A

Progress Report
on

OPTIMIZATION OF PROCESS PARAMETER

OF CNC
Submitted in Partial Fulfillment of the Requirements
For the award of the Degree of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING

by
ABHISHEK KUMAR SINGH (1613240007)
ADARSH KUMAR YADAV (1613240013)
ABDULLAH RAGHIB (1613240003)
GUDDU KUMAR PANDIT (1613240055)
DIVYANSHU KUMAR (1613240049)

Under the supervision of

Mr. ANUJ DIXIT

DEPARTMENT OF MECHANICAL ENGINEERING

GREATER NOIDA INSTITUTE OF TECHNOLOGY, GREATER NOIDA
Affiliated to Dr. A.P.J. Abdul Kalam Technical University, Lucknow
(Formerly Uttar Pradesh Technical University, Lucknow, U.P.)
NOV, 2019
 LIST OF CONTENT

1. Introduction………………………………...………………………….(01)
2. Literature review………………………………………………………(02-10)
3. Gap in literature review………………………………………………..(11)
4. Objective……………………………………………………………....(12)
5. Methodology…………………………………………………………...(13)
6. Application ……………………………………………………………(14)
References……………………………………………………………..(15-16)
 1. INTRODUCTION OF CNC
The term “CNC” is a generic term which can be used to describe many types of device, this
would include plotters, vinyl cutters, 3D printers, milling machines and others. CNC stands
for computer numerically controlled and basically means that the physical movements of
the machine are control by instruction, such as coordinate positions that are generated using
a computer.

The term “CNC machine” is typically used to refer to a device which uses a rotating cutting
tool which moves in three or more axes (x, y and z) to cut out or carve parts in different
types of materials. The information on these pages will focus on what are typically referred
to as “CNC routers” although it would be applicable to most CNC milling and engraving
machines too.

CNC’s are incredibly versatile and allow you to cut a variety of different type of product
and materials. The exact abilities of a machine will vary with size, rigidity and power.
Typically most CNC router can shaft and hard wood, plastic, other composite and non-
ferrous metals. Signage, custom furniture, plaques, trophies, chocolate and cookie molds,
awards, folk-arts, toys, wall-hangings, plates and bowls, lithophanes, memorials, cabinets,
doors, boxes, clocks, religious carvings, panel goods, architectural millwork and moldings,
picture frames, mantels, archways, prototypes, remote control vehicle parts, face plate,
heirloom gifts, military awards, education projects, movie and theatre props, coasters,
chests, bottle totes, pool cues, rustic carvings and many other application.

Development of CNC machine is an outstanding contribution to the manufacturing

industries. It has made possible the automation of the machining process with flexibility to
handle small to medium batch of quantities in part production.

Initially, the CNC technology was applied on basic metal cutting machine like lathes,
milling machine, etc. later, to increase the flexibility of the machine in handling a variety
of components and to finish them in a single setup on the same machine, CNC machine
capable of performing multiple operations were developed. To start with, this concept was
applied to develop a CNC machining centre for machining prismatic components
combining operation like milling, drilling, boring and taping, further, the concept of multi-
operation was also extended for machining cylindrical components,

1
 3. Gaps in literature review
After a comprehensive study of the exiting literature review, a number of gaps have been
observed in machining of CNC-

➢ Effect of process parameters like cutting speed , feed rate , depth of cut on surface
roughness were studied.
➢ Taguchi Technique can be used for optimization of process parameters for surface
roughness.
➢ Multi response optimization has been less focused by researchers.
➢ For multi response optimization utility concept can be used along with TAGUCHI
Technique.
➢ Experimental methods are preferred as compared to analytical methods.

11
 4. Objective of CNC
➢ The main objective of the experiment is to optimize the milling parameters (spindle
speed, feed rate, depth of cut and cutting tool grade) to achieve low value of the
surface roughness.

➢ The objective is to establish a correlation among spindle speed, feed per tooth and
depth of cut to the three directions of cutting force in the milling process. In this study,
the optimum cutting parameters were obtained by the Taguchi method.

12
 6.Application
➢ Higher accuracy
➢ Increase productivity
➢ Reduced lead time
➢ Electrical industry
➢ Reliable operation

14
 2. LITERATURE REVIEW
Tlhabadira, et al [1] determined the effect of process parameters (cutting speed, width
of cut, depth of cut and cutting feed, spindle speed) on surface roughness and the factor levels
with minimum surface roughness during M200 TS milling process using the Taguchi’s L9
orthogonal array of eight degree of freedom input parameter, depth of cut (0.5mm), spindle
speed (5172-5471rpm), cutting feed (828-2188mm/tooth), cutting speed(260-275m/min).
The surface roughness was measured using the Mitutoyo sj-201, surface roughness
machine. The result obtained of M200 TS during milling process max. indused stress
(117kpa) was significantly higher compared to the yield strength of workpiece (207Mpa).
Displacement of the work piece due to indused stress and thermal stress was 0.5887mm in
x, y, z direction.

Vincent, et al [2] corelated the specific cutting energy and process mechanism in order
to determine the efficiency of machining process and evaluate the specific energy
optimization for sustainable machining. The formation of chip is to be depend on feed rate
per tooth to cutting edge radius. Ratio between 5% and 35% of the tool edge radius. It’s
below no chip formation. Machine feed and variation (0.01 & 0.55 mm/rev.), cutting
velocity and depth of cut (156 m/min. &3.5mm), radial width of cut varied between (0.25
& 1.00mm), accelerate (10m/s) for cutting test use AISI 1045 steel alloy on mikron HSM
400. Finally electric energy demand at the rubbing and ploughing mechanism is about 39%.
And also clear that MRR increases, the specific energy decreases.

Das, S., et al [3] Based on to save energy and ensure machining quality. Three cutting
parameter selected for the present investigation are: spindle speed, feed rate and cutting
depth. The experiments were designed using Taguchi methodology. The material removal
rate was set to 15.7 mm^3/s for each turning conditions. NSGA-III is used to solve the
proposed optimization model. Set population size N=100, maximum number of iteration
=500, crossover probability Pc=0.8, mutation probability Pu=0.9. The obtained 3D pareto
solution are shown the minimal surface roughness, minimal specific cutting energy and

2
maximal energy efficiency can not obtained simultaneously. As a result, it can be inferred
that the optimization operation is beneficial to energy saving and quality guarantee. The
comparison between experience setting and the optimized parameter show the surface
roughness diminished 16.72%, the cutting energy consumption and the energy efficiency
decreased in 13.58% and 2.5% respectively. The reason for decline in energy efficiency can
be the decreases of spindle speed.

Anderl, T., et al [4] focused on possibilities for the automated generation of CNC
programs. The primary goal is to enable a seamless flow of individual product information
from the product configurator into CNC program at the machine tool control. The research
investigate the direct transfer of geometric parameters into the CNC program. And use the
CAD model in CAM software to generate the individual CNC program and also raw
material added into CAM software. Tool path are saved in cutter location data. We can also
use G-code programing which is done by the technologist remotely. When G-code
programming is utilized each movement of the tool is coded using command that are listed
in DIN 66025/ISO 6983. As a result the rework rate was reduced down to 0.15%. At the
same time, the throughput time could be decreased, and the on time delivery was raised to
100%, this indicates, that the process platform machining was stabilized by the
implementation of automated CNC program generation and does not cause assembly stops
anymore.

Bhivsane, S.V., et al [5] evaluated the effect of input Parameters such as nose radius,
cutting speed, feed and depth of cut and output parameter surface roughness on hardened
AISI 4340 steel material. Taguchi's technique was used as experimentation method and
multiple regression method is used in order to optimize machining parameter for minimum
surface roughness . The work material was AISI 4340 steel received in the form of 600 mm
length and diameter 32 mm and cut to 3 equal parts of 200 mm . The regression analysis
through the software, the new value of roughness estimated from the regression analysis
derived formula. At last the absolute error and percentage error calculated for 0.4 mm, 0.8

3
mm and 1.2 mm tool nose radius . In the research it is found that the nose radius and cutting
speed play an important role in the experimentation to achieve lowest surface roughness.
Simultaneously the feed and depth of cut have played least role in the experimentation to
achieve desirable surface roughness.

Ramya, G., et al [6] conducted to improve the floor end pleasant of aluminium alloy
6061 work piece by way of the use of carbide device, insert cutter, HSS and by using
Taguchi’s approach including L9 orthogonal array. A series of experiments can be
accomplished by means of various the milling parameters spindle speed, feed price and depth
of reduce. The spindle speeds are 800rpm, 1000rpm and 1200rpm. The feed charges are
150mm/min, 200mm/min and 250 mm/min. Depth of cut is 0.5mm and 1.0mm and 1.5 mm.
To get better surface finish, the project it can be observed that optimal value of surface finish
is obtained at third level of Spindle Speed and it was 1200rpm, third level of Feed Rate and
it was 250mm/min and third level of depth of Cut and it was1.5mm.

Sawant, B.D., et al [7] The challenge of machining industries was to reduce lead time
and increase production rate in order to maintain their competitiveness and to increase the
product accuracy. This paper investigates the analysis of cutting parameter in CNC machine
of Aluminium. In the present paper, an effective approach for the optimization of turning
parameter based on the Taguchi method with Analysis of Variance is presented for
minimizing required surface roughness and maximizing the Material Removal Rate (MRR)
in machining of Aluminium. Experiment were conducted based on Taguchi’s technique L9
orthogonal array. Best parameters found for surface finish machining are cutting speed:-
3000 rpm; depth of cut:– 0.3 mm; feed :- 30 mm/rev. Best parameters found for MRR are
cutting speed - 2500 rpm; depth of cut - 0.7 mm; feed - 30 mm/rev.

Park, H.S., et al [8] optimized the important aspect of getting shorter machining time
and increase the potential of efficient machining. This paper presents an automatic
system and optimization strategies to predict and improve the performance of milling
operations. The machining process was simulated and analysed in virtual machining
4
 framework to extract cutter-workpiece engagement conditions. The frame machining
system to adjust machining process parameter. The material removes volume, material
remove rate, cutting force were calculated in smart machining systems. The results indicate
that the machine time can be reduced by 26% without occurrence of any tool breakage or
chipping.

Xuefeng, W., et al [9] mold plays an important role in the development of manufacturing
technology especially for machinery manufacturing, radio instruments and eletrical
appliances field. In the machining process, there are two main reasons that affect the surface
roughness. One is cutting residual are formed by blade and workpiece relative motion; the
first reason, relative motion between the blade and workpiece has connected with machining
parameters such as spindle speed, feed rate, axial depth of cut ,radial depth of cut and so on.
Xu wei analysis the influence of both cutting edge radius and cutting parameters on high
speed milling hardness steel surface roughness when she was doing high speed milling
cr12MoV harden steel surface test; the three axis vertical CNC milling machine whose
maximum spindle speed is 1800r/min. For both ball end and plane milling, feed rate and
spindle speed are the

Shokrani, A., et al [10] Inconel 718 is the most used nickel based super alloy. High
material strength, hardness and corrosion resistance at elevated temperature with good creep
resistance. Approximately 80% of the super alloy used aerospace industries are nickel alloys.
This account for over 50wt.%of material use aero engines. Inconel 718 can maintain is high
temperature and has high tensile strength for high temperature applications such as aerospace,
gas turbine and oil and gas. Inconel is used for high temperature static and rotating parts of jet
engines such as blade, blisks and shaft in high pressure compressor and turbine stage. The
heat accumulates at the cutting zone resulting in high cutting temperatures 1300°C. The
graph of tool flank wear as a function of machine time was generated. The cutting tool used
In flood cooling machining environment the tool life hybrid cooling environment was 50%
longer than mql and 33% longer than the cryogenic machine environment. The Three graph
are ploted in flank wear and machining time in high speed milling to the value mension .
5
Denkena, B., et al [11] Nowadays, the trend production sector is endging towards more
individual product. System for proces monitoring in milling are widely used. They allow the
early detection of process failures such as chattering. Tool wear and breakage, tool
deflection, clamping failure, however, previously developed control systems are generally
restricted to optimization regarding process load. The monitoring system is based on a
feeling spindle slide of milling centre DMG HS30 liner. As the product are becoming more
and more individual, intelligent manufacturing systems are required to reduce addition. The
three graph plot time and residual error, over ride signal , process stataeDue to a different
guidance concept of the spindle slid in this machine compared to an existing feeling machine
linear further process test shows that the deflection control increases significantly the milling
accuracy.

Gusev, V.G., et al [12] Technology operation for milling of materials are discrete and
are characterized by a relatively high dynamic activity system machine instrument tool
workpiece is the appearance in the course of stocks removal of the high vibration level,
during oncoming milling of workpiece by cylindrical cutters with rectangular cutting teeth
extending parallel to the axis rotating between the tool and workpiece. Dynamic profile
milling with the shaping cutter is fundamental different from the cylindrical milling cutter,
which is the direct connected curved cutting counter tool. the dynamic impact of elementary
cutting blade permanently increases the tool. they are two cylinder effect of feed angular
velocity and cutter in geometry roughness surface. The result obtained reveal the dynamic of
the stock removal in the profiles milling using shaping cutter and are necessary for high
quality design of efficient processes for profiles milling of mechanical engineering products.

DurgaPrasad, K.G., et al [13] employed Taguchi method for optimizing process

parameters in end milling of glass-fibre-reinforced plastic (GFRP). In end milling, surface
roughness and material removal rate (MRR) refer to quality and productivity respectively.
The cutting tool used was a commercially available solid carbide tool. The specifications
of the cutting tool were as follows: Cutter Diameter = 10 mm; Fluted Length = 75 mm
Angle = 30 ; No. of flutes = 04. They take 3 different Speeds 2000RPM, 4000RPM,

6
Feed 300mm/min 600mm/min 900mm/min and Depth of cut 1.0mm, 1.5mm, 2.0mm.It was
found that the optimal process parameters for MRR and surface roughness are speed 4000
rpm, feed 900 mm/min. and depth of cut 2.0mm.

Chun Yu, T., et al [14] were carried out to investigate the best parameter settings of
machining of rubberised fly ash geopolymer (RFAG) material with respect to tool wear and
the most significant parameters with respond to tool wear. The RFAG samples were
machined by CNC milling machine. They take 3 different Cutting Speed 30
m/min,90m/min,150m/min Feed Rate 80mm/min,160mm/min,240 mm/min Depth of Cut
0.5mm,1.0mm,1.5mm. After applying L9 of Taguchi method, analysis of variance
(ANOVA) and the signal-to-noise ratio were employed to find the optimal levels of the
significant factor affecting and to analyse the cutting parameters on tool wear. The best
combination of machining parameters to minimise tool wear are: A1 (cutting speed, 30
m/min), B3 (feed rate, 240 mm/min) and C1 (depth of cut, 0.5 mm). According to ANOVA
analysis, the results show that cutting speed is the most significant parameter for the tool
flank wear with percentages contribution of 72.

Pena-Paras, L., et al [15] were using nanoparticle additives to optimize the parameters of
CNC end milling machine on AISI 1018 steel. The nanoparticle (NP) selected for this study
was a montmorillonite clay (MMT) due to being naturally occurring, inexpensive, and
environmentally friendly. A total of 27 different combinations of these parameters (cutting
speed, feed rate, depth of cut, and nanoparticle concentration in the cutting fluid) were done
by this method. Response characteristics investigated were: spindle load (related to power
consumption), cutting insert radius (wear), and surface roughness (quality of the AISI 1018
steel work-piece). Input were taken as cutting speed of 1040–1345 rpm, depth of cut of 0.012
0.012–0.040 in, feed rate of 4–12 in/min, and MMT clay NP concentration of 0.00–0.3. It was
found that different optimization variable for different response factor. The recommended
optimal input parameters were 1145–1182 rpm, depth of cut of 0.02–0.03 in, feed rate of 7–8

7
 in/min, and MMT clay NP concentration of 0.13–0.15 wt%. The highest impact of NP
additives was found for reducing wear of inserts producing sharper radii thus potentially
lowering the frequency of replacing cutting inserts and reducing the associated costs.

Rao, H.P., et al [16] were carried out “Optimization and Modelling of End Milling
Process Parameters by Using Taguchi Method”. They described that an integrated
optimization approach utilizing Taguchi method. The average value of surface roughness
and S/N ratio were calculated and were found to be within the range. Taguchi parameter
design can provide a systematic procedure that can efficaciously and efficiently identify the
optimum surface roughness in the process control of individual end milling machines. As
speed increases surface

Jorn Mehnen, et al [17] roughness decreases and victual increases surface roughness
Optimization of CNC End Milling Process Parameters for Aluminium 6061 Alloy using
Carbide Tool. For achieving good surface finish on the D2 work piece, higher cutting haste,
lower aliment and lower depth of cut are preferred. Improvements in the energy efficiency
of manufacturing equipment have started to reduce the impact of such equipment on the
environment while at the same time ensuring a safe working environment. Machine tools,
being the major power consumption source in workshop, have been the focus of a great
amount of research. Energy efficiency is one of the main drivers for achieving sustainable
manufacturing. Advances in machine tool design have reduced the energy consumption of
such equipment, but still machine tools remain one of the most energy demanding equipment
in a workshop. In the field of energy efficient machining several researches have been
presented focusing on the modeling of the energy consumption of machine tools according
to their statuses. In their research measured the energy consumption during machining and
presented that the power required for machining accounts for just over a third of the total
energy consumption during machining

Das, B., et al [18] Milling is the most common and versatile technology among different
8
 machining processes, characterized by an extensive range of metal cutting capacity that places
it in a central role in the manufacturing industries. Manna and Bhattacharyya have
investigated the effect of cutting speed, feed and depth of cut on wear of the cutting tool and
built-up edge formation during the turning operation of Al-SiC particulate composite, using a
rhombic uncoated tool of carbide material. However, less amount of built up edge formation
was found at a lower depth of cut and at higher cutting speed. examined the effect of SiC
particulate size on the wear of the tool and surface finish with cubic boron nitride (CBN) tool
insert at constant depth of cut, feed and at varying cutting speeds. It was suggested that for 30
μm and 45 μm size of SiC in aluminium metal matrix, optimum cutting speed was achieved
at 150 m/min. For better size of SiC reinforcements (110 μm), CBN tool was not found
appropriate for turning operation. Chambers have found that the performance of PCD insert
was significantly superior than carbides insert while turning Al- 5Mg reinforced with a
combination of 5 vol.% saffil and 15 vol.

Shunmugesh, K., et al [19] Carbon-fiber-reinforced polymers are composite materials in

which it consists of two parts: matrix and reinforcement. The reinforcement within the CFRP
is carbon fiber, that really provides the strength and also the matrix is two-part epoxy resin, to
combine the reinforcements together. The thrust force and torque are measured by using the
Kistler dynamometer for all the experimental trials. The surface roughness of the drilled holes
is measured by Mitutoyo Surftest SJ-210 Surface Roughness Tester. The optimum process
parameter combination for minimum thrust force, torque and surface roughness are higher
cutting speed(50 m/min), lower feed rate(0.025 mm/rev) and TiAlN drill tool for the range
selected.

Guzeev,V.I., et al [20] milling is the micro cutting process with low value stock removal.
Workpiece machining by designing cycle based on switching radial feed of grinding wheel.
When calculating the surface roughness limitation of the radial feed was formed area in the
interval in workpiece frequency of rotation. For details type "ring" with a different TS stiffness
workpiece frequency of rotation from 50 to 150 rev./min. For details such as "body" – from 50
to 100 rev./min. the cycle of circular plunge grinding for Studer CNC machine. Based on
9
preliminary testing of the technological system identified the actual technological system
stiffness – 0,294·107 N/m. Workpiece mounted in the chuck with a boring ɫam. Machining
surface diameter Ø50f6. Based on the design method of grinding cycle was calculated rotation
frequency interval of the workpiece n=20...130 rev/min .

10
 REFERENCES
[1] Prajina, N.V. multi-response optimization of CNC end milling using response surface
methodology and desirability function. International journal of engineering research and
technology, 6(6):739-746,2013

[2] Brundtaland, G.H, report of the world commission on environment and development
“our common future”;1987:united nations.

[3] Zhong Q, Tang R, Peng T. Decision rules for energy consumption minimization during
material removal process in turning. Journal of Cleaner Production, 2016, 140:1819-1827.

[4] Anderl, T, Heimrich, F., Reinke, P, CAM-Automatisierung. Anstaz zur CAM-

Automatisierung mithilfe eines product-configurators, in:, zeitschrift fur wirtschaftlichen
fabrikbetrieb, 110 (2015) 9,pp.542-544.

[5] Bartarya, G., & Choudhury, S. K.,. International Journal of Machine Tools and
Manufacture, 53(1), 1- 14(2012).

[6] N. Gopikrishna and M. ShivaChander Determining the Influence of Cutting Fluid on

Surface Roughness during Machining of EN24 and EN8 steel by using CNC Milling
Machine,
Journal for Research| Volume 01| Issue 11 | January 2016 ISSN: 2395 – 7549 pp 1 – 4

[7] U.D.Gulhane, B.D. Sawant, P.M.Pawar. “Analysis of Influence of Shaping Process

Parameters on MRR and Surface roughness of Al6061 using Taguchi method.”
International Journal of Applied Research and Studies.ISSN:2278-9480 Vol 2, Issue 4,pp
01-07, 2013.

[8] Jianxin Guo, Qiang Zhang, Xiao-Shan Gao, Hongbo Li Time optimal feed rate
generation with confined tracking error based on linear programming Journal of Systems
Science and Complexity, 28 (2015), pp. 80-95.

[9] Xiangsheng HE, Huang L. Dry milling experiment of Die steel and parameters
optimization. Light industry machinery 2016.

[10] D'Addona, D.M., S.J Raykar, and M.M. Nark, High speed machining of Inconel 718:
Tool wear and surface roughness analysis, procedure CIRP 62,P.269-274(2017).

15
[11] Denkena B, Kiesner J. Strain gauge based sensing hydraulic fixtures. Mechatronics,
DOI: 10.1016/J. Mechatronics, DOI: 10.1016/J. Mechatronics. 2015.
[12] E. Azemovic,I. Hornman, I. Busuladzic, impact of planing treatment regime on solid
fir wood surfaces, procedia engineering 69(2014) 1490-1498. Huicheng Zhou, Pengcheng
Hu, Huiling Tan , Jihong Chen, Guoan Liu National NC System Engineering Research
Center,Huazhong University of Science and Technology,Wuhan,430074,China,2017.

[13] Svetlana Kolevaa , Milko Encheva , Tamas Szecsib, a University of Rousse,

Department of Manufacturing Engineering, 7000 Rousse, Bulgaria b Dublin City
University, School of Mechanical and Manufacturing Engineering, Dublin 9, Ireland,2018.

[14] Yair Shneor Center for Advanced Manufacturing Technology, Rotem Ind. Ltd.
D.N.Arava, Israel 86800,2019.
[17] European Environment Agency (EEA),Final energy consumption by sector and fuel
(CSI 027/ENER 016)01 jan 2015.
[18] S. Gururaja, M. Ramulu, W. Pedersen, Machining of MMCs: a review, Mach. Sci.
Technol. 17 (1) (2013) 41–73.
[19] S. Gururaja, M. Ramulu, W. Pedersen, Machining of MMCs: a review, Mach. Sci.
Technol. 17 (1) (2013) 41–73.
[20] E.N. Maslov, Grinding Theory, Mashinostroenie, Moscow, 1974.

16
 5. Methodology

Selection of work material and tool material from the literature

Review.

The experiment is designed by taking speed, feed as a significant

Factors into consideration.

Optimization of speed, feed and depth of cut parameter performed

Using Taguchi technique.

Creating a model using Minitab software. And confirmation test

And corelate the data obtained from optimization of parameters
And predicted values through model.

12