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Materials Today: Proceedings 4 (2017) 3608–3617 www.materialstoday.com/proceedings

5th International Conference of Materials Processing and Characterization (ICMPC 2016)

Process Capability Analysis and Optimization in Turning of

11sMn30 Alloy
S Aravinda*, K Shunmugesh b,K.T. Akhilc, M Pramod kumar d
a
Asst. Professor,Dept. of Mech. Engg., Viswajyothi College of Engineering and Technology, Kochi-686670-India,
b
Asst. Professor,Dept. of Mech. Engg., Viswajyothi College of Engineering and Technology, Kochi-686670-India,
c
Asst. Professor,Dept. of Mech. Engg., Viswajyothi College of Engineering and Technology, Kochi-686670-India,
d
Dean, Faculty Development & Research, Viswajyothi College of Engineering and Technology, Kochi-6866702-India,

Abstract

This article depicts the optimization of the three prominent turning process parameters, cutting speed, fede rate and depth of cut
respectively for obtaining better process capability index(Cpk) of turning operation performed on the 11SMn30 alloy using
carbide tool in dry condition.Surface roughness (Ra and Rz) is the output parameter identified in the study to optimize the
process capability index(Cpk) . The influence of various input parameters of the turning process and their impact on
determining the process capability were studied by adopting Taguchi approach. The surface roughness values (Ra and Rz) are
optimised individually for optimizing the input machining parameters with the objective of identifying the optimum cutting
speed, feed rate and depth of cut which can maximize the turning process capability. The ANOVA result reveals that the feed rate
and cutting speed have equal significance in determining the surface roughness (Ra and Rz).

©2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials
Processing and Characterization (ICMPC 2016).

Keywords:Turning, Surface Roughness, Taguchi Method, Process Capability,Optimization

1. Introduction

Many researchers are in the process of identifying the various methods for optimising the input machining
parameters which indicates the significance of the machining process optimization in different industrial sectors
involved in manufacturing of goods and services.

* Corresponding author. Tel.: 9947976422

E mail: aravinds111@gmail.com

2214-7853©2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and
Characterization (ICMPC 2016).
 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617 3609

This work is performed with the objective of identifying the optimal values of the cutting speed, feed and depth
of cut which can maximise the process capability.11sMn30 Alloys are widely used in the manufacturing of
components like shafts, gears, clutches where machinability is an important factor. Since the 11sMn30 Alloys are
used for making large number of goods, hence the optimization of the turning parameters for minimising the surface
roughness and improving the process capability index (Cpk) is relevant.
Rajmohan et al. [1] studied the influence of machining parameters on thrust force, surface roughness and burr
height in drilling of metal matrix composite and have reported that feed rate and weight percentage of silicon
carbide(SiC) affect the responses. Krishna raj et al. [2] studied the drilling of carbon fiber reinforced polymer and
analyze the effect of process parameter on thrust force ,circularity and delamination factors using genetic
algorithm(GA).It is reported that low feed rate minimizes the thrust force and delamination factor, while higher
spindle speed reduces the circularity.Pandey et al.[3,4] Reported on bone drilling using grey relation analysis
(GRA) and fussy logic analysis to optimize the multiple performance characteristic and concluded that the
combination of low feed rate and high spindle speed minimizes the responses simultaneously. Sahu et al. [5]
Studied the effect of process parameter on the response variables of friction stirs welding by using taguchi method
GRA and reported that the proposed techniques improves the quality of welding. Abhishek, Kumar et al. [6] Have
investigated the influence of speed , feed and drill diameter on the multiple performance characteristics in drilling
of CFRP, the results shows that the affect of feed rate increases the performance of output variables using harmonic
search algorithm.ShaileshDewangan et al. [7] have optimize the multiple performance characteristics of EDM
process using grey fuzzy approach and observed that the hybrid approach of grey fuzzy improves the performance
characteristics.GauravChaudhary et al. [8] Optimized the drilling parameters for hybrid metal matrix composites
using response surface methodology and reported that the AMCs have good machinability as compared with
HAMCs.the predicted values are in good terms with actual value.Vikas et al. [9] studed the effect and Optimization
of various Machine Process Parameters on the Surface Roughness in EDM for an EN41 Material using Grey-
Taguchi method, obtained were compared with the theoretical results and they were found very close to one another.
V.Saikumaret al. [10] conducted study on optimization of CNC Milling Process parameters of Al-Cu-Zn Alloy
Matrix Composite by using Taguchi-Grey Relational Analysis. Aditya Kumar et al.[11] optimized Submerged Arc
Welding process parameters based on the Flux constituents by Hybrid Grey, Fuzzy and Taguchi methods.
Sharma et al. [14] Improve the machining process of connecting rod using the process capability techniques and
reported that the process capability index helps to increase the machining process. Rajvanshi et al. [13] implemented
the process capability in boraing operation and the results shown adequate improvement in the application of the
process. Chalisgaonkar, et al. [14] reported the optimization of WEDM process and analyse the characteristics using
process capability. Process capability index shows improvement in the surface quality of the machined work piece

Nomenclature

cs Cutting speed
fr Feed rate
dd Depth of cut

2. Materials and Methods

2.1. Machine

CNC Turning Center STALLION 200 is used for turning the 11sMn30 Alloys in this experimental study is
shown in Fig. 1.
The specification of the turning center is given below.
Drive power - 0.5 KW
Speed range- 100-4000rpm.
Rapid traverse-cross/longitudinal -15/20 m/min
3610 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617

2.2. Cutting Tool

WIDIA CNMG 120408-49-TN 2000 was used as tool tip

Fig. 1.CNC Lathe

2.3. Material

An alloy of mild steel and magnesium 11SMn30rod of diameter 22 mm and length 150mm was used for the turning
operation in the study. The composition of 11SMn30 alloy was C: 0.08%, Si: 0.04%, Mn: 1.10%, P: 0.07%, S
0.30%. The alloy had a Tensile Strength of 395N/mm2 and hardness of 159HB respectively.

Table. 1. Process input parameters of Turning Process and their respective levels and values

C Si Mn P S

0.08% 0.04% 1.10% 0.07% 0.30%

2.4. Experimental Design

Three turning parameters such as cutting speed, feed rate and depth of cut respectively were selected as the input
parameters for optimization of the output parameter Surface Roughness (Ra and Rz) with the ultimate objective of
optimizing the process capability of the turning operation perfomed.

The turning experiments were carried out using Taguchi L27 Orthogonal array on 11SMn30 alloys with various
cutting speed, feed rate and depth of cut. The Taguchi orthogonal array selected for the experimental study was to
minimize the number of experiments involving the input factors. The process parameters used for the experimental
study along with their respective levels are presented in Table 2.

Table. 2. Process input parameters of Turning Process and their respective levels and values

Process input Level 1 Level 2 Level 3 Unit Notation

Parameter
Cutting Speed 80 160 240 m/min cs
Feed Rate 0.1 0.15 0.2 mm/rev fr
Depth of Cut 0.5 1 1.5 mm dd
 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617 3611

The turning operations were carried out in random fashion and replicated four times to rule out the experimental
error so as to improve the accuracy for results. The 27 experimental setups are shown in Table.3.

Table.3. Orthogonal array with input parameters and levels

Expt No Cs fr dd

m/min mm/rev mm

1 80 0.1 0.5
2 80 0.1 1.0
3 80 0.1 1.5
4 80 0.15 0.5
5 80 0.15 1.0
6 80 0.15 1.5
7 80 0.2 0.5
8 80 0.2 1.0
9 80 0.2 1.5
10 160 0.1 0.5
11 160 0.1 1.0
12 160 0.1 1.5
13 160 0.15 0.5
14 160 0.15 1.0
15 160 0.15 1.5
16 160 0.2 0.5
17 160 0.2 1.0
18 160 0.2 1.5
19 240 0.1 0.5
20 240 0.1 1.0
21 240 0.1 1.5
22 240 0.15 0.5
23 240 0.15 1.0
24 240 0.15 1.5
25 240 0.2 0.5
26 240 0.2 1.0
27 240 0.2 1.5

2.5. Measurement

The surface roughness of the machined surface was measured using of Mitutoyo Subtonic tester SJ-201P. The
average of the four independent readings on each surface of machined surface was taken to find out the more precise
surface roughness value (Ra and Rz).
3612 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617

2.6. Taguchi Technique

The statistical analysis of the response variables are carried out using Minitab 16 software. The results of the four
times replicated experimental data were taken and their average was considered for analysis. The analysis of process
capability was carried out in terms of Signal to Noise ratio (S/N ratio) in Taguchi Technique. The objective of the
study was to maximize the process capability hence Signal to Ratio in terms of larger the better was taken for
analysis.

3. Experimental results and discussion

3.1. Estimation of process capability

The procedure for calculating the Process capability of output response parameters, surface roughness (Ra and Rz) are as
shown in figure 2 as follows.

Fig 2. Steps in calculating the process Capability

Computation of mean ( X ):The equation (1) is used for calculating the mean value of the surface Roughness (Ra and
Rz)measured in four experimental replication.

𝑀𝑒𝑎𝑛(𝑥) = ∑𝑁
𝑖=1 𝑥𝑖/𝑁 (1)
Where xi is the value of surface roughnes Ra and Rz for ithreplicate of a particular experiment and N is the number of
replications of the experiments.
Computation of standard deviation (σ): Equation (2) is used for computing Standard deviation Standard deviation
(σ)
∑𝑁
𝑖=1(𝑥𝑖−𝑥 )²
𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 (𝜎 ) = � (2)
𝑁
th
Where xi represents the value of response parameter for i replicate of a particular trial and is the mean of the N
replications for a trial.
Process capability index (Cpk) = Equation (3) is used for computing process capability index (Cpk) of each
experimental run
𝑥−𝐿𝑆𝐿 𝑈𝑆𝐿−𝑥
𝐶𝑎𝑝𝑎𝑏𝑖𝑙𝑖𝑡𝑦𝑖𝑛𝑑𝑒𝑥 𝐶𝑝𝑘 = 𝑀𝑖𝑛 � , � (3)
3𝜎 3𝜎
Where
USL= Upper specification limit of Surface Roughness (Ra and Rz)
LSL= Lower specification limit of Surface Roughness (Ra and Rz)

In this study the USL for the surface roughness (Ra and Rz) are fixed as 3.5 µm and 13.2 µm respectively.
Also the LSL for the surface roughness (Ra and Rz) are fixed as 7.6 µm and 1.9 µm respectively. The values
of the surface roughness (Ra and Rz) for the 27 experiments with four replications are presented in Table 4.
And the plots are shown in figure 3 and 4.The mean value of the surface roughness (Ra and Rz ) and the
process capability index (Cpk) for surface roughess (Ra and Rz ) obtained in each experimental setup is
shown in Table 5.
 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617 3613

Table.4. Experimental results (raw data).

Experiment
No Ra1 Ra2 Ra3 Ra4 Rz1 Rz2 Rz3 Rz4

µm µm µm µm µm µm µm µm

1 1.95 2.185 2.224 2.112 7.8 8.74 8.9 8.5

2 2.09 2.3 1.996 2.42 8.36 9.2 8 9.7

3 1.985 2.05 2.0225 2.02 8 8.2 8.2 8.5

4 2.073 2.22 2.1556 1.9 8.3 8.88 8.8 7.9

5 2.01 2.5 1.998 2.4 8.04 10 8 9.5

6 1.998 2.066 2.116 2.2 8.01 8.33 8.5 9

7 2.012 2.05 2.116 2.2 7.95 8.33 8.45 9

8 1.895 2.001 1.996 1.32 7.6 8 8 5.55

9 2.019 2.117 2.14 2.116 8.1 8.5 8.7 8.5

10 2.229 2.445 2.2 2.335 8.9 9.8 9 9.5

11 2.22 2.85 2.544 2.445 8.88 11.5 10.22 9.8

12 2.44 2.556 2.6 2.115 9.76 10.33 10.5 8.5

13 2.197 2.65 2.662 2.665 8.8 10.8 10.66 10.8

14 2.3 2.665 2.2668 2.225 9.2 10.7 9.23 9

15 2.22 2.45 2.182 2.446 8.88 10 8.8 9.65

16 2.26 2.223 2.733 2.225 9 8.9 10.932 9

17 2.37 2.556 2.496 2.556 9.5 10.5 9.984 10.5

18 2.4 2.221 2.357 2.335 9.6 8.9 9.5 9.5

19 2.352 2.993 2.235 2.885 9.4 12 9 11.7

20 2.875 3.011 2.779 2.556 11.5 12.1 11.3 10.5

21 2.9 2.454 2.443 2.335 11.6 9.9 9.8 9.5

22 2.622 2.449 2.512 2.552 1.5 9.8 10.5 10.5

23 2.667 2.355 2.448 2.443 10.7 9.5 9.8 9.9

24 2.533 2.554 2.45 2.332 10.2 10.33 9.8 9.5

25 2.62 2.36 2.45 2.665 10.48 9.55 9.8 10.8

26 2.607 2.453 2.354 2.335 10.44 9.8 9.6 9.5

27 2.563 2.42 2.445 2.44 10.29 9.8 9.8 9.8

3614 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617

Table.5.Calculation steps for evaluating process capability index (Cpk)

Exp No Ra Cpk of Ra Rz Cpk of Rz

µm µm
1 2.278 1.040591 8.631342 0.708312
2 2.30525 0.698789 8.734592 0.487885
3 2.33 5.379599 8.82837 1.986157
4 2.63375 1.765743 9.979279 1.729573
5 2.87825 0.794791 10.90569 0.750075
6 2.96725 2.087243 11.24291 1.578196
7 3.0375 1.870508 12.26689 0.716292
8 3.0725 0.437544 13.02374 0.050063
9 3.0467 2.807471 13.13646 0.084157
10 2.30225 1.20296 8.723225 0.882489
11 2.4375 0.68541 9.235688 0.501019
12 2.52775 0.954824 9.577645 0.728059
13 2.5435 0.928206 9.637322 0.693749
14 2.642 1.219187 10.01054 1.023583
15 2.845 1.521952 10.77971 1.373744
16 2.96025 0.722324 11.21639 0.672094
17 3.04945 1.712722 11.55437 1.142395
18 3.02825 2.057549 12.43739 0.793995
19 2.1775 0.244511 8.250548 0.140489
20 2.2015 0.524814 8.341484 0.374029
21 2.019375 0.158856 7.651412 0.018064
22 2.18715 1.319895 8.287111 0.052104
23 2.227 0.820262 8.438103 0.54527
24 2.095 0.645298 7.937955 0.296975
25 2.2945 0.918669 8.693861 0.627266
26 2.36 1.232282 8.94204 1.059619
27 2.4 2.567853 9.0936 2.032109

Signal to Noise ratio (S/N ratio), Taguchi analysis and the ANOVA was performed using the software MINITAB 16.
The values of Signal to Noise ratio (S/N ratio) for surface roughness (Ra and Rz). The ANOVA results of Surface
Roughness (Ra and Rz) are shown in table 7 and table 8 respectively.
 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617 3615

Table. 6. S/N ratio of Cpk of SurfaceRoughness ( Ra and Rz)

SN ratio SN ratio
Exp No cs fr dc
Cpk(Ra) Cpk(Rz)
m/min mm/rev mm
1 80 0.1 0.5 1.040591 0.708312
2 80 0.1 1 0.698789 0.487885
3 80 0.1 1.5 5.379599 1.986157
4 80 0.15 0.5 1.765743 1.729573
5 80 0.15 1 0.794791 0.750075
6 80 0.15 1.5 2.087243 1.578196
7 80 0.2 0.5 1.870508 0.716292
8 80 0.2 1 0.437544 0.050063
9 80 0.2 1.5 2.807471 0.084157
10 160 0.1 0.5 1.20296 0.882489
11 160 0.1 1 0.68541 0.501019
12 160 0.1 1.5 0.954824 0.728059
13 160 0.15 0.5 0.928206 0.693749
14 160 0.15 1 1.219187 1.023583
15 160 0.15 1.5 1.521952 1.373744
16 160 0.2 0.5 0.722324 0.672094
17 160 0.2 1 1.712722 1.142395
18 160 0.2 1.5 2.057549 0.793995
19 240 0.1 0.5 0.244511 0.140489
20 240 0.1 1 0.524814 0.374029
21 240 0.1 1.5 0.158856 0.018064
22 240 0.15 0.5 1.319895 0.052104
23 240 0.15 1 0.820262 0.54527
24 240 0.15 1.5 0.645298 0.296975
25 240 0.2 0.5 0.918669 0.627266
26 240 0.2 1 1.232282 1.059619
27 240 0.2 1.5 2.567853 2.032109
3616 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617

Fig 3.Process Capability of Surface Roughness of (a) Ra and (b) Rz

(a) (b)

Fig 4. Effects Plot for S/N of process capability Cpkof (a)Rz and (b)Ra

Table.7.Analysis of Variance for Ra, using Adjusted SS for Tests

Source DF Seq SS Adj SS Adj MS F-ratio % contribution

Cs 2 1.48959 1.48959 0.74479 36.90 47.30
Fr 2 1.21243 1.21243 0.60622 30.04 38.50
dd 2 0.04805 0.04805 0.02403 1.19 1.5
Error 20 0.40365 0.40365 0.02018 12.7
Total 26 3.15373 100

Table.8. Analysis of Variance for Rz, using Adjusted SS for Tests

Source DF Seq SS Adj SS Adj MS F-ratio % contribution
cs 2 28.3732 28.3732 14.1866 27.82 41.70
fr 2 28.1337 28.1337 14.0668 27.58 41.30
dd 2 1.4628 1.4628 0.7314 1.43 2.0
Error 20 10.1997 10.1997 0.5100 15.00
Total 26 68.1693 100
 S Aravind/ Materials Today: Proceedings 4 (2017) 3608–3617 3617

4. Conclusions

In this experimental study machining parameters of turning of 11SMn30Alloy has been studied. The Taguchi
method has been successfully implemented for optimizing the input parameters like cutting speed, feed rate and
depth of cut for maximizing the process capability in terms of surface roughness (Ra and Rz) on 11SMn30 Alloy.
The ANOVA for Surface roughness (Ra and Rz) shown in Table 6 and Table 7 it is identified that key parameter
influencing the surface Roughness (Ra and Rz) are cutting speed and feed rate. From the main effects plot for
surface Roughness Ra, given in fig 4 the optimised values of cutting speed,feed rate and depth of cut
are80m/min,0.2mm/rev and 1.5 mm respectively for the range of values considered in the study. The optimised
values of input parameters cutting speed, feed rate and depth of cut for surface roughness Rz are 160 m/min, 0.15
mm/rev and 1.5 mm respectively for the range of values considered in the study. The confirmation tests were carried
out to validate the optimal process setting and it gives the process capability index (Cpk) value greater than one for
the final optimum parameter settings of minimizing the surface roughness (Ra and Rz)

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