 L/d is 3 to 5 times the diameter.
 FSWL type is 7°positive insert.
S Type Boring Bars:

 The minimum cutting diameter is from Φ11.
 ISO standard. 7°positive insert.

c) Inserts
The inserts are used for machining of the material. There are two types of inserts we have used
1-Turning inserts, 2-Boring inserts. Turning inserts were used for initial facing and turning of the
raw material. Turning inserts are TNMG 16 04 08-PM 4325, boring inserts are CNMG 12 04 08-
PM 4325.
For example 1:- CNMG 432
C N M G 4 3 2
Clearance
Shape Tolerance Groove / Hole Size (IC) Thickness Radius
Angle
Table 5.1 - Notations
For example: CNMG 120404WP
The meaning of different designation is given below:
C=Diamond shape
N= 00 angle
M=Tolerance (corner point=0.002-0.005",thikness=0.005",inscribed circle=0.002-0.005")
G=Chip breaker (cylindrical and double sided)
Width=12
Thickness=04
Radius (corner) =04
CNMG TNMG
Fig 5.4 Inserts

5.3 CNC PROGRAMMING
F code- feed
G code – preparatory function
M code- machine function
N code- block number
P,Q,R code- Parameters used in cycles
S code- spindle speed
T code – tool function
U,V,W code- second movement in parallel to X,Y,Z axes respectively
X code- movement in X-axis
Y code- movement in Y-axis
Z code- movement in Z axis
CNC Programming M codes
M00 - Program stop

M01 - Optional program stop
M02 - Program end
M03 - Spindle on clockwise
M04 - Spindle on counter clockwise
M05 - Spindle off
M06 – Tool change
M08 - Coolant on
M09 - Coolant off
M10 - Chuck or rotary table clamp
M11 - Chuck or rotary table clamp off
M19 - Orient spindle
M30 - Program end, return to start
M97 - Local sub-routine call
M98 - Sub-program call
M99 - End of sub program

CNC Programming G codes
G00 - Positioning at rapid speed

G01 - Linear interpolation (machining a straight line)
G02 - Circular interpolation clockwise (machining arcs)
G03 - Circular interpolation, counter clockwise
G04 - Mill and Lathe, Dwell
G09 - Mill and Lathe, Exact stop
G10 - Setting offsets in the program
G12 - Circular pocket milling, clockwise
G13 - Circular pocket milling, counter clockwise
G17 - X-Y plane for arc machining
G18 - Z-X plane for arc machining
G19 - Z-Y plane for arc machining
G20 - Inch units
G21 - Metric units
G27 - Reference return check
G28 - Automatic return through reference point
G29 - Move to location through reference point
G31 - Skip function
G32 - Thread cutting
G33 - Thread cutting
G40 - Cancel diameter offset; Mill. Cancel tool nose offset
G41 - Cutter compensation left; Mill. Tool nose radius compensation left
G42 - Cutter compensation right; Mill. Tool nose radius compensation right
G43 - Tool length compensation
G44 - Tool length compensation cancel
G50 - Set coordinate system and maximum RPM
G52 - Local coordinate system setting
G53 - Machine coordinate system setting
G54/G59 – Work piece coordinate system settings
G61 - Exact stop check
G65 - Custom macro call
G70 - Finish cycle
G71 - Rough turning cycle
G72 - Rough facing cycle
G73 - Irregular rough turning cycle
G73 - Chip break drilling cycle
G74 - Left hand tapping
G74 - Face grooving or chip break drilling
G75 - OD groove pecking
G76 - Fine boring cycle
G76 - Threading cycle
G80 - Cancel cycles
G81 - Drill cycle
G82 - Drill cycle with dwell
G83 - Peck drilling cycle
G84 - Tapping cycle
G85 - Bore in, bore out
G86 - Bore in, rapid out
G87 - Back boring cycle
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point
G92 - Thread cutting cycle
G94 - Per minute feed
G95 - Per revolution feed
G96 - Constant surface speed control
G97 - Constant surface speed cancel
G98 - Per minute feed
G99 - Per revolution feed

Few programs which were generated are: -
STEP TURNING SIMPLE TURNING

G28 U0.0 W0.0;
G28 U0.0 W0.0;
T0404;
T0404; M04 S1200;
G0 Z2.0;
M04 S1000;
G0 X45.0;
G0 X25.0; G71 U0.2 R0.5;
G71 P10 Q20 U0.2 W0.0 F0.1;
Z2.0;
N10 G0 X25.0;
G71 U0.075 R0.5; G01 Z0.0;
X25.0 Z-10.1;
G71 P21 Q21 U0.0 W0.0 F0.1;
X30.0 Z-10.0;
N21 G0 X20.0; X30.0 Z-20.0;
X40.0 Z-20.0;
G01 Z0.0;
N20;
X20.0 Z-25.0; G0 G40 X45.0 ;
G28 U0.0;
X45.0;
G28 W0.0;
N21; M01;
G0 G40 Z2.0; M30;

%
G0 X45.0;
G28 U0.0;
G28 W0.0;
M01;
M30;

5.4 CNC PROGRAM FOR BORING USED FOR EXPERIMENTATION
G28 U0.0 W0.0;
T0505;
M03 S900;
G0 Z2.0;
G0 X-83.0;
G71 U0.1 R0.5;
G71 P50 Q100 U0.1 W0.0

F0.02;
M50 G0 X-85.0;
Fig 5.5- Work piece
G01 Z0.0;
X-85.0 Z-50.0;
X-83.0;
N100;
G40 Z10.0;
G0 X-75.0;
G70 P50 Q100 F0.1;
G0 G40 X-75.0;
G0 Z10 ;
G28 U0.0 W0.0;
M01;
M30;

5.5 WORK PIECES
The work pieces selected for the experiment are:
(EN refers to the European Norms)
i. EN 8
Carbon % 0.36 – 0.44
Silicon % 0.1 – 0.4
Manganese % 0.6 - 1
Sulphur % 0.05 max
Phosphorous % 0.05 max
Table 5.2 – Chemical Composition of EN 8
Hardness – 74.5 HRB

Application: EN 8 finds its application in crank shafts, automobile axle beams,
connecting rods, lightly stressed gears. It is generally used for moderately stressed parts
of motor vehicles and general engineering works.
ii. EN 9
Carbon % 0.5 – 0.6
Silicon % 0.5 - 0.8
Manganese % 0.05 – 0.35
Sulphur % 0.04 max
Phosphorous % 0.04 max
Table 5.3 – Chemical Composition of EN

9
Hardness – 70 HRB
Application: EN 9 finds its application in crank shafts, cylinders, gears, sprockets. It is
mainly used in machine parts which require moderate wear resistance.

iii. EN 31
Carbon % 0.9 – 1.2
Silicon % 0.3 – 0.75
Manganese % 0.1 – 0.35
Sulphur % 0.04
Phosphorous % 0.04
Chromium % 1 – 1.6
Table 5.4 – Chemical Composition of EN 31
Hardness – 82 HRB
Application: EN 31 finds its application in ball and roller Bearings, spinning tools,
beading rolls, punches and pies.
Specifications:
Type: Hollow Shaft

Outer diameter: 110 mm
Inner Diameter: 80 mm
Length: 140 mm
Figure 5.6 – Work piece

5.5.1 Cross Reference of Standards For Equivalent Grades Of Steel
1. BEARING QUALITY STEEL
BS DIN IS EN SAE/AISI
534A99/535A a)
99 100Cr6 103Cr1 EN31 52100
2. ALLOY STEEL
530A40 37Cr4 40Cr1 EN18 5140
817M40 34CrNiMo6 40NiCr4Mo3 EN24 4340
709M40 - 40Cr4Mo3 EN19C 4140,4142
709M40 42Cr4Mo2 40Cr4Mo3 EN19 4140,4142
530A40 37Cr4 40Cr1 EN18D 5140
530A40 37Cr4 40Cr1 EN18C 5140
815M17 - 15NiCr1Mo12 EN353 -
530A40 37Cr4 40Cr1 EN18A 5140
820M17 - 15NIVCr1Mo15 EN354 4320
- 28Mn6 27C15 - 1527
- 20MnCr5 20MnCr1 - -
150M28 - 20Mn2 EN14A 1524
- 16MnCr5 17Mn1Cr95 - 5120
523A14 15Cr3 15Cr65 EN206 5015
530A40 37Cr4 40Cr1 EN18B 5140 b)
805M20 - 20NiCrMo2 EN362 SAE8620
3. CARBON STEEL
150M36 36Mn5 37Mn2, 37C15 EN15B 1536
- CK15 C14 EN32B 1015,1016,1018
- CK38 - - 1038
- - C50 EN43C 1050
- CK45 45C8 1045 -
070M55 CK55 C55 EN9 1055
- C35 35C8, C35Mn75 - 1035
- CK75 80C6 EN42 1074
- C67 65C6 EN42B 1065
080M50 C55 60C6 EN43 1055
080A47 CK45 - EN43B 1045
150M36 36Mn7 37C15 EN15,15A SAE1541
080A40 CK45 45C8 EN8 1040,1045
080A40 CK45 45C8 EN8A 1040,1045
080A40 CK45 45C8 45C8 1040,1045
080A40 CK45 45C8 EN8C 1040,1045 c)
080A40 CK45 45C8 EN8D 1040,1045

4. HIGH CARBON STEEL
EN SAE/AISI JIS***
- 1075 SWRH77B
- 1080 SWRH82B
- 1080 SWRH82B
- 1080 SWRH82B
- 1080 SWRH82B
EN5D 1030 SWRH32B
- 1035 SWRH37B
EN8 1040 SWRH42B
EN43B 1045 SWRH47B
- 1050 SWRH52B
EN9 1055 SWRH57B
EN43D 1060 SWRH62B
EN42B 1065 SWRH67B
- 1070 SWRH72B
- 1075 SWRH77B, SUP3
- 1080 SWRH82B
- 1085 SWRH87B d)
- 1090 3CD95A
5. SPRING STEEL
BS DIN IS EN SAE/AISI JIS

- 60Si7 60Si7 EN45A - -
- 59Si7 - EN45A 9260 SUP7
685A57 54SiCr6 - - 9254 SUP12V
- 55Si7 55Si7 EN45A - -
250A53 55Si7 55Si2Mn90 EN45 9255 -
- 65Si7 - EN45A 9260 -
250A58 - - EN45A 9260 -
735A51 50CrV4 50Cr4V2 EN47 6150 SUP10
- - - - 9254 -
- - - - 9260 SUP7N
- - - - 51B60 SUP11A
- 55Cr5 - - 5155 SUP9
e)

6. COLD HEADING QUALITY STEEL - CHQ

070M20 CK22 C20 EN 3A SAE1020 SWRCH20A
- - - - SAE1022 -
709M40 42CrMo4 40Cr4Mo3 EN19 SAE4140 SCM440
- H111 C-15Mn75 EN2C SAE1018 -
150M36 36Mn7 37C15 EN15,15A SAE1541 SMn438
- - - - 15B41 -
- CK45,C45 45C8,C45 - 1045 -
- CK15 - EN32B SAE1015 -
- CK38 - - 1038 -
040A12 CK10 C7, C10 2A/1,2B SAE1012 SWRCH12A
- - 26C10BT - 15B25 -
- CK10 C10 - SAE1010 -
- - 21C10BT - 10B21 -
040A04 C10 C5 2A,2A/1,2B SAE1008 SWRCH8A
f)
7.. FREE CUTTING STEEL

216M36 - 40Mn15S12 ENI5(AM) 1137 -
220Mo7 9SMn28 11C10S25 EN1A 1213 SUM22
220Mo7Pb 9SMnPb36 - EN1APB 12L14 SUM24L
212M36 - 40C10S18 EN8M 1I46 -
- - 40C10S18 EN8M SAE1146 -
g)
8. LOW CARBON STEEL

040A04 C10 CS 2A, 2A/1, 2B SAE1008 SWRCH8A
- CK15 - - SAE1015 -
040A12 CK10 C7, C10 2A/1, 2B SAE1012 SWRCH12A
- CK10 C10 - SAE1010 -
040A04 C10 C5 2A, 2A/1, 2B SAE1008 SWRCH8A
070M20 CK22 C20 EN 3A SAE1020 SWRCH20A
- CK15 C15Mn75 EN32B,EN32C SAE1018 -
h)

9. MATERIAL CROSS REFERENCE LIST FOR CARBON STEEL
USA Japan Germany U. K. France China
AISI/SAE JIS W-nr. DIN BS EN AFNOR
STKM 12A 4360 E 24- 2
A570.36 1.0038 RSt.37-2 – 15
STKM 12C 40 C Ne
1015 – 1.0401 C15 080M15 – CC12 15
1020 – 1.0402 C22 050A20 2C CC20 20
1213 SUM22 1.0715 9SMn28 230M07 1A S250 Y15
12L13 SUM22L 1.0718 9SMnPb28 – – S250Pb –

– – 1.0722 10SPb20 – – 10PbF2 –
1215 – 1.0736 9SMn36 240M07 1B S300 Y13
12L14 – 1.0737 9SMnPb36 – – S300Pb –
1015 S15C 1.1141 Ck15 080M15 32C XC12 15
1025 S25C 1.1158 Ck25 – – – 25
4360 55
A572-60 – 1.890 StE380 – – –
E
1035 – 1.0501 C35 060A35 – CC35 35
1045 – 1.0503 C45 080M46 – CC45 45
1140 – 1.0726 35S20 212M36 8M 35MF4 –
1039 – 1.1157 40Mn4 150M36 15 35M5 40Mn
1335 SMn438(H) 1.1167 36Mn5 – – 40M5 35Mn2
1330 SCMn1 1.1170 28Mn6 150M28 14A 20M5 30Mn
1035 S35C 1.1183 Cf35 060A35 – XC38TS 35Mn
1045 S45C 1.1191 Ck45 080M46 – XC42 Ck45
1050 S50C 1.1213 Cf53 060A52 – XC48TS 50
1055 – 1.0535 C55 070M55 9 – 55
1060 – 1.0601 C60 080A62 43D CC55 60
1055 S55C 1.1203 Ck55 070M55 – XC55 55
1060 S58C 1.1221 Ck60 080A62 43D XC60 60Mn
1095 – 1.1274 Ck101 060A96 – XC100 -
W1 SK3 1.1545 C105W1 BW1A – Y105 -
W210 SUP4 1.1545 C105W1 BW2 – Y120 -
i)
Table 5.5 (a-i) – Cross Reference of Standards for Equivalent Grades Of Steel

5.6 SENSORS
a) Integrated Circuit Piezoelectric (ICP) Accelerometer Sensor
An integrated circuit piezoelectric sensor or ICP sensor is a device used to measure dynamic
pressure, force, strain, or acceleration. It contains a sensing element made of
a piezoelectric material, which converts mechanical strain into an electrical signal, and
an electronic circuit to amplify this signal and transmit it to an external device. In an ICP sensor,
the built-in electronics convert the high-impedance charge signal that is generated by the
piezoelectric sensing element into a usable low-impedance voltage signal that can be readily
transmitted, over ordinary two-wire or coaxial cables, to any voltage readout or recording device.
Function
Piezoelectric accelerometers rely on the piezoelectric effect of quartz or ceramic crystals to
generate an electrical output that is proportional to applied acceleration. The piezoelectric effect
produces an opposed accumulation of charged particles on the crystal. This charge is
proportional to applied force or stress. A force applied to a quartz crystal lattice structure alters
alignment of positive and negative ions, which results in an accumulation of these charged ions
on opposed surfaces. These charged ions accumulate on an electrode that is ultimately
conditioned by transistor microelectronics.
Specifications:
Sensitivity: 101.1 mV/g

Discharge Time Constant: 1.4 seconds
Output Bias: 11.1 VDC
Transverse Sensitivity: 0.2%
Resonant Frequency: 57.3 Hz
Figure 5.7 – ICP Accelerometer

b) G.R.A.S Microphone
Its small ceramic thick-film substrate has very high input impedance and is shielded by a
guarding to minimize the influence of stray capacitance and micro phonic interference. The
G.R.A.S. 26CB is delivered with a built-in TEDS chip and can be programmed as a single unit
with a microphone fitted.
Specifications:
Frequency range: 2.5 Hz – 200 kHz

Noise: 1.8 µV
Gain: -0.35 dB
Figure 5.8 G.R.A.S Microphone
5.7 SENSOR MOUNTING
The G.R.A.S microphone and the ICP Accelerometer sensor were mounted on the boring bar.
The mounting on the boring bar would be done by the industrial fibre glass tape. Industrial Fibre
glass Tapes offers comprise narrow, cloth strip that feature woven edge support that assists in
preventing unravelling. These tapes are developed using twisted strands of fibreglass that come
woven at right angles with one another with cloth support featuring high glass-to-resin ratio.
Also known by the name of non-alkali tapes, the main component in this tape is E-glass,
oxidation sodium and oxidation potassium with oxidation of alkali metals content not more than
0.5%.
Features:
1. Provides for complete binding solutions.
2. Having high tensile strength & reinforcing quality.
3. Suitable for handling the process needs of electrical
mending.
4. Are deformation-resistant and deliver superior self-
adhesive performance.
5. Used at 1000°F /537°C continuous, 1112°F /600°C.
Fig 5.9 Fibre glass tape

Accelerometer
Microphone
Fig 5.10 Sensor Mountings on Boring
Bar

5.8 DATA ACQUISITION SYSTEM (DAQ)
Data acquisition is the process of sampling signals that measure real world physical conditions
and converting the resulting samples into digital numeric values that can be manipulated by a
computer. Data acquisition systems (abbreviated with the acronym DAS or DAQ) typically
convert analog waveforms into digital values for processing. DAQ device drivers are needed in
order for the DAQ hardware to work with a PC. The device driver performs low-level register
writes and reads on the hardware, while exposing API for developing user applications in a
variety of programming environments. Data acquisition applications are controlled by software
programs developed using various general purpose programming languages such
as LABVIEW, BASIC, C, FORTRAN, JAVA, LISP, PASCAL. Stand-alone data acquisition
systems are often called data loggers. The components of data acquisition systems include:
i. Sensors that convert physical parameters to electrical signals.

ii. Signal conditioning circuitry to convert sensor signals into a form that can be converted
to digital values.
iii. Analog-to-digital converters, which convert conditioned sensor signals to digital values.
Fig 5.11 DAQ System

5.9 SURFACE MEASUREMENT TESTER
Surface roughness, often shortened to roughness, is a component of surface texture. It is
quantified by the deviations in the direction of the normal vector of a real surface from its ideal
form. If these deviations are large, the surface is rough; if they are small, the surface is smooth.
Roughness is typically considered to be the high-frequency, short-wavelength component of a
measured surface (see surface metrology). However, in practice it is often necessary to know
both the amplitude and frequency to ensure that a surface is fit for a purpose. The Surface Finish
was measured using a Portable Surface Roughness Tester - Surftest SJ-201P. It allows, by means
of a tip attached to a rigid cantilever that cans the surface of a sample, to provide a fast and
accurate measurement of the surface texture. This roughness measurement technique is widely
used in surface science and especially in tribology, where the detail of the surface state before
and after test can lead to a better understanding of the results.
Fig 5.12 - Terminologies

Fig 5.13 Surface Roughness Fig 5.14 Working principle
Tester - MITUTOYO SJ201-P
Measuring range (X-axis) 12.5mm
Measuring speed 0.25, 0.5mm/s (0.25mm/s: S-type)
Range 350µm (-200µm to +150µm)

Measurement method skidded
Measuring force 4mN or 0.75mN
Stylus tip Diamond, 90º / 5µmR (60º/2µmR)
Skid radius of curvature 40mm
Skid force less than 400mN
Type Differential inductance
Dimensions (W*D* H)
Control unit 156.5 x 62 x 52mm (SJ-201)
Drive unit 115 x 23 x 26mm
Mass
Control unit Approx. 0.3kg (SJ-201)
Drive unit 0.2kg
Table 5.6 Specifications

5.10 ANALYTICAL BALANCE
Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term
often associated with tipped tools, tool bits, or drill bits that are used with machine tools.
Types of wear include:
 Flank wear in which the portion of the tool in contact with the finished part erodes. Can
be described using the Tool Life Expectancy equation.
 Crater wear in which contact with chips erodes the rake face. This is somewhat normal
for tool wear, and does not seriously degrade the use of a tool until it becomes serious
enough to cause a cutting edge failure.
Fig 5.15 - Terminologies

Tool wear was calculated by the measuring the initial and final weight of the insert. The weight
of the insert was measured using the analytical balance. The analytical balance has a least count
of 0.1mg.
Specifications:
 Interfaces: RS232
 Adjustment: Internal / FACT
 Resolution: 0.1 mg
 Housing: Die-cast Aluminium, plastic
ABS
 Dimensions Depth: 331.0 mm
 Dimensions Height: 290.0 mm
 Dimensions Width: 193.0 mm
 Max. Capacity: 220.0mg
 Repeatability: 0.08mg
 Min. Weight: 160.0mg
 Weighing Pan Diameter: 90.0mm
Fig 5.16 Analytical balance
5.11 LABVIEW & MINITAB SOFTWARE
LABVIEW (short for Laboratory Virtual Instrument Engineering Workbench) is a system-design

platform and development environment for a visual programming language from National
Instruments. A virtual interface was created in the LABVIEW for acquiring the sound signal,
vibration signal and vibration frequency. MINITAB software is a statistical design software. It
was used for ANOVA calculations and generation of orthogonal array.
We used MINITAB version 17 and LABVIEW version 8.0 .

Fig 5.17 Virtual Interface and Block Diagram (LABVIEW Software) for
acquisition of sound signals through microphone
Fig 5.18 Virtual Interface and Block Diagram (LABVIEW Software) for
acquisition of vibration signals through accelerometer

Fig 5.19 Acquisition of sound signals through microphone in LABVIEW
Software
Fig 5.20 Recorded Sound Log data in Excel Sheet

Fig 5.21 Acquisition of vibration signals through accelerometer in LABVIEW Software
Fig 5.22 Recorded Vibration Log data and Frequency in Excel Sheet

Fig 5.23 Complete Experimental Setup

CHAPTER 6:
OBSERVATIONS

CHAPTER 6 OBSERVATIONS
The observation table includes the input and output factors of the boring operation. Input factors
are spindle speed, depth of cut, feed, and work piece material. Output factors are Surface
roughness, Tool wear, Sound and Vibration. Two trial runs were done to check the repeatability
of the experiment. The data acquired through the sensors in the excel sheet was taken in 2
iterations for each experimental run and then the average of the 2 iteration was considered as the
observation for the Sound and vibration. The sound signal is measured in terms of sound
pressure (Pascal). The vibration is measured in terms of sound pressure (Pascal) and also the
vibration frequency. 9 work pieces were used for the experimentation which includes 3 work
pieces each for the EN 8, EN 9, and EN 31 respectively. Tool wear was calculated using the
weight of the insert before and after the machining.
The first four columns in the observation table indicate the L9 orthogonal array with the levels of
the experiment and the next 4 columns indicate the output factors of the experimentation.
The observation tables are as follows :

Table 6.1 Observation table for first run
Table 6.2 Observation table for second run

Level INITIAL FINAL WEIGHT TIME TOOL
WEIGHT(gm) (gm) (min) WEAR RATE
(mm3/min)
1 8.8896 8.8893 30.02 0.000689195
2 8.8806 8.8793 32.06 0.00279648
3 8.8867 8.8858 29.42 0.00210975
4 8.8860 8.8856 13.4 0.00205867
5 8.8893 8.8890 15.67 0.00132033
6 8.8793 8.8802 19.68 -0.00315391
7 8.8802 8.8808 14.01 -0.00295355
8 8.8858 8.8865 18.32 -0.00263514
9 8.8890 8.8904 9.65 -0.010005
Table 6.3 Observation table for tool wear
Tool Wear rate (mm3/min) = (Wi) – (Wf)/T*ρ

Where, Wi = Initial weight (gm)
Wf = Final weight (gm)
T= Time (min)
ρ = Density (14.5 gm/cm3)

CHAPTER 7:
CALCULATIONS

CHAPTER 7 CALCULATIONS
7.1 ANOVA CALCULATIONS FOR FIRST RUN
ANOVA TERMS
DOF – Degree of freedom

SS- Sum of Squares
MS- Mean Square
F, P- Statistical Parameters of ANOVA
Percent Contribution – It shows how a input factor contributes to the output factor
7.1.1 ANOVA Calculations for Surface Roughness

Regression Equation
Surface Roughness = 1.096 - 0.116 Spindle Speed_150 - 0.296 Spindle Speed_200

+ 0.411 Spindle Speed_250 - 0.072 Feed_0.08 + 0.201 Feed_0.09
- 0.129 Feed_0.10 - 0.259 Depth of Cut_0 + + 0.191 Depth of
Cut_0.3+ 0.068 Depth of Cut_0.4
S R-sq R-sq(adj) R-sq (pred)

0.825840 49.19% 0.00% 0.00%

In Table 7.1.1, column 1 represents variable sources such as spindle speed, feed, and depth of
cut. In next columns degree of freedom (DF), adjusted sum of square (Adj SS), adjusted mean of
square (Adj MS), distribution (F) and probability (P) are calculated respectively. The standard
deviation of errors in modelling, S= 0.825840, R2 =49.19% which indicates that model is not
capable of predicting response with higher accuracy. The table shows Spindle speed has the
maximum percent contribution of 30.144% and Feed and Depth of Cut has 6.95% and 12.084%.
There are three assumptions in ANOVA analysis: normality, constant variance, and
independence. The normality plot of the residuals is used to check the normality of the treatment
data. If the distribution of residuals is normal, the plot will resemble a straight line. Here, since
the distribution of residuals is about the straight line, it confirms the normality of treatment data.
The constant variance assumption is checked by the plot of residuals versus fitted values. If the
plot of residual vs. fitted values (treatment) does not show any pattern, the constant variance
assumption is satisfied. The residuals v/s fitted value plot confirms the second assumption of
constant variance as there is no specific pattern can be detected. If the plot of residual vs. run
order (time order of data collection) does not reveal any pattern, the independence assumption is
satisfied. Here as there is no specific pattern detected, the assumption of independence is
satisfied.

When the effect of one factor depends on the level of the other factor, one can use an interaction
plot to visualize possible interactions. Parallel lines in an interaction plot indicate no interaction.
The greater is the difference in slope between the lines, the higher the degree of interaction.
However, the interaction plot doesn't alert you if the interaction is statistically significant.
Since the factors are more than two, the matrix for interaction plot is shown in the graph. In this
graph, the first row shows the interaction plot between spindle speed vs feed, spindle speed vs
depth of cut, spindle speed vs workpiece material. From this we can conclude that there is
interaction between spindle speed, feed, depth of cut and workpiece material for different levels.
The second row shows the interaction plot between feed vs depth of cut and feed vs workpiece
material. As different lines have steep slope and intersecting each other, there is significant
interaction. The third plot is between depth of cut vs workpiece material. Since all the lines are
intersecting, there is interaction between depth of cut and workpiece material.

Graph 7.3 Main effect plots for Surface Roughness
When the line is horizontal (parallel to the x-axis), then there is no main effect. Each level of the
factor affects the response in the same way, and the response mean is the same across all factor
levels. When the line is not horizontal, then there is a main effect. Different levels of the factor
affect the response differently. The steeper is the slope of the line, the greater the magnitude of
the main effect.
This plot is plotted against the data means for surface roughness and spindle speed, feed, depth
of cut, workpiece material. From spindle speed 150 rpm to 200 rpm the surface roughness
decreases but From 200 rpm to 250 rpm the surface roughness increases. For the feed rate of
0.08mm/rev the surface roughness is low but it increases for feed rate 0.09 mm/rev and again
decreases for a feed rate 0.10 mm/rev. The mean values increases as depth of cut increases from
0.2 to 0.3 and decreases again for 0.4mm.The EN 8(3) workpiece has the highest value for
surface roughness and EN 31(1) has the lowest surface roughness. This means that, the EN 31
grade material gives the good surface finish as compared to EN 8 grade material for defined
levels of parameters.

The smaller the better approach is used for the S/N ratio analysis of surface roughness. On the Y-
axis mean values for SN ratios are plotted against the different levels of parameters. The graph
shows the optimum value of the all the factors. The dotted line shows the optimum mean of SN
ratio. So, the graph represents that if we perform the experimentation with Spindle Speed -
200rpm, Feed – 0.1mm/rev and Depth of Cut – 0.4, we will get the minimum value of the S/N
ratio.

7.1.2 ANOVA Calculations for Sound Signal (Pressure)
Table 7.1.2 ANOVA table for Sound signal

Regression Equation
Sound Signal = -0.01106 + 0.0297 Spindle Speed_150 - 0.0450 Spindle Speed_200

+ 0.0153 Spindle Speed_250 - 0.0022 Feed_0.08 - 0.0234 Feed_0.09
+ 0.0256 Feed_0.10 + 0.0020 Depth of Cut_0.2 - 0.0007 Depth of Cut_0.3
- 0.0013 Depth of Cut_0.4
S R-sq R-sq(adj) R-sq (pred)

0.0246673 91.47% 65.88% 0.00%
In Table7.1.2, column 1 represents variable sources such as spindle speed, feed, and depth of cut.
In next columns degree of freedom (DF), adjusted sum of square (Adj SS), adjusted mean of
deviation of errors in modelling, S= 0.0246673, R2 =91.47% which indicates that model is
capable of predicting response with higher accuracy. The table shows Spindle speed has the
maximum percent contribution of 65.968% and Feed and Depth of Cut has 25.36% and 0.133%
respectively.

satisfied.

interaction between spindle speed , feed, depth of cut and workpiece material for different levels.
interaction. The third plot is between depth of cut v/s workpiece material. Since all the lines are

Graph 7.7 Main effect plots for Sound Signal
the main effect. In the graph 7.7, the line is not horizontal, then there is a main effect and it also
justifies that Spindle speed is the significant factor.

7.1.3 ANOVA Calculations for Vibration Signal (Pressure)
Table 7.1.3 ANOVA table for Vibration Signal (Pressure)

Regression Equation
Vibration signal = 0.1508 - 0.018 Spindle Speed_150 - 0.017 Spindle Speed_200

+ 0.035 Spindle Speed_250 - 0.037 Feed_0.08 - 0.150 Feed_0.09
+ 0.187 Feed_0.10 + 0.075 Depth of Cut_0.2 + 0.084 Depth of Cut_0.3
- 0.159 Depth of Cut_0.4
S R-sq R-sq(Adj) R-sq(pred)

0.240383 71.93% 0.00% 0.00%
In Table, column 1 represents variable sources such as spindle speed, feed, and depth of cut. In
next columns degree of freedom (DF), adjusted sum of square (Adj SS), adjusted mean of square
(Adj MS), distribution (F) and probability (P) are calculated respectively. The standard deviation
of errors in modelling, S= 0.240383, R2 =71.93% which indicates that model is capable of
predicting response with medium accuracy.. The table shows Feed has the maximum percent
contribution of 42.97% and Spindle Speed and Depth of Cut has 1.3% and 27.65% respectively.

Graph 7.8 Residual plots for Vibration Signal (Pressure)
satisfied.

Graph 7.9 Interaction plots for Vibration Signal (Pressure)
interaction between spindle speed , feed, depth of cut and workpiece material for different levels.
material. As different lines has steep slope and intersecting each other, there is significant

Graph 7.10 Main effect plots for Vibration Signal (pressure)
justifies that Feed is the significant factor.

7.1.4 ANOVA Calculations for Vibration Signal (Frequency)
Table 7.1.4 ANOVA table for Vibration Signal (Frequency)

Regression Equation
Vibration signal = 750.1 - 39.1 Spindle Speed_150 + 36.6 Spindle Speed_200

+ 2.5 Spindle Speed_250 + 23.5 Feed_0.08 + 56.8 Feed_0.09
- 80.2 Feed_0.10 + 29.7 Depth of Cut_0.2 –
6.6 Depth of Cut_0.3 - 23.1 Depth of Cut_0.4
S R-sq R-sq(adj) R-sq(pred)

82.9367 76.03% 4.14% 0.00%
In Table7.1.4, column 1 represents variable sources such as spindle speed, feed, and depth of cut.
In next columns degree of freedom (DF), adjusted sum of square (Adj SS), adjusted mean of
deviation of errors in modelling, S= 82.9367, R2 =76.03% which indicates that model is capable
of predicting response with medium accuracy. The table shows Feed has the maximum percent
contribution of 53.37% and Spindle Speed and Depth of Cut has 15.02% and 7.635%
respectively.

Graph 7.11 Residual plots for Vibration Signal (Frequency)
satisfied.

Graph 7.12 Interaction plots for Vibration Signal (Frequency)

Graph 7.13 Main effect plots for Vibration Signal (Frequency)
justifies that Feed is the significant factor.

7.2 ANOVA CALCULATIONS FOR SECOND RUN
7.2.1 ANOVA Calculations for Surface Roughness

Regression Equation
Surface Roughness = 1.946 - 0.069 Spindle Speed_150

0.596 Spindle Speed_200+ 0.664 Spindle Speed_250 - 0.392 Feed_0.08
+ 0.108 Feed_0.09+ 0.284 Feed_0.10 + 0.134 Depth of Cut_0.2 -
0.106 Depth of Cut_0.3 - 0.029 Depth Of Cut_0.4
0.964319 63.47% 0.00% 0.00%
capable of predicting response with medium accuracy. The table shows Spindle speed has the
maximum percent contribution of 47.188% and Feed and Depth of Cut has 14.215% and 1.77%.

satisfied.


Graph 7.16 Main Effect plot for Surface Roughness

The smaller the better approach is used for the S/N ratio analysis of surface roughness. On the Y-
axis mean values for SN ratios are plotted against the different levels of parameters. The graph
shows the optimum value of the all the factors. The dotted line shows the optimum mean of SN
ratio. So, the graph represents that if we perform the experimentation with Spindle Speed -
150rpm, Feed – 0.08mm/rev and Depth of Cut – 0.4, we will get the minimum value of the S/N
ratio.

7.2.2 ANOVA Calculations for Sound Signal
Table 7.2.2 ANOVA table for Sound Signal

Regression Equation
Sound signal = 0.02564 - 0.02693 Spindle Speed_150 - 0.00857 Spindle Speed_200

+ 0.03550 Spindle Speed_250 - 0.01557 Feed_0.08 + 0.03069 Feed_0.09 -
0.01512 Feed_0.10 + 0.02624 Depth Of Cut_0.2 - 0.00054 Depth Of Cut_0.3 -
0.02571 Depth Of Cut_0.4
0.0207419 94.39% 77.54% 0.00%
capable of predicting response with medium accuracy. The table shows Spindle speed has the
maximum percent contribution of 47.297% and Feed and Depth of Cut has 27.665% and
20.419%.

satisfied.


Graph 7.20 Main Effect plot for Sound Signal

7.2.3 ANOVA Calculations for Vibration Signal (Pressure)

Regression Equation
Vibration signal (pressure) = 0.0771 - 0.0449 Spindle Speed_150 - 0.0765 Spindle Speed_200
+ 0.1214 Spindle Speed_250 - 0.0771 Feed_0.08
+ 0.1370 Feed_0.09 - 0.0599 Feed_0.10 + 0.1608 Depth Of Cut_0.2
- 0.0739 Depth Of Cut_0.3 - 0.0869 Depth Of Cut_0.4
0.202642 76.63% 6.53% 0.00%
capable of predicting response with medium accuracy. The table shows depth of cut has the
maximum percent contribution of 33.170% with Feed and spindle speed as 24.156% and
19.305% respectively.

Graph 7.21 Residual plots for Vibration Signal (Pressure)
(
satisfied.

Graph 7.22 Interaction plots for Vibration Signal (Pressure)
material. As different lines has steep slope and intersecting each other , there is significant

Graph 7.23 Main Effect plot for Vibration Signal (Pressure)
justifies that Depth of Cut is the significant factor.

7.2.4 ANOVA Calculations for Vibration Signal (Frequency)
Table 7.2.4 ANOVA table for Vibration Signal (Frequency)

Regression Equation
Vibration signal (frequency) = 792.3 + 28.9 Spindle Speed_150 - 0.3 Spindle Speed_200 -
28.6 Spindle Speed_250 + 19.6 Feed_0.08 - 1.5 Feed_0.09 -
18.1 Feed_0.10 - 18.4 Depth of Cut_0.2- 45.7 Depth of
Cut_0.3 + 64.1 Depth of Cut_0.4
96.8972 58.73% 0.00% 0.00%
capable of predicting response with medium accuracy. The table shows depth of cut has the
maximum percent contribution of 43.083% with Feed and spindle speed as 4.727% and 10.92%
respectively.

Graph 7.24 Residual plots for Vibration Signal (frequency)
satisfied.

Graph 7.25 Interaction plots for Vibration Signal (frequency)
interaction between spindle speed, feed, and depth of cut and workpiece material for different
levels.

Graph 7.26 Main Effect plot for Vibration Signal (frequency)
justifies that Depth of Cut is the significant factor.

7.3 ANOVA CALCULATIONS FOR TOOL WEAR
Source DOF SS MS F P % Contribution

Spindle 2 0.000081 0.000040 5.35 0.158 60.447
Speed
Feed 2 0.000031 0.000015 2.04 0.329 23.134
Depth 2 0.000007 0.000003 0.685 0.685 5.223

of cut
Error 2 0.000015 0.000008
Total 8 0.000134
Table 7.3 ANOVA table for Tool Wear
Regression Equation
Tool wear(mm3 /min) = -0.001086 + 0.00295 Spindle Speed_150

+ 0.00116 Spindle Speed_200 - 0.00411 Spindle Speed_250 + 0.00102 Feed_0.08
+ 0.00158 Feed_0.09 - 0.00260 Feed_0.10 - 0.00061 Depth Of Cut_0.2 -
0.00063 Depth Of Cut_0.3 + 0.00124 Depth Of Cut_0.4
0.0027508 88.69% 54.77% 0.00%
capable of predicting response with medium accuracy. The table shows spindle speed has the
maximum percent contribution of 60.447% with Feed and depth of cut as 23.134% and 5.223%
respectively.

Graph 7.27 Residual plots for Tool Wear
satisfied.

Graph 7.28 Interaction plots for Tool Wear

Graph 7.29 Main Effect plot for Tool Wear
justifies that Spindle Speed is the significant factor.

CHAPTER 8:
RESULT AND
DISCUSSION

CHAPTER 8 RESULT AND DISCUSSION
8.1 COMPARISON OF RESULT OF 2 RUNS
Output parameter Factors % contribution
Run 1 Run 2
Surface Roughness Spindle Speed 30.144 47.188
Feed 6.95 14.515

Depth of Cut 12.084 1.770
Sound Spindle Speed 65.968 40.297
Signal(Pressure) Feed 25.36 27.665
Vibration Spindle Speed 1.3 19.305
Signal(Pressure) Feed 42.97 24.156
Vibration Spindle Speed 15.02 10.92
Signal(Frequency) Feed 53.37 4.727
Tool Spindle Speed 60.869 -
3
Wear(mm /min) Feed 23.478 -
Depth of Cut 5.217 -
Table 8.1 Comparison Table

8.2 DISCUSSION
1. The factors that affect surface roughness are spindle speed, feed and depth of cut with
their percent contribution as 30.144%, 6.95% and 12.084% from run 1 and 47.188%,
14.515%, and 1.770% from run 2 respectively.
2. The factors spindle speed, feed, and depth of cut with percent contribution as 65.968%,
25.36%, 0.133% has significant effect on sound signal. Also from run 2 the dominance of
spindle speed can be seen with %contribution of 40.297% along with %Contribution of
feed and depth of cut as 27.665%, 20.419% respectively.
3. Feed has the contribution of 42.97% in the analysis of vibration signal(pressure) from
run 1.But the analysis of run 2 depth of cut has major contribution with 33.170%,
followed by feed 24.156% and spindle speed 19.305% in the vibration signal (pressure).
4. Again in the analysis of vibration signal (frequency) the feed has the major contribution
with a percentage of 53.37.But in run 2 the contribution of depth of cut is 43.083%,
followed by spindle speed 10.92% and feed 4.727% respectively.
5. The factors that affect Tool wear rate (mm3/min) are spindle speed, feed and depth of cut
with their percent contribution as 60.447%, 23.134%, 5.223% respectively.

CHAPTER 9:
CONCLUSION AND
FUTURE SCOPE

CHAPTER 9 CONCLUSION AND FUTURE SCOPE
1. From the analysis of both the runs it can be concluded that, Spindle speed is the most
significant factor in surface roughness.
2. The spindle speed has the major contribution in the sound occurring during machining
along with feed rate and depth of cut.
3. The feed and depth of cut are the major factors that should be controlled to reduce the
vibrations on the Boring bar along with L/D ratio (L/D ratio is assumed constant (=6) for
this analysis).
4. The spindle speed and feed are major factors that contribute towards Tool Wear.
5. This experimental investigation was carried out to find the suitability of Vibration and
acoustic signals for monitoring tool life.

CHAPTER 10:
REFERENCES

CHAPTER 10 REFERENCES
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ANNEXURES

ANNEXURE 1: PROJECT GROUP MEMBERS
ANURAG SARDA
1417 C, Deshpande Layout, Nagpur
07620360999
anuragsarda.09@gmail.com
ARYABHAT DARNAL
5,Swalambi Nagar, Nagpur
07304462120
arya284@gmail.com
CHAITANYA SAKHARE,
Satyabhama Nagar, Behind Prabodhan
Vidyalaya, Daryapur
07620535359
chaitanyasakhare@gmail.com
PRASAD RATHI
31A,Radke Layout, Hingna Road, Nagpur
08055505641
aaidanrathi@yahoo.com
RHITURAJ BHALERAO
179, Gandhi Nagar, Nagpur
09403116653
rhituraj.bhalerao@gmail.com

ANNEXURE 2: PROJECT GROUP PHOTO
Standing from left Anurag Sarda, Rhituraj Bhalerao, Aryabhat Darnal, Prof. Pranjali Deole,
Chaitanya Sakhare, Prasad Rathi with the CNC machine.

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PROJECT REPORT

EXPERIMENTAL ANALYSIS OF BORING OPERATION FOR STUDYING PROCESS

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT

in partial fulfilment of the Bachelor’s Degree in

Mr. ANURAG SARDA (34) Mr. ARYABHAT DARNAL (36)

Mr. CHAITANYA SAKHARE (39) Mr. PRASAD RATHI (61)

Mr. RHITURAJ BHALERAO (70)

Under the Guidance of

Prof. PRANJALI S DEOLE

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT

EXPERIMENTAL ANALYSIS OF BORING OPERATION FOR STUDYING PROCESS

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT

in partial fulfilment of the Bachelor’s Degree in

Mr. ANURAG SARDA (34) Mr. ARYABHAT DARNAL (36)

Mr. CHAITANYA SAKHARE (39) Mr. PRASAD RATHI (61)

Mr. RHITURAJ BHALERAO (70)

Under the Guidance of

Prof. PRANJALI S DEOLE

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT

This is to certify that this is a bonafide record of project work entitled

EXPERIMENTAL ANALYSIS OF BORING OPERATION FOR STUDYING PROCESS

Mr. ANURAG SARDA (34) Mr. ARYABHAT DARNAL (36)

Mr. CHAITANYA SAKHARE (39) Mr. PRASAD RATHI (61)

Mr. RHITURAJ BHALERAO (70)

of the Final Year B.E. MECHANICAL ENGINEERING

during the academic year 2014-2015 in partial fulfilment

of requirement for the award of Degree of

offered by the RASHTRASANT TUKADOJI MAHARAJ NAGPUR UNIVERSITY, NAGPUR

Prof. PRANJALI S DEOLE

We feel indebted to Department of Chemistry, SRCOEM; Mr. Jamdar, M/s Kinetic

Mr. ANURAG SARDA (34) Mr. ARYABHAT DARNAL (36)

Mr. CHAITANYA SAKHARE (39) Mr. PRASAD RATHI (61)

Mr. RHITURAJ BHALERAO (70)

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | i

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | ii

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | iii

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | iv

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 1

Figure 1.1 Boring operation

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 2

Figure 1.2 – Types of Boring operation

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 3

1.2 NUMERIC CONTROL (NC) MACHINES

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 4

1.3 CNC LATHE MACHINE

1.4 OPERATIONS PERFORMED ON CNC MACHINES

1.4.1 External operations

Fig 1.3 Turning operation

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 5

Fig 1.4 Facing operation

Fig 1.5 Grooving operation

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 6

Fig 1.6 Cut-off parting operation

Fig 1.7 Thread cutting operation

SHRI RAMDEOBABA COLLEGE OF ENGINEERING AND MANAGEMENT | 7

Fig 1.8 Drilling operation

Fig 1.9 Boring operation