APPLICATIONS OF TAGUCHI

METHOD AND GREY RELATIONAL

ANALYSIS FOR MULTI OBJECTIVE
OPTIMIZATION OF PLANNING
OPERATION ON AISI 4140

Submitted by
WASEEM ULLAH 16JZIND0037
WASIM AKRAM 16JZIND0038
MUHAMMAD ATIF 16JZIND0023

Supervisor
ENGR. ISHRAT NOOR

INDUSTRIAL ENGINEERING DEPARTMENT

UNIVERSITY OF ENGINEERING AND TECHNOLOGY
PESHAWAR JALOZAI, PAKISTAN
Applications of Taguchi Method and Grey
Relational Analysis for Multi-Objective
Optimization of Planning Operation on
AISI 4140
Submitted by
WASEEM ULLAH 16JZIND0037
WASIM AKRAM 16JZIND0038
MUHAMMAD ATIF 16JZIND0023

Submitted for the incomplete fulfillment of the Bachelor of Science Degree in

Industrial Engineering

Supervised by:
Engr. Ishrat Noor

Approved by:
Prof. Dr. Shahid Maqsood

External Examiner:
Dr. Sikandar Bilal
 Application of Taguchi Method and Grey
Relational Analysis for Multi Objective
Optimization of Planning Operation on
AISI 4140

by

Waseem Ullah
Wasim Akram
Muhammad Atif

The thesis is presented to the University of Engineering and Technology Peshawar, Jalozai in
incomplete fulfillment for the degree requirement of
Bechelors of Scienece
in
Industrial Engineering
2020

Peshawar, Khyber Pakhtunkhwa, Pakistan

i
 AUTHOR’S DECLARATION

We say publically that we are the one and only authors of this thesis. This is a real copy of
the thesis, which is revised and accepted by our examiners. We further announced that the
Higher Education Commission has Quality Assurance guidelines; we have completed all the
necessities to follow those guidelines.
We made the public accessible electronically to our thesis.

ii
 Abstract

To check the quality of machining is done through the surface finishing of work piece and it
is become the most important feature in machining. To reduce surface roughness and
increase material removal rate the suitable and optimal setting of process parameters is
important and necessary. The main objective of this research is to determine the effect of
process parameter or factors on the response variable (material removal rate and surface
roughness) using low carbon steel AISI 4140 in CNC 5-axis Milling machine with the aid of
Carbide and High Speed Steel (HSS) cutting tools. The four factors are assessed i.e. spindle
speed, cutting tool type, feed rate, and depth of cut. For the analysis we used the L18 mixed
Taguchi design and three techniques i.e. Taguchi Signal-to-Noise (S/N) ratio, Analysis of
Variance (ANOVA), and Grey Relational Analysis (GRA).

Keywords: Design of Experiment, Analysis of Variance, Grey Relational Analysis, Taguchi

Signal-to-Noise Ratio

iii
 Acknowledgements

We are very thankful to Almighty Allah, Who gratifying us with the somatic and intellectual
competency and conceded us implicit to fulfill this research work.

Special tribute is upon His last Messenger, Hazrat Muhammad (Peace Be Upon Him), whose
teachings remain always a source of knowledge for the whole humanity.

It is sincere gladness to shows our deep sense of thanks and appreciation to Engr. Ishrat Noor
and Engr. Mohsin Iqbal Qazi. Their loyalty and keenness above all their awesome attitude to
aid their students had been solely, appreciated and especially responsible for finalizing and
finishing our work. Their advice on time, careful analysis, scholarly and intellectual advices,
and logical and technical tactics have assisted us to a very great extent to complete this
research work.

We are also very grateful to our parents and siblings for their supports mentally and
financially and their praise and inspiration to successfully and fruitfully accomplish our
project.

iv
 Dedication

We dedicate this thesis to our teachers specially Engr. Ishrat Noor and Engr. Mohsin Iqbal
Qazi they always supported us whatever we had a problem, our parents, siblings and others
whom we care about.

v
 Table of Content

AUTHOR'S DECLARATION ................................................................................................ ii

Abstract.................................................................................................................................... iii
Acknowledgements.................................................................................................................. iv
Dedication ………………. ...................................................................................................... v
Table of Contents..................................................................................................................... vi
List of Figures.......................................................................................................................... ix
List of Tables ........................................................................................................................... x
List of Acronyms .................................................................................................................... xi

CHAPTER 1 INTRODUCTION ............................................................................................ 12

1.1 THE RESEARCH PROBLEM ............................................................................................... 12

1.2 SCOPE OF RESEARCH ...................................................................................................... 13
1.3 APPLICATION OF RESEARCH ........................................................................................... 13
1.4 THE OBJECTIVES OF THE STUDY ..................................................................................... 13
1.5 THE RESEARCH QUESTIONS ............................................................................................ 13
1.6 CONTRIBUTION TO KNOWLEDGE (ACADEMIC CONTRIBUTION) ...................................... 14
1.7 STATEMENT OF SIGNIFICANCE (PRACTICAL CONTRIBUTION) ......................................... 14
1.8 RESEARCH METHODOLOGY ........................................................................................... 14
1.9 THESIS CHAPTER’S ORGANIZATION ............................................................................... 15
1.10 SUMMARY .................................................................................................................... 15

CHAPTER 2 LITERATURE REVIEW ................................................................................. 16

2.1 INTRODUCTION............................................................................................................... 16

CHAPTER 3 SELECTION OF PROCESS PARAMETERS AND RESPONSE

VARIABLES .......................................................................................................................... 26

3.1 INTRODUCTION............................................................................................................... 26
3.2 PROCESS PARAMETERS .................................................................................................. 27
3.2.1 Cutting Tool ........................................................................................................... 27
vi
 3.2.2 Cutting Speed ......................................................................................................... 30
3.2.3 Depth of Cut ........................................................................................................... 32
3.2.4 Feed Rate ............................................................................................................... 33
3.3 RESPONSE VARIABLES ................................................................................................... 33
3.3.1 Material Removal Rate (MRR) .............................................................................. 33
3.3.2 Surface Roughness ................................................................................................. 34
3.4 SUMMARY ...................................................................................................................... 37

CHAPTER 4 EXPERIMENTATION AND TESTING ......................................................... 38

4.1 INTRODUCTION............................................................................................................... 38
4.2 POWER HACKSAW .......................................................................................................... 39
4.2.1 Types of Power Hacksawing Horizontal Machines ............................................... 39
4.2.2 Main Parts of Power Hacksawing .......................................................................... 40
4.2.3 Clamping of Power Hacksawing ........................................................................... 41
4.2.4 Advantages and Limitations of Power Hacksawing .............................................. 41
4.2.5 Safety and Security of Power Hacksawing ............................................................ 42
4.3 5-AXIS CNC MILLING MACHINE ................................................................................... 42
4.3.1 Advantages of 5-Axis CNC Milling Machine ....................................................... 44
4.3.2 Disadvantages of 5-Axis CNC Milling Machine ................................................... 45
4.4 ROUGHNESS TESTER ...................................................................................................... 46
4.4.1 Importance of Roughness ...................................................................................... 46
4.4.2 Measurement of Roughness ................................................................................... 47
4.4.3 Measuring Line Lengths ........................................................................................ 48
4.4.4 Measuring Shapes and Offsets ............................................................................... 48
4.4.5 Data Options ...........................................................Error! Bookmark not defined.
4.5 SUMMARY ...................................................................................................................... 49

CHAPTER 5 RESULTS AND ANALYSIS........................................................................... 50

5.1 INTRODUCTION............................................................................................................... 50
5.1.1 History of Minitab.................................................................................................. 50
vii
 5.1.2 Key Features of Minitab ........................................................................................ 51
5.1.3 Why We Use Minitab in Our Project ..................................................................... 52
5.2 MICROSOFT EXCEL ........................................................................................................ 64
5.2.1 History of Microsoft Excel .................................................................................... 65
5.2.2 Why We Use Microsoft Excel Software in Our Project ........................................ 66
5.3 SUMMERY ...................................................................................................................... 70

CHAPTER 6 SUSTAINABILITY OF PROJECT ................................................................. 71

6.1 INTRODUCTION............................................................................................................... 71
6.2 ENVIRONMENTAL, ECONOMIC, AND SOCIAL BENEFITS OF THE PROJECT ........................ 71
6.2.1 Environmental Benefits ......................................................................................... 71
6.2.2 Economic Benefits ................................................................................................. 72
6.2.3 Social Benefits ....................................................................................................... 72
6.3 ROLE AND ADVANTAGE OF THE PROJECT....................................................................... 73
6.3.1 Economically ......................................................................................................... 73
6.3.2 Socially .................................................................................................................. 73
6.3.3 Environmentally..................................................................................................... 73

CHAPTER 7 CONCLUSIONS AND RECOMMENDATIONS ........................................... 74

7.1 PROJECT CONCLUSION ................................................................................................... 74

7.2 FUTURE WORK RECOMMENDATION ............................................................................... 75

REFERENCES ....................................................................................................................... 76

viii
 List of Figures
Figure 1.1: Research Methodology......................................................................................... 14
Figure 3.1: Flow Chart of Process Parameters & Response
Variables................................................................................................................................. 27
Figure 3.2: Flow Chart of Machining Operations................................................................... 30
Figure 3.3: Process Factors..................................................................................................... 33
Figure 3.4: Roughness............................................................................................................ 35
Figure 3.5: Roughness through Height................................................................................... 36
Figure 3.6: Roughness through Area...................................................................................... 37
Figure 4.1: Experimental Setup.............................................................................................. 38
Figure 4.2: Mechanism of Power Hacksaw............................................................................ 39
Figure 4.3: Power Hacksawing............................................................................................... 40
Figure 4.4: Different Methods of Holding & Clamping......................................................... 41
Figure 4.5: 5-Axis CNC Milling Machines............................................................................ 43
Figure 4.6: Surface Roughness Tester.................................................................................... 47
Figure 5.1: Key Features of Minitab....................................................................................... 52
Figure 5.2: Analysis Steps on Minitab.................................................................................... 53
Figure 5.3: Different Plots of Ra............................................................................................. 56
Figure 5.4: Different Plots of MRR........................................................................................ 58
Figure 5.5: Percentage Contribution of Parameters on Ra..................................................... 61
Figure 5.6: Percentage Contribution of Parameters on
MRR........................................................................................................................................ 63

ix
 List of Tables
Table 2.1: Composition of AISI 4140 Material..................................................................... 18
Table 2.2: Mechanical Properties of AISI 4140 Material.......................................................18
Table 3.1: Process Parameters & Levels................................................................................ 26
Table 4.1: Results from Experiments & Testing.................................................................... 49
Table 5.1: S/N of Ra............................................................................................................... 55
Table 5.2: S/N of MRR........................................................................................................... 57
Table 5.3: ANOVA for Ra...................................................................................................... 60
Table 5.4: Response Table for Ra........................................................................................... 61
Table 5.5: Optimal Level of Parameters for Ra...................................................................... 62
Table 5.6: ANOVA for MRR................................................................................................. 62
Table 5.7: Response Table for MRR...................................................................................... 63
Table 5.8: Optimal Level of Parameters for MRR................................................................. 64
Table 5.9: Values of S/N of Ra and MRR.............................................................................. 68
Table 5.10: GRA Overall Results........................................................................................... 69
Table 5.11: Optimal Combination of Factor Levels............................................................... 70

x
 List of Acronyms
DOE Design of Experiments
GRA Grey Relational Analysis
ANOVA Analysis of Variance
S/N Signal to Noise Ratio
HSS High Speed Steel
OA Orthogonal Array
AISI American Iron and Steel Institute
CNC Computer Numerical Control
HSS High Speed Steel
MRR Material Removal Rate
CLA Centre Line Average
RMS Root Mean Square
BMW before Machining Weighing
AMW after Machining Weighing

xi
CHAPTER 1 INTRODUCTION

Dr. Genichi Taguchi proposed a method called Taguchi method which is used to save time,
reduce cost by reducing waste and defects, and to get better the value of finished goods. This
technique is used to identify the factors that affect response variables of the process. Taguchi
technique has more significance in marketing and engineering areas.
Taguchi Orthogonal Array (OA) is used when there are a multiple factors at multiple levels
(high, nominal, low) and they give multiple combinations. Taguchi Orthogonal are objectives
to make sure that every level of the entire process parameters are considered equally. That’s
why each factor can be evaluated independently of each other. When experiments are done
through orthogonal array, then these experiments give results. These results are then used for
the prediction of improvement in excellence of the manufactured goods, data analysis, reduce
defects and waste.
Taguchi S/N ratio is used for single factor optimization process. Taguchi S/N ratio
determines how mean of experimental value near to target value. Taguchi S/N ratio has three
criteria:
❖ Higher-the-better
❖ Nominal-the-best
❖ Lower-the-better

Multi factors optimization process makes use of GRA technique. GRA technique is part of
theory proposed by Julong called is Grey System Theory. This theory is used when there are
incomplete, poor, and uncertain information’s. GRA technique is appropriate to solve
problems by means of complex relationship among variables and multi factors.
ANOVA is based on the law of total variance, in which the variance in a particular variable
or process parameters is divided into different parts. It is used in the analysis of experimental
data and to check the significance of each process parameter.
To establish connection between parameters (inputs) which effect process & response
variables (outcome) the DOE systematic method is used.
This research compacts with use of Taguchi technique to analyze process parameters of
milling machining operations and get different arrangement of inputs or process parameters
for best possible response variables.

1.1 The research problem

Waste and defective production leads to high cost and low quality. To compete in local and
global market, the machining industry always has great concern on the non-conformity of
machining and on low productivity. The local industry is facing issues of productivity and
surface roughness in the machining of AISI 4140. Variation in the cutting parameters such as
feed rate, depth of cut, cutting speed, and cutting tool cause the surface roughness problem
during machining operation. Material removal rate and surface roughness affect the
productivity and accuracy of the part respectively. Due to surface roughness, problems are
produced in assembly.

To cope with these issues, optimum combination of process parameters is need of the day.

1.2 Scope of Research

This research includes tools and knowledge that are necessary to optimize the multi
objectives of machining process. In this research, the only armor industries are in focuses
specially Daud Son’s Industry.

1.3 Application of Research

This research includes the minimization of surface roughness and to increase the material
removal rate during machining of window cover plate in any armor industry producing it.
This research also reduces rework and reduces time consumption.

1.4 The objectives of the study

The main objectives of the study are

a) To find out the effect of varying factors on machining.

b) To sort out the significant factors and their effect on response variable.
c) To optimize the process parameters of Plate Window Cover.
d) To improve the quality of Plate Window Cover.
e) To reduce cost by reducing rework.

1.5 The research questions

❖ What will be the effect of machining on response variables?
❖ How we can find the optimal setting of parameters that will help in achieving objectives?
❖ Are optimum values of factors/parameters related with achieving specific dimension?

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1.6 Contribution to Knowledge (Academic Contribution)
Taguchi and grey Relational Analysis (GRA) will help in the optimization of machining
process. This research will identify the optimum parameters for reduction in deterioration of
mechanical properties and dimension. Further, statistical analysis will be made for the
identification of dominant factors in optimization of mechanical properties.

1.7 Statement of Significance (Practical Contribution)

This research will aid industry in the direction of manufacture good quality plate window
covers and reduce surface roughness. Optimal setting will reduce the angular distortions to
minimum level. Mechanical properties such as tensile strength, impact strength, and micro
hardness will be improved.

1.8 Research Methodology

To achieve multi objectives optimization need a problems to work on it. The problems can be
identified by visiting the different industries, literature reviews, and through expert opinions.
Select the response variables, factors, and levels through literature review, industry visit and
expert opinions. Applications of some tools such as Analysis of Variance (ANOVA),
Taguchi Signal-to-Noise Ratio (S/N), Grey Relational Analysis (GRA) can give optimal
parameters.

Figure 1.1: Research Methodology

14
1.9 Thesis Chapter’s Organization
This thesis has six chapters i.e. 1) Introduction, 2) Literature Review, 3) Selection of Process
Parameters and Response Variables, 4) Experimentation and Testing, 5) Results and
Analysis, and 6) Conclusion and Recommendation.

Chapter 1 briefly introduced the Taguchi method and Grey Relational Analysis.

Chapter 2 revised the literature and covers the topic of introduction of chapter, mines the data
from literature, and studied the literature from different research papers and case studies.

Chapter 3 is the selection of process parameters (spindle speed, cutting tool type, feed rate,
and depth of cut) and response variable (surface roughness and MRR) and their explanation.

Chapter 4 Experimentation and Testing includes introduction of the chapter, equipment’s

applications, perform testing and machining and results of Ra and MRR.

Chapter 5 Results and Analysis contains the optimum combination of process parameters
through Minitab tools such as ANOVA, Taguchi S/N and Excel tool (GRA).

Chapter 6 Conclusion and Recommendation concludes the overall research and

recommended the research work for future.

1.10 Summary
In this chapter we briefly discussed the Taguchi method and Grey Relational Analysis. Also
problem of this research has been described with explanation. The scope, application,
objectives, and methodology have also been discussed. The contribution to the knowledge
and statement of significance is explained. In coming chapter, the literature is revised and
mines the data from literature through research papers and case studies.

15
CHAPTER 2 LITERATURE REVIEW

2.1 Introduction
AISI 4140 steel is a chromium molybdenum-based alloy steel which is a general purpose and
high tensile strength steel. It is majorly used in making of components such as bolts, gears,
axels, shafts, and other components like this which are widely used and are in demand. Their
production is increasing day by day as the needs are increasing for better transmission,
assembly, fastening and other requirements. It is similar to the AISI 4130, which is chrome-
moly alloy with the difference in carbon content. AISI 4140 contains slightly higher content
of carbon as compared to AISI 4130. Due to this greater carbon content it has more strength
and heat treatment properties as compared to AISI 4130. The disadvantage of this higher
carbon content appears in the form of lower weld ability properties.
Now a day the processes are more efficient, tools are more powerful and the machines have
been updated for precision. But if the controls of material are neglected the whole process
and quality assurance is lost. We cannot afford to neglect the properties of our material as it
is basically the base of product. If it’s not standardized whole process may fail. The material
AISI 4140 has to go through the processes of forging, sheet metal processing, coil formation,
wire drawing, mold making, flat sheets and plates, deformation and other thermal activities to
provide the required material strength, mechanical properties and heat treat abilities. (Stein
1995)
Precision is needed and for this control measures are to be applied during production of raw
steel. This will require high precision machines and micro level studies for materials
multipurpose or multi-objective optimization. For this purpose, the most widely used tools
are DOE based techniques. The most widely and preferred technique in this case is Taguchi
Method and Grey (GRA) analysis method. Before going towards the studies and the
technique results from the previously conducted studies by scholars we would be diving
through the major composition of AISI 4140.
AISI 4140 is versatile steel with the major compositions being 0.40% carbon, 0.85%
manganese, 0.1% chromium. These all add toughness and heat treatment properties along
hardness of steel. However, it is not that enough to equalize with that of stainless steel. The

16
detailed composition of different elements with their percentage of composition in common
AISI 4140 steel is shown in the Table 2.1 composition of AISI 4140 (Hirsch 2014).
(Joe and Jaganathan), proposed that Taguchi technique is used when there is need of efficient
and effective continuous improvement of inputs or process factors to get the best outcomes or
response variables and if not achieved these response variables then go for more advance
strategy.
Another works on grinding operation by using new cooling method. This research works to
analyze the different process parameters as forceful basics, based on Taguchi technique.
They used Taguchi technique tools such as Taguchi OA, S/N ratio and ANOVA etc. to get
the optimal condition of input factors. (Shaji and Radhakrishnan 2003)
In the direction of optimization, process factors during partially and fully ending condition of
high cutting speed by Ti N coated P10 carbide insert cutting tool during machining of
material AISI H13. The Taguchi technique is used to minimize No. of experiments of stated
problem compared to use full factorial design. The Taguchi technique tools i.e. Taguchi OA,
S/N ratio, and ANOVA are employed for the analysis to determine the impact of milling
process factors. The relative analysis on end milling process factors at different levels (high,
nominal, and low) shown by this research paper. (Ghani, Choudhury et al. 2004)
Surface finishing depends on cutting speed, when cutting speed is more, then more chips will
be removed during machining as a result the surface roughness will be more and vice versa.
(Dragičević, Jozić et al. 2015), used the Taguchi technique and GRA integration on behalf of
the optimization of input factors or parameters within end milling of 42CrMo4 material is to
achieve the maximum quantity of removed material and surface finish or minimum quantity
of surface roughness.
(Nalbant, Gökkaya et al. 2007), works on turning operation in favor of surface roughness by
using Taguchi technique in order to find out the best process factors. To get knowledge about
process parameters in turning processes of AISI 1030 material coated by Ti N tools used
Taguchi technique tools i.e. Taguchi OA, S/N ratio, and ANOVA.
(Baek, Hong et al. 2010), has been done works on the impacts of different machining process
factors on the response variables of finished products. On the way to perform different
experiments on AISI 304 plate material by carbide insertion applied Taguchi OA technique

17
tool. To find out the significance of each machining process factors on the response variables
be employed ANOVA technique.
Table 2.1: Composition of AISI 4140 Material (Hirsch 2014)
Elements Content

Carbon, C 0.380 - 0.430 %

Chromium, Cr 0.80 - 1.10 %
Iron, Fe 96.785 - 97.77 %
Manganese, Mn 0.75 - 1.0 %
Molybdenum, Mo 0.15 - 0.25 %
Phosphorous, P ≤ 0.035 %
Silicon, Si 0.15 - 0.30 %
Sulfur, S ≤ 0.040 %
2.1.1 Mechanical Properties

Now if we are going to analyze the multi-optimization of AISI 4140 we need to deal with its
properties too. As the material goes through forging, casting, rolling either hot or cold and
drawing etc. this will eventually affect the properties either Physical or mechanical. The
physical properties mostly include and vary in size, shape, volume and grams per meter
square.
Whereas the mechanical properties are the main concern and they is the base of
machinability and material removal. They are measured mostly in annealed state and the
major properties are Hardness, toughness, tensile strength and heat treatability etc.
Table 2.2: Mechanical Properties of AISI 4140 Material (Hirsch 2014)
Properties Metric Imperial
Tensile Strength 655 MPa 95000 psi
Yield Strength 415 MPa 60200 psi
Bulk Modulus 140 GPa 20300 ksi
Shear Modulus 80 GPa 11600 ksi
Elastic Modulus 190-200 GPa 27557-30458 ksi

18
2.1.2 Machining

AISI 4140 is good at machinability. It has to go through operations like turning, tapping,
milling, broaching, hobbing, sawing, cutting off and shaping etc. Thus, the moderately
preferred and used feeds and speeds are as:
❖ Machinability rating as 66% of B1112
❖ Average Cutting speed of 100 ft/min. (Ko, Chang et al. 2003)

2.1.3 Heat Treatment

The steel is rarely used without heat treatments before finalizing it as a product at the end of
process. The steel needs hardness, deforming and shaping which is done by different world
wide used processes. The mostly widely heat treatment processes which ISI4140 possibly
goes through are (Ko, Chang et al. 2003):

a) Forging

b) Tempering

c) Flame and induction hardening

d) Hardening

e) Stress relieving

f) Annealing

g) Normalizing

h) Nitriding

These all processes are not supposed to be done on same steel at a time, yet I may go through
one or two of these before being used as the raw material to be machined for changing it into
products. Therefore, choosing material is also based on processes it will go through and
required properties at end of process. These properties are affected with the change of
composition and forming processes.

19
Whereas other important operations which need to be kept in mind are:
a) Hardening,
b) Tempering
c) Flame & Induction Hardening
d) Nitriding
e) Normalizing
f) Annealing, Stress Relieving and Forging Etc. ( Ikashi, K.Zumi & A.Yang, 2003)

2.2 Taguchi Method of Quality Control

This is an engineering method that focuses the role of R&D, product designing and
production in decreasing the number of waste and defects produced in manufactured goods.
This system was developed and emphasized by Genichi Taguchi\ (J.Carol & K.Alvin 2007).
This method considers that design is more important in quality control than manufacturing
processes, with the aim of eliminating production variations before they can occur and are
needed to be corrected. It’s basically the quality assuring technique in which we study the
variables and their effects on parameters of the process and production. We concisely choose
the variables and then study the effects of specific variables by changing or keeping other
variables constant. This provides us with the facts to justify faults reduction procedures
before occurring. (Miyake, Yamamoto et al. 1991)
Whenever we have to face the failure of processes or products the contribution of external
variables cannot be neglected. There are always the variables that are influencing the whole
process results. They can be called as noise or the variations. To reduce the variance among
the parameters we need to control those variables to optimize the process I.e. the results. This
technique focuses on the optimization of processes and designs keeping some variables
constant and changing others to get required parameters. (Miyake, Yamamoto et al. 1991)
In our studies we focused on the optimization of variation in AISI 4140 for planning
operations and processes. In the multi objective study we will be dealing with process
parameters like spindle speed, cutting tool, feed rate, and depth of cut. The effect of these
variables will be measured in parameters of Surface Roughness and material removal rate.
These factors are widely studied worldwide and due to rapid change in machining abilities

20
and design/ specs requirements of products and process this is need of the d1ay to optimize
the material for operations. (J.Luise & Ambrio 2006)
2.2.1 Aims of Taguchi Method

The major aim of Taguchi method is to make processes such robust that variations and
uncontrollable conditions can not hinder the process. It aims to amend the process parameters
to the optimal conditions that process becomes insensitive to variations and parameters are
concise and precise. This process was published and established by Taguchi after the world
war-2 so that japan can stand again and reduce the after effects of war on manufacturing and
economic conditions of country. This process has become a standard now and is widely used
to enhance the processes. (Miyake, Yamamoto et al. 1991)
2.2.2 Optimization of Process

It is the discipline of adjusting a process to optimize certain specified set of parameters

without infringing any limitation. The most common goals are cost prevention, value creation
and/or efficiency throughout. It is one of the major quantitative tools for making industrial
judgments.
The goal is to maximize one or more of the process areas when optimizing a process while
keeping all others within their constraints. Process Optimization Tools almost all directly
relate optimization to the use of statistical methods to select the suitable solution. That is not
the point. We obviously need statistical techniques. But it’s essential to have such a tool like
Taguchi and GRA analysis for better processes understanding, relations finding among
variables and parameters. (T.Yamamoto & A.Kiyake 2004)
2.2.3 Data Mine from Literature Review

Effects of Parameters on Surface Roughness (Ra)

❖ As cutting speed increases the surface roughness decreases, (Anil, Vikas et al. 2017).
❖ By increasing the feed rate surface roughness increases, (Nurhaniza, Ariffin et al.
2016).
❖ The surface roughness increases as the depth of cut increases, (Bhogal, Sindhu et al.
2015).

21
Effects of Parameters on Material Removal Rate (MRR)
❖ As cutting speed increases the material removal rate (MRR) increases, (Mgbemena,
Etebenumeh et al. 2016).
❖ By increasing the feed rate material removal rate (MRR) increases, (Surekar,
Bhatwadekar et al. 2014).
❖ The material removal rate (MRR) increases as the depth of cut increases, (S.G.
Bhatwadekar, et al).
2.2.4 Methodology Used

This Methodology is based on Signal-to-Noise (S/N) ratios, which are log functions, are
based on "Orthogonal Array" experiments that will provide much reduced "variance" to the
system parameter experiment with "optimum settings." Thus, the Taguchi process achieves
the marriage of experiment design with optimization of control parameters to obtain best
results.
It provides the better variables i.e. experiments that are conducted to optimize the ultimate
objective/process. It uses than a mathematical analysis which is conducted to obtain and
verify the results of our studies. This output gives the optimal conditions where we can say
the process parameters will stay unchanged and the output will be maximized. (Gillespie &
L. K. `1998)
2.3 Taguchi Method and GRA Usage to Optimize Operations

Studies are conducted worldwide to optimize operations with multiple performance

characteristics. They are the base of our study and provide us the key research points for the
experimentation setup, variable election, parameters to be measured, results to be analyzed
and tools to be used during whole methodology. As going through multiple studies there are
great researches that provide clear experimental results and analysis-based outputs for the
relations of our responses and other factors that are considered to be noise in operations.
In one of studies the scholar found optimization of CNC operations using GRA relational
analysis method. After conducting nine experimental runs based on Taguchi’s method the

22
roughness and roundness were selected as the required quality outputs. The cutting depth was
listed as having the greatest impact on the average roughness and the cutting speed is the
most critical aspect to the optimum roughness and roundness. Therefore, the variance
analysis is often used to determine the most significant factor; the cut depth is the most
significant regulated criteria for turning operations according to the weighted total grade of
the average roughness, max roughness and roundness of the material. (Gillespie 1998)
The multi-objective optimization using GRA has be successfully applied in processes like
drilling, laser welding, plasma arc welding, laser micro turning, friction stir welding process,
grinding process, electrical discharge machining, electrical discharge drilling, turning,
abrasive water and air jet machining and many others. To improve process output the
combination of process parameters are to be focused for which the maximum response can be
obtained. [Cao et al. 2018]
Study conducted on milling operation of spur gear through vertical axis mill used the
Taguchi’s method of orthogonal array along signal to noise ratio, analysis of variance to find
out the effect of these milling parameters that were chosen and done as doe processes and
steps for runs and results analysis. So the results provided that the optimum parameters for
this process on these conditions were possible for optimum cutting force and better surface
finish. The factors tested were the cutting tool quality and shape, the feed rate and depth of
cut. The depth of cut had positive i.e. directly related to the material removal rate, whereas if
it was increased beyond preferred limits it had adverse effect on the life of tools and burrs
were produced causing poor surface finish of the processed steel. (Cao et al & Lee.K 2011)
Therefor now there was need to adjust other factors for better results and thus the feed rate
was increased causing increase in the material removal rate, it also reduced the preciseness
after some time of continual increasing it, also caused the improper chipping during material
removal causing poor finish and less accuracy of process results. Then it comes to the cutting
tool quality and its point of cut properties (geometric). The tool’s cutting edge was varied
according to roundness and then the results were found. As studies already had shown that
higher strength of tool required higher cost as it needed the carbide tips and other expensive
metals at the edge. Therefore, the angle and point of contact were changed. The rounder tip
had less material removal but higher life of tool tip. Whereas the pointed tip caused more

23
reduced life of tip as it broke or consumed up quicker than round one. (Aurich, Dornfeld et
al. 2009)
The Taguchi method provides an efficient and effective strategy for designing cutting
improvement Parameters with much less influence than would have been required most
techniques for optimization process. It has been proven Reduction of the cutting forces and
surface roughness for the milling operations is effective and should be considered for better
optimized results which will be more accurate and closer to the required quality. Setting
these values will provide great improvement and quality assurance of resultants of process.
(Shaji and Radhakrishnan 2003)
‘’This Study determined, that the overall plan for process is to 500 0.75 mm rpm, 20 mm /
min.
The surface roughness values needed for normal milling range from 75μin to 125μin. With
this mixture, the expected result is 2.03μm, i.e. approximately equivalent to 79.921μin. The
achieved minimum cutting force is 45.82N.’’ (Shaji and Radhakrishnan 2003)
Taguchi technique provides practically efficient approach for the betterment of the process
parameters. It has been demonstrated that cutting forces and surface roughness can be
reduced for milling tasks causing the good effect over resultants. Due to the high friction and
intense heat generation involved in the operation, cooling and lubrication are especially
essential to ensure work piece quality in grinding. Liquid coolants in stream form are usually
used during grinding. However, on some technical, technological and social grounds there
has been an afterthought about the use of coolant in this way. Minimizing and possibly
removing fluid coolants by substituting their functions by some other means is of current
interest to the research. Studies investigate the potential of using graphite as a lube to reduce
the heat generated while grinding. Studies provided efficient results at the end and were
adopted in many scenarios of production and are being examined in changed conditions. Our
aim is same as all others to studies to test and provide the optimum condition for
multipurpose operational optimization. (Aurich, Dornfeld et al. 2009)
Thus, these all factors were combined and studied to provide the better and optimal
conditions for resultant product from processes. Therefore, Taguchi method is to be used
here by us in our regional condition of work, material and environment. The factors will be

24
varied and responses will be recorded over the time and then the data will be analyzed for
variance and verification. The end results will be again precisely verified and the optimal
conditions will be used in usual working for better implementation of studies.

2.4 Summary

In this chapter we revised the literature for the project through research papers. Collected
data through literature review and get the effect of process factors on the response variables.
We learned about the AISI 4140 low carbon steel, their mechanical properties and heat
treatment. In next chapter, we will discuss about the selection of response variables and
factors and their levels.

25
CHAPTER 3 SELECTION OF PROCESS PARAMETERS AND
RESPONSE VARIABLES

3.1 Introduction
Process parameter sometime it is called process variable are the certain measures that tell
about the position of the process and their values shows whether the process meets the plan
or it’s require adjustment. There are so many process factors that is tool type, speed, rack
angle, feed rate etc. But our selected parameter is speed, tool type, feed rate, and depth of cut.
The cutting procedure is what but removal of unnecessary materials from work piece by
machining which contains operation such as turning, facing, planning, etc.
Turning is the process during this materials is detached from a cylindrical job keeping tool
stationary and work piece rotating while planning is the operation within that materials is
detached from a stationary job keeping tool while rotation. The cutting operation is effected
by the process parameters, shape and geometry of tool and coolant that is used.
And planning operation is also effected that could be done by lath and numerical control
milling mechanism.
The process factors are accountable in favor of surface irregularities the work piece materials
after planning process. As well they are dependable to speed of manufacture and tool time.
Due to which it is the need of the day to attain optimal arrangement of factors in order to
maximize the efficiency in the form of manufacturing and surface roughness that is the
purpose of our project. The following is the values and flow chart of selection of process
factors and response variables as shown in table 3.1 figure 3.1 and respectively.
Table 3.1: Process Parameters & Levels
Level of Parameters
Parameters Notations Units L1 L2 L3
Spindle Speed N rpm 500 800 1000
Feed Rate F mm/min 60 120 180

Depth of Cut dc mm 0.4 0.7 1.0

Cutting Tools Types Tc --- HSS Carbide

26
 Figure 3.1: Flow Chart of Process Parameters and Response Variables

3.2 Process Parameters

In our research we have four factors as discussed below:

3.2.1 Cutting Tool

As you know, the cutting tool is a device that is used to hack object to achieve required
shape. The Cutting tool that we could be used normally hack crop, trees, and other things etc.
but the device that is created by means of Mitsubishi substances can hack rigid objects that is
brace or other metal.
Cutting is also called cutter is a block shape and spiky edge tool which is used to cut the
extra material from the given job via shearing throughout cutting so as to achieve the
required size shape and dimension.
A comparative speed connecting job and machining device is furthermore given by different
automatic and other provisions for cutting process.
Various machining operation can performed through use different cutting devices that is
Single point turning tool, drill, and fly etc. but the cutting tool we used is milling cutter for
milling operation executed on milling mechanism.

27
Basic properties of the cutting tools are:
a) Job materials must be softer than the tool material by thirty to fifty percent.
b) It is necessary that tool have high hardness temperature
c) Must have elevated stiffness
d) must have large bear resistance than job
e) need to have large electrical conductor property

3.2.1.1 Types of Cutting Tool

Various cutting tool used for various cutting operation for their purpose and each tool have
their own properties and are used accordingly but the tool we used for our cutting tool is of
two types one HSS tool plus second is carbide tool, they both are different from each other
on the basis of their carbon percentage that it contains.

High Speed Steel

HSS is the tool of very hard materials and the name high speed steel is given to it due to its
ability of cutting things at very high rate or speed. It is made of molybdenum tungsten and
vanadium.
M sequence (6, 6, 4, 2)
M series contain 6, 6, 4, 2, are molybdenum, tungsten, chromium, and vanadium and cobalt
percentage respectively. M chain has high abrasive strength and high speed steel mostly is
made of M sequence.
T sequence (18, 4, 1)
Contain 18 percent tungsten 4 percent chromium and one percent vanadium and cobalt.
During heat treatment it is unable to deform. The biggest use of HSS is in manufacturing of
different cutting object that is drill cutter, milling cutter, gear cutter, and other etc.
The valuable hacking characteristic of HSS has more extensive through relate slight,
however very tough, carbide coating that minimize rubbing and rising resistance so as to
maximize cutting velocity and time of device.

28
Applications of HSS
Generally, HSS is used for 18-4-1. 18-shows the amount of Tungsten is to enlarge the hot
rigidity and strength. While four 4-shows the quantity of Chromium which increase power of
HSS. And 1-is the magnitude of Vanadium that is accustomed to keep up intensity of
arrowhead of tool. Also 2.5 percent to 10 percent cobalt is to maximize rigidity. HSS lost
property at elevated temperature that is 600 degree centigrade and above. Sometimes the
amount of molybdenum is used instead of tungsten but HSS which contain high molybdenum
is of low priced than that of HSS which have high quantity of tungsten and little bit large
stiffness and low wet opposition.
Carbide
Carbide cutting tool is manufactured by the following way:
First of all, combine tungsten carbide in the company of cobalt to compose fine particles
which is used as initial resources. Fine particles combination is transferred in a die hollow
space and pushed. It provides a humble power like soft material. Then, the pushed solid are
located in a oven and intense to1400°C heat, ensuing in smooth carbide. Then the dimensions
minimize significantly.
Cemented Carbides
a) It is formed as a result of fine particles method by sintering and elevated up
to 1400°C.
b) It has more velocity up to some times than the velocity of HSS.
c) It can with stand approximately to 1000°C temperature.
d) It has low tensile power than compressive power.
e) It has very high toughness and young modulus too.
Benefits of carbide tools
Some benefits of carbide are used in various resources that it has high production rate
than of HSS and low surface roughness mean greater surface finish. It can easily cut
the harden materials etc.

29
3.2.1.2 Classification of Cutting Tools
Cutting tool can be classified by several methods but the most general method is due to the
number of cutting ends to perform cutting process at the instance which is classified into
three different types
1) One point cutting tool
2) Two point cutting tool
3) Multiple point cutting tool
But the cutting tool that we are using is the single point cutting tool which is clear by the
name has only one cutting edge which perform cutting at a moment for example includes
rotating, and milling tool etc.

3.2.2 Cutting Speed

In machining operation cutting speed or velocity is one of the important factor among the
four selected factors and can be categories by four different method rotation of job while tool
is stationary (in lath) rotation of tool while work piece is in rest (in milling and drilling etc.)
reciprocating job (that is planning process). Reciprocating tool (that is and slotting process)

Figure 3.2: Flow Chart of Machining Operations

30
While both work piece or job is revolving, its revolving property may be categories into two
methods primary one is the numeral of revolution per entity time calculated into revolution
per minutes which is scalar quantity which is called cutting speed and next one is the
peripheral speed at a specific end in the body calculated in meter per minute is the vector
quantity which is the velocity of removing of material from the job with the help of cutting
device.
Cutting velocity is rotating velocity of both cutting tool or work piece based on the rotation
of the each one such as in case of lath the rotation speed of work piece is the cutting speed
while in case of milling the rotating speed of tool is the cutting speed and it is represented v
and measured in rpm or meter per minute or mm/min.
Calculation of cutting speed
Mathematically is written as:

(3.1)
Here;
V is the symbol of speed or velocity
D is the symbol of diameter of work piece measured in millimeter
N is the symbol of number of revolution of work piece
The parameter that the cutting velocity are
1) Materials of the tool from which it is made
2) Materials of the jobs
3) Speed or velocity is also affected by depth of cut
4) Shape, size and geometry of the tool
5) It is affected by the machine tool type too
6) It also depend upon the quality of the surface that is required
This is typical values of cutting speed for different tool that is used;
Different types of values is used for various cutting tools but the values we used for HSS and
carbide are 500 to 1000 revolution per minutes

31
3.2.3 Depth of Cut
The space of the tool bit into the job or work piece is referred to as depth of cut. It is
generally calculated in millimeter. Usually the depth of cut that is used is about five of the
feed rate, like in irregular cutting of low carbon steel is about 0.2 feed rate and depth of is
about 1 inch respectively.
Depth of cut is the amount of material that is detached from the job or work piece in one
revolution of the cutting tool. Mostly it is calculated in millimeter. It can change with the
type of materials of cutting tool and work piece or job.
Mathematically it is half of the difference of diameter of job or work piece before and after
machining operation.
Depth of cut (mm) = (initial diameter-final diameter) divided by 2 (3.2)
Here;

Initial diameter is outer diameter

Final diameter is inner diameter

Both measured in millimeter (mm)

In general tool time is little bit changed by changing in depth of cut as compare to changes in
any other factor of the process either in feed or cutting speed specially in rough cut. However
the tool life decreased by increasing depth cut in semi roughing and finishing cut. Only 15%
decrease in tool life by increasing depth of cut to 50% in partially roughing and finishing cut.
The cause of depth of cut is rather greater once the early depth of cut is fewer than ten times
the feed rate.
The choice of the greatest depth of cut is depend on:
a) Materials of the cutting tool and job also
b) The power of the cutter
c) The efficiency of the machine and the horsepower
d) The dimension precision and quality of the surface
e) And the surface finishing of the job that is required

32
 Figure 3.3: Process Factors

3.2.4 Feed Rate

The most important factor among all the factors is feed rate while executing any of computer
numerical control approach. Simply feed rate is the relative motion of tool in one revolution
work piece and is measured in mm/rev.
Feed rate changes with changing the type of the job material (aluminum etc.) and also
material the tool (carbide, HSS etc.) and some other factor including depth of cut, cutting
velocity, required surface and feature of the CNC milling machine by themselves.
The maximum feed speed has great effect has greatly affected velocity of the spindle and
speed of production also.

3.3 Response Variables

In our research we have two response variables that is MRR and surface roughness.

3.3.1 Material Removal Rate (MRR)

The first selected output variable is rate material removal is the amount or quantity of
materials that is detached in unit time from the job during machining operation by using
milling or lath machine.
In simple words it is volume of material that is removed per unit time
Unit
The unit of material removal rate is gram per minute.

33
How to find MRR
Material removal rate can be finding by several ways but the simplest way is before
machining weight of sample minus after machining weight of sample dividing by total
machining time and then multiplies with the density of that material. MRR is directly
proportional to the production rate. Greater the MRR value, greater will be the productivity
and vice versa. MRR can be calculated by the following formula,

MRR = (Wb - Wa)/ρ*T (3.3)

Here;

Wb = before machining weight of sample

Wa = after machining weight of sample

ρ = density of the material

T = machining time

Effect of parameter and response variable on MRR

1) When we increase the production speed then other response variable plane
irregularity increased and hence is directly related to production rate in the form of
MRR.
2) The MRR is also dependent on process parameter as with increasing cutting speed,
depth of cut, and feed rate increased.
3) The cutting tools affect the material removal rate too.

3.3.2 Surface Roughness

Surface texture describes the variation or irregularities of the plane from the perfect surface.
Surface texture is made up of;
a) Roughness
b) Waviness
c) Lay
d) Flaw
34
3.3.2.1 Roughness
Roughness is a minute, thinly gap deviations from supposed surface confine by material
attribute along with procedures so as to produce the surface.
The present irregularities in a surface either in the form of peak and valleys is called surface
roughness, when the deviation is huge the surface will be irregular and when it is small then
the surface will be plan and regular.
Surface irregularities produced during a process of cutting, planning in simple machining and
occur is due to tool vibration, or when material is hard etc. are the few reasons of surface
irregularities.

Figure 3.4: Roughness

As we know that roughness is opposite to surface finishing.

Unit: Unit of surface roughness is micron where 1mm is equal to 1000micron. The symbol
of surface roughness is Ra

3.3.2.2 Parameters of Roughness

It is distributed in various parameters in which the three most important parameters are Ra,
Rz, and Ry.

Ra: Roughness average is the simple mean of complete values of the roughness summary.

35
Rz: Simply it is the average sum of maximum peak Rp and lowest valley Rv within
evaluation length. Where Rp is the highest peak and Rv is the lowest depth of only one
sample.

Ry: It is the highest length between the peak and the depth of the valley within one sampling
length.

Ry =Rp+Rv (3.4)

3.3.2.3 Measure of Surface Roughness

Mainly we can found surface roughness by two different methods one is Centre line average
method (CLA) and second is Root Mean Square method (RMS)

Figure 3.5: Roughness through Height

(3.5)

Also we can found it with help of area,

36
 Figure 3.6: Roughness through Area

(3.6)

3.4 Summary

In this chapter we discussed about the factor as input and variables as output. The factors are
cutting tool, feed rate, spindle velocity and depth of cut while the variables are surface
roughness and material removal rate. The flow chart of machining operation and process
parameters and also the cutting tool type and surface roughness parameter are discussed. In
next chapter we will discuss about the experimentations, methodology and testing.

37
CHAPTER 4 EXPERIMENTATION AND TESTING

4.1 Introduction
In this chapter we will discuss about the experimentation and testing of the project.
Experiment, is simply a test or series of tests or investigation in which we should try to
determine the effects of inputs or (process parameters) on the outputs (response variables).
We take a AISI 4140 raw material, cut the material in eighteen pieces of almost (60 x 60),
weight each and every piece by electric balance before machining, use 5-axis CNC milling
machine for planning process on each work piece, again weight each and every piece by
electric balance after machining and then use the surface roughness tester to test the surface
roughness of all the parts respectively. The figure 4.1 showing overall the experimentation
and testing process;

Figure 4.1: Experimental Setup

The Figure 4.1 (a) shows the marking of raw material with ruler, (b) cutting of the raw
material in 18 pieces through power hacksawing, (c) is the weighing of each sample before
machining, (d), (e) shows the machining of each sample through 5-axis CNC milling
machine, (f) shows the weighing of each sample after machining, (g) shows all the samples,
and (h) shows the testing of surface roughness of each samples through surface roughness
tester.

38
4.2 Power Hacksaw
Many years ago, saws had been used for cutting metal of momentous developments in
durability and competences were made by Max Flower Nash in 1880s. Clemson was the
American which done with various enhancements in the hacksaw.
A hacksaw is a saw which have a fine teeth, which are made for usually cutting a metal. In
contrast, there is another saw which are used for the cutting of wood called is bow saw. The
power hack saw is described by the responding action of a comparatively small, straight,
notched blade that do to and fro motion over the work piece as like the hand hacksaw worked
as shown in Fig. 4.2.

Figure 4.2: Mechanism of Power Hacksaw

4.2.1 Types of Power Hacksawing Horizontal Machines

We have different types of horizontal machines. The division is based on their cutting
depending on their design. The following are some types of horizontal machines are:

4.2.1.1 Hinge Type Horizontal Sawing Machine

We have different type’s power hacksaw machines and also available in market in different
design, but the horizontal machine is the most widespread one. On the back of the hacksaw
base the cutting edge and the returning or reciprocating frame is fixed.

39
4.2.1.2 Column Type Horizontal Sawing Machine

It is the another type of horizontal power hacksawing machine in which the cutting edge or
saw blade and the frame is fixing or mounted on one or more than one upright columns by
ways. To cut the metal, the mechanism is served downhill in upright plane on the columns.

4.2.2 Main Parts of Power Hacksawing

We have different types of power hacksaws but they have basically same in designing. The
following are the main parts of power hacksaw as discussed below and as shown in Figure
4.3.

Base: Each saw has a base which frequently comprises a pump and a coolant tank intended
for carrying the coolant to the work. The tank has baffles due to which the chips are settled
down to the bottom of the reservoir. The base has a table which help in supporting the vise
(used for clamping a metal) and placed at on the uppermost part of the base.

Figure 4.3: Power Hacksawing

40
Vise: The vise is another part of power hacksaw, which is used for clamping and grasping of
a material which have been sawed. It is changeable and flexible because to hold the different
size and shapes of material for cutting. Where some hacksaws have the rotated vise because
to cut or sawed the metal at some angle. To find out the size of the hacksaw just through
holding the largest part of material or metal in the vise for cutting.

Frame: The third part of the power hacksaw is frame. It helps in supporting and moving the
power hacksaw blades. During cutting stroke metal links with saw blade only because the
power hacksaw machine is designed in such a manner. Due to which the saw blade avoided
excessive or unnecessary wear and tear trough this act. The power hacksaws have two
strokes the forward and backward. The backward is used for the cutting.

4.2.3 Clamping of Power Hacksawing

The power hacksaw is a machine which has a vise to seize so much stock and then be able to
cut all the stock in one setup. We have different methods of fastening and holding metals in
power hacksaw are shown in Figure 4.4.

Figure 4.4: Different Methods of Holding & Clamping Number of Parts in Power Hacksaw

4.2.4 Advantages and Limitations of Power Hacksawing

As we know that anything that we are using in our life has some benefits and drawbacks. The
hacksaw has also have some advantages such as the power hacksaw have required relatively

41
not as much of principle and capital investment, little caution, ,maintenance and tooling
costs. If we want to cut a material and if the material is well and good then we get the finest
part accuracy through power hacksaw.

As we discussed above that each and every thing has some benefits and drawbacks. So the
power hacksaw has also the limitation like power hacksawing is much slower than other
sawing machines. During cutting which is the non-continuous action, the power hacksaw has
strokes forward and backward or reciprocating or returning which is the fruitful one. The
returning action excludes the usage of blades supports nearer to the cutting section,
consequently, hacksaws cutting or sharp edges are denser or thicker than the band sawing
machine, so need extra power and turn out more chips.

4.2.5 Safety and Security of Power Hacksawing

a) Before to start the cutting of material, the blade will be placed at the corner of the
metal or piece, it is essential that start with less amount of pressure cut and then
increasing slowly and gradually once the blade or cutting edge hold large cutting area.
b) When the cutting area is thin or like tube then cutting speed will be high, less feed,
and blades having more tooth/inch.
c) Damaged blades should be shunned, when previously in a hole or slot the cutting is
done with new blades.
d) Some metals are tough and hard except cast iron, so for power hacksawing the cutting
fluid is recommended to use it.

4.3 5-Axis CNC Milling Machine

Computer Numerical Control (CNC) machines brings up the procedure of eliminating or

removing materials through high speed accuracy and precision which use different types of
cutting tools. The CNC is mostly used in advanced industries, and also its machining process
is making use of mostly manufacturing processes. For different actions CNC use various
cutting tools such as drill, mill, and lathe etc. and contracting with the use of one tome setup.

42
5-axis CNC Milling machining is a completely great methodology which is used to produce
various components and final products from different types of materials such as steel, plastic,
iron in great precision and accuracy. 5-axis milling machining means that the milling
machine has the capability of moving the cutting tools or work piece in a five various axis.
Generally, milling machine operates in three dimensions axis i.e. X, Y, and Z. While the 5-
axix CNC milling machining have the ability to move in a two extra axis i.e. A and B. due to
these two additional axis the cutting tools of the 5-axis CNC milling machine moving in
multi directions. As 5-axis CNC milling machines have 5-axis, the three-axis (X, Y, and Z)
are moving linearly while the remaining two-axis (A and B) are moving rotationally used for
complex surfaces. To attain difficult geometry with fitted tolerances that milling machine
will aid us. The following are some best features of 5-axis CNC milling machines:

❖ Increase efficiency and reduce lead time

❖ Better access to work piece and avoid collision
❖ Maintained cutting position, improved cycle time, and tool life

The following are the 5-axis of CNC milling machine as shown in Figure 4.5.

Figure 4.5: 5-Axis CNC Milling Machines

43
4.3.1 Advantages of 5-Axis CNC Milling Machine

5-axis CNC milling machining aids in producing good end products of the best design. It is
due to the following benefits of 5-axis CNC milling machines are:

4.3.1.1 Reduced Setup Time

A 5-axis CNC milling machining have large surface area, which permits us that we can work
on each surface except the bottom and holding area. Normally, when we use the 3-axis
milling manual machine for machining the work piece on different surfaces, to get the
difficult geometry, we need to change setup again and again for each surfaces. But 5-axis
CNC milling machines require only one setup to achieve the final geometry of the work
piece. In this way, the number of setups and it’s time is reduced.

4.3.1.2 Achieve Complex Designs

As we discussed above that 5-axis CNC milling machining have two additional axes, which
are basically the rotation axis, which helps us in getting the complex geometries and designs.
We can easily do machining of part that is cutting with some angles. Eventually, 5-axis CNC
milling machine helps in machining complex geometries, such as we can clamp the work
piece and orient in a single setup to get the desired product.

4.3.1.3 Improved Accuracy

In 3-axis milling machining, when the machining process is done and we take away the work
piece from a machine, each and every time we misplace the cutting tools and lost accuracy.
Due to which we cannot achieve the best quality of the product. While 5-axis CNC milling
machining, improves precision and accuracy because 5-axis CNC milling machines require
only one setup to complete the work and to achieve the complex geometry of the work piece
without losing accuracy need to achieve the best quality of the product.

44
4.3.1.4 Increased Material Removal Rate

In 5-axis CNC milling machining, the machining or cycle time is low compared to manual
machine, because the cutting tool is maintained the peripheral to the work piece. As a result,
the material removal rate is increased and cost is reduced, because MRR is equal to the
difference in before and after machining weight of work piece divided by density *
machining time.

4.3.1.5 Best Surface Finish

5-axis CNC milling machines gives the best quality surface finish of the complex geometries.
As we know that the in 5-axis CNC milling machine has two additional oriented and rotary
axis which helps the cutting tool to be closer to the work piece. That closeness of the cutting
tool to the part, do not allow the machine to vibrate with high speed and helping us to
achieve the better quality of surface finish.

4.3.2 Disadvantages of 5-Axis CNC Milling Machine

Ad we know that each and every thing have some pros and there will be its some cons. The
following are the some disadvantages of 5-axis CNC milling machines:

4.3.2.1 High Initial and Maintenance Cost

Firstly, the 5-axis CNC milling machines are very high initial purchasing costs and also its
software costs than the cost manual machine or three axis machines. Secondly, the
maintenance and repair is also more difficult of the 5-axis CNC milling machines compared
to ordinary machine. These two main features directly increase the cost of 5-axis CNC
milling machines the manual 3-axis machine.

4.3.2.2 Tough Programming

As we know that 5-axis CNC milling machines have moves in five different directions in
which in three directions it linearly move and the remaining two direction it rotationally

45
moves. So, it’s quite difficult to do programming for such a complicated geometries, because
to avoid the collision, interruption, and intrusion motion.

4.3.2.3 Need of Technical Operator

Each and every advanced technology need high level technical operator to operate and
control the technology. Thus, 5-axis CNC milling machine is also an advanced technology
which means it will be needed to best operator to operate it. So, you should to pay for it,
which increases the labor costs.

4.4 Roughness Tester

In our project, we have an essential response variable, with the help of which we are trying to
determine that the work piece have proper and suitable surface or not for specific purpose. It
is known as roughness. Smoother surfaces are not sap rapidly than rough surfaces. Rough
surfaced can help in bonding, but it is more exposed to erosion, deterioration, wear and tear,
and crakes and crushes.

To rapidly and accurately find out the surface roughness and texture of a work piece, we used
a surface roughness tester. That tester shows the different values of roughness such as Rq, Ra
(average mean roughness value), and Rz in micrometers.

4.4.1 Importance of Roughness

As we know that surface roughness is an important response variable aid in determining
appropriateness of a surface of work piece for a specific purpose. Sometimes during
machining irregularities occurs on the surface of a metal, it is due to the process parameters
(speed, feed, depth of cut, and cutting tools etc.), which have an effect on the quality and
performance of that surface of the metal and on final product. . Smoother surfaces are not sap
rapidly than rough surfaces, and can help in bonding, but it is more exposed to erosion,
deterioration, wear and tear, and crakes and crushes.

46
4.4.2 Measurement of Roughness
We have different types of roughness testers, which have different methods for measuring
roughness of a surface. Classical roughness tester deliver a lined roughness measurement,
placing a mechanical tip laterally on the surface of the work piece to be measured their
roughness beside a random line as shown in Figure 4.6. But the advanced versions of the
tester provides floating measurement of surface roughness without touching or contacting
methods like optics, laser, and so on to give sophisticated and finer resolution and extensive
space of measurement.

Figure 4.6: Surface Roughness Tester

Surface roughness values are normally described in Ra and Rz.

a) Ra: Roughness average is the simple mean of complete values of the roughness
summary.
b) Rz: Simply it is the average sum of maximum peak Rp and lowest valley Rv within
evaluation length. Where Rp is the highest peak and Rv is the lowest depth of only
one sample.

47
4.4.3 Measuring Line Lengths
Different encoded and programmed dimensions or lengths can be measured through surface
roughness tester. When the distances are longer than the tester used for rough surfaces, and
when there are smaller distances than it is used for finer and better surfaces.

4.4.4 Measuring Shapes and Offsets

For measuring various shapes (regular and irregular), and offsets several surface roughness
tester have switchable tips or probe. When to check the roughness of the diameter (inner or
outer), make assured that the tip or probe of the tester can come across to our requirements.

If we want the surface roughness value in system international (SI) or in metric system, the
tester have the ability to gives results of the roughness also in micrometers, or in micro
inches to save the time by converting it by hand.

In last we got the following values of Ra and MRR from the experiments and testing as
shown in Table 4.1.

Table 4.1 contains levels of factors, Ra, and MRR values which are achieved from the
experiments and testing. The Ra values are got, when machining is done and all the samples
are tested on surface roughness tester. The MRR values are achieved in such a way that all
the samples are weighted before machining and after machining, note the machining time and
using the equation 3.3.

48
Table 4.1: Results from Experiments and Testing

Milling Parameters Levels Response Variables

S.No. Cutting Spindle Feed Depth Ra MRR
Tool Types Speed Rate of Cut
1 HSS 500 60 0.4 1.09 0.2396
2 HSS 500 120 0.7 0.27 0.5948
3 HSS 500 180 1.0 0.45 1.0211
4 HSS 800 60 0.4 0.575 0.2433
5 HSS 800 120 0.7 0.64 0.573
6 HSS 800 180 1.0 0.41 1.019
7 HSS 1000 60 0.7 0.68 0.2958
8 HSS 1000 120 1.0 0.37 0.7514
9 HSS 1000 180 0.4 0.365 0.1262
10 Carbide 500 60 1.0 0.11 0.3979
11 Carbide 500 120 0.4 0.28 0.1559
12 Carbide 500 180 0.7 0.585 0.6795
13 Carbide 800 60 0.7 0.16 0.1006
14 Carbide 800 120 1.0 0.185 0.4824
15 Carbide 800 180 0.4 0.28 0.4688
16 Carbide 1000 60 1.0 0.23 0.2053
17 Carbide 1000 120 0.4 0.30 0.32
18 Carbide 1000 180 0.7 0.26 0.7967

4.5 Summary
In this chapter we discussed about the experimentation and testing of the project. For the
experimentation use the power hacksaw and 5-axis CNC milling machining. The roughness
tests are performed through surface roughness tester. We discussed the power hacksawing, 5-
axis CNC milling machine and surface roughness tester. In next chapter we will perform
analysis using different analysis tools and will get the results.
49
CHAPTER 5 RESULTS AND ANALYSIS

5.1 Introduction
Minitab is a statistical tool used to analyze the statistical data and improve statistical
education also analyzes information related with data like population of country or
arrangement in different sector education, industry, bank etc. Minitab has large and wide
application and uses a six sigma technique for data evaluation. It’s very flexible software and
shows the input data by graph.

5.1.1 History of Minitab

Minitab software was first invented in 1972 by RAYN. In start the statistics instructors want
to combine computer with the statistic courses at that time student were using desk
calculators to solve the tiresome problem.

But in start when Minitab was connected with statistical subject the freed student concentrate
on this software and learn what its really show and is the basic concept of this software. But
in start the Minitab inventor RYAN goal is to analyze and make data easy.

Before 1980 Minitab was expend to the academic institution also in the business and other
industry sectors. After this Minitab use in different colleges and universities student use in
classroom. After 1980 Minitab is one of the top rank software and easy use software inside
industries and other organization to implement six sigma. Over the two year there is a lot of
changes occur in Minitab and add different type of features by the customer and market
demand.

50
5.1.2 Key Features of Minitab

Following are the 8 key features mentioned below:

1. Basic Statistics: This feature includes all types of statistical tests, descriptive
statistics, correlations, and variance. Click Stat then -> Basic Statistics
2. Graphics: This graph tool bar is used to draw different kind of statistical graph
like scatter plot, histograms, boxplots, matrix plot, marginal plot, bubble chart etc.
Click Graph > Probability Plot
3. Regression: The regression feature is available inside state. This feature is use to find
the relationship between variables that how much one variable effect on another
(which is a key feature of any statistical tool). Click Stat then -> Regression
4. Analysis of Variance: Analysis of variance i.e. ANOVA is used to analyze the
difference between the groups means also show the significance of each factor. Click
Stat then -> ANOVA
5. Statistical Process Control: Statistical process control is a feature use to create cause
and effect diagram, variable control charts, multi-variation control charts, time-
weighted charts etc. Click state>then multivariable >item analysis
6. Measurement System Analysis: It is a mathematical method used to determine
amount of variation that exist in a measurement process Variability in a process can
also impact the overall variance of a process. Click Stat then go to -> Quality Tools
then -> Gage Study
7. Design of Experiment: It is a systematic approach which determined the relationship
between the process parameters which affect the response variables. Click state
then>DOE>factorial>create factorial design
8. Reliability/Survival: It is used for distribution for modeling data. It helps you in
identifying which one is the best function that best describes your data.

51
 Figure 5.1: Key Features of Minitab

5.1.3 Why We Use Minitab in Our Project

We use Minitab in our project for analyzing the data and we use two techniques inside
Minitab. The first one is Analysis of variance and the second is Taguchi signal to noise ratio
in Taguchi signal to noise ratio there is three criteria the first one is
❖ Larger the batter
❖ Nominal the better
❖ Smaller the better
The first one ANOVA shows the significances of each factor that which one factor is most
significance and the second one Taguchi signal to noise ratio shows the effect of single factor
on a response variable one at a time.

52
 Figure 5.2: Analysis Steps on Minitab

5.1.3.1 Taguchi S/N Ratio

Taguchi S/N ratio is used for single factor optimization process. Taguchi S/N ratio
determines how mean of experimental value near to target value. Taguchi S/N ratio has three
criteria:
❖ High the better
❖ Nominal the best
❖ Low the better

Measure of forcefulness is used to recognize control process parameter in Taguchi design. By

means of reducing the impacts of uncontrollable parameters or nuisance factors the control
parameters reduce the unevenness in a process or product. Control factors are those process
parameters which can be controlled like in our project we have four controlled factors i.e.

53
spindle speed, cutting tool type, feed rate and depth of cut. During production the noise or
nuisance factors can’t be controlled, however during experimentation it can be controlled.
We use the nuisance parameters to produce variability in a Taguchi designed testing as a
result, to isolate the optimal control parameters settings which make the product or process
strong. When the values of S/N ratio is high to recognize the control factors settings which
reduce the impacts of the uncontrollable factors.
Two steps optimization process frequently used by Taguchi design. The control process
parameters which decrease the variability is recognized by using S/N ratio is the first step.
While in second step, isolate control factors which travel the mean value near to target value
and have no or less effect on the S/N ratio. The following are the three criteria of S/N ratio:

Low-the-Better

This criterion of S/N ratio reduces the response and used for all type of unwanted features
such as defects, surface roughness, waste etc. In this research this criterion we used for the
response variable which is surface roughness (Ra). The following is the mathematical form
of the low-the-better criteria;

(5.1)

Or,

n = -10 Log10 [mean of sum of squares of measured data] (5.2)

54
The value of Ra and corresponding signal-to-noise ratio is given in table 5.1 below:

Table 5.1: S/N Ratio of Ra

S.No. Ra S/N Ratio for Ra

1 1.01 -0.08643
2 0.395 8.068058
3 0.49 6.196078
4 0.755 2.441061
5 0.535 5.432924
6 0.35 9.118639
7 0.68 3.349822
8 0.245 12.21668
9 0.495 6.107896
10 0.29 10.75204
11 0.37 8.635966
12 0.525 5.596814
13 0.31 10.17277
14 0.125 18.0618
15 0.435 7.230215
16 0.165 15.65032
17 0.3 10.45757
18 0.195 14.19931

The Table 5.1, shows the results of S/N ratio for surface roughness of all the samples using
Minitab. Used smaller-the-better criterion of S/N ratio to reduce the Ra.

55
 (a) (b)

(c)
Figure 5.3: (a) Probability Plot of Ra, (b) Main Effect Plot for Mean, and (c) Main Effect Plot
for S/N Ratio of Ra

In figure 5.3, the probability plot indicates that the data samples are valid and we can use the
data for further analysis, because in the plot all the samples are within the limits. The main
effect plot for mean shows that when the first level of tool type, low level of spindle speed
and feed rate, and first level of depth of cut are used then it gives the optimal results for Ra
and reduces it. The main effect plot for S/N ratio means that the level of factors which have
least value in the graph gives the best surface finishing.
56
Higher-the-Better

This criterion of S/N ratio increases the response and used for all type of wanted features
such as zero defects, MRR etc. In this research this criterion we used for the response
variable which is MRR. The following is the mathematical form of the higher-the-better
criteria;

(5.3)

Or,

n = -10 Log10 [mean of sum squares of reciprocal of measured data] (5.4)

The value of MRR and corresponding signal-to-noise ratio is given in table 5.2 below

Table 5.2: S/N Ratio of MRR

S.No. MRR S/N Ratio for MRR
1 0.2396 -12.4103
2 0.5948 -4.51258
3 1.0211 0.181366
4 0.2433 -12.2772
5 0.573 -4.83691
6 1.019 0.163484
7 0.2958 -10.58
8 0.7514 -2.48258
9 0.1262 -17.9788
10 0.3979 -8.00452
11 0.1559 -16.1431
12 0.6795 -3.35621
13 0.1006 -19.948

57
 14 0.4824 -6.33185
15 0.4688 -6.58025
16 0.2053 -13.7522
17 0.32 -9.897
18 0.7967 -1.9741

The Table 5.2, shows the results of S/N ratio for MR of all the samples using Minitab. Used
larger-the-better criterion of S/N ratio to increase MRR.

(a) (b)

(c)
Figure 5.4: (a) Probability Plot of MRR, (b) Main Effect Plot for Mean, and (c) Main Effect
Plot for S/N Ratio of MRR

58
In figure 5.4, the probability plot shows that the data samples are valid and we can use the
data for further analysis, because in the plot all the samples are within the limits. The main
effect plot for mean indicates that when the first level of tool type, low level of spindle speed
high level of feed rate, and depth of cut are used then it gives the optimal results for MRR
and increases it. The main effect plot for S/N ratio means that the level of factors which have
greater value in the graph gives the optimal MRR.

Nominal-the-Best

This criterion of S/N ratio target the response and we want to base the S/N ratio on standard
deviation and mean deviation. The following is the mathematical form of the nominal-the-
best criteria;

(5.5)

Or
n = 10 Log10 (Square of mean/Variance) (5.6)

5.1.3.2 ANOVA

ANOVA is based on the law of total variance, in which the variance in a particular variable
or process parameters is divided into different parts. It is used in the analysis of experimental
data and to check the significance of each process parameter. It is also used to check the
variation among two or more arithmetic means.
ANOVA in statistics used an analysis tool for the splitting of perceived total variability
which originates in the data into two main portions i.e. random factors and systematic
factors. The random factors do not have a statistical impact on the originated data, and the
systematic factors have. In our project we have to analyze the effect of process parameters on
response variables. It also helps in to find out which factor is more significant.

59
5.1.3.3 Types of ANOVA Tests

We have two main types of ANOVA tests based on the process parameters or independent
variables:
One Way ANOVA: One way ANOVA is also called a unidirectional ANOVA because it
has only one process parameter or independent variable in the analysis. That type of ANOVA
test calculates the influence of a single factor on a single response variable. One way
ANOVA is also helps in calculating the statistical differences among the means of all the
process parameters. It is used to relate two means from two different process parameters
through the F-test. The null hypothesis (Ho) will be equal to the two means are equal.
Two-Way ANOVA: Two-way ANOVA is also called a bidirectional ANOVA because it
has two process parameter or independent variables in the analysis. It is the extension of one
way ANOVA. This type of ANOVA test calculates the influence of a two factors at the same
time on a response variable. A two-way ANOVA is best for the quantitative results not for
the qualitative. The following are the analysis of Ra through ANOVA;

Table 5.3: ANOVA for Ra

Analysis of Variance for Surface Roughness (Ra)

Source DoF Adj SS Adj MS F-Value P-Value % Contribution Remarks

Tool 1 0.27876 0.27876 24.77 0.001 32.91 Most

Type Significant

2 0.08388 0.04194 3.73 0.062 9.90 Not Significant

Speed

Feed 2 0.12924 0.06462 5.74 0.022 15.27 Significant

Depth of 2 0.24257 0.12128 10.78 0.003 28.64 Most

Cut Significant

Error 10 0.11253 0.01125 13.29

Total 17 0.84698 100

60
Table 5.3, have the ANOVA results for Ra. It shows the significant factors and their
contribution in reducing the Ra. The significance can check through the F and P values. The
Factors have the higher F-values and lower P-values up to 5% will be the significant
parameter for Ra. So, the most significant parameters are tool type and depth of cut, feed rate
is the significant, and speed is insignificant factor for Ra. In the table the error have 10 values
which mean that the 10 samples are contributing in the variance calculations.

The percentage contribution of parameters on Surface Roughness is shown in Figure 5.5.

Percentage Contribution of Parameters on Ra

1 2 3 4 5

Error, 13.29%
Tool Type,
32.91%
Depth of
Cut,28.64%

Feed Rate, Speed, 9.90%

15.27%

Figure 5.5: Percentage Contribution of Parameters on Ra

Response table is obtained by averaging S/N values of parameters at each level.

Table 5.4: Response Table for Ra Based on Average S/N Ratio

S/N Ratio Process Parameters

Level Tool Type Speed Feed Depth of Cut

1 0.5506 0.5133 0.5350 0.5608
2 0.3017 0.4183 0.3283 0.4400
Ra
3 0.3467 0.4150 0.2775
Delta 0.2489 0.1667 0.2067 0.2833

Rank 2 4 3 1
The Table 5.4 is the response table which is obtained by averaging S/n ratio values of factors
at each level. To get the first level of tool type value, add all the S/N values of tool type of
HSS divided by 9; for second level of feed, add all the S/N values of feed of second level i.e.
61
120 mm/min divided by 6. We achieved all the remaining values by the above procedure. In
the table the delta is the difference between the maximum and minimum values of each
factor. From S/N response table and Main effects plot, the optimal level of parameters that
will achieve minimum Ra is T1, S1, F1, DC1;

Table 5.5: Optimal Level of Parameters for Ra

Optimal Levels of Parameters for Ra

Tool Type Speed Feed Depth of Cut

HSS 500 rpm 60 mm/min 0.4 mm

In Table 5.5 we see that which level of factors is significant for surface roughness. The first
level of tool type HSS, low level speed 500 rpm, feed rate 60 mm/min, and depth of cut 0.4
mm (T1, S1, F1, and DC1) are the significant level of factors.

Now we are interested in the analysis of MRR through ANOVA. The following results we
got from the ANOVA through Minitab.

Table 5.6: ANOVA for MRR

Analysis of Variance for MRR

Source DoF Adj SS Adj MS F-Value P-Value % Contribution Remarks

Tool Type 1 0.08779 0.08779 3.02 0.113 6.07 Not

Significant
Speed 2 0.03035 0.01517 0.52 0.609 2.1 Not
Significant
Feed 2 0.57660 0.28830 9.91 0.004 39.84 Most
Significant
Depth of 2 0.46154 0.23077 7.93 0.009 31.89 Significant
Cut

Error 10 0.29087 0.02909 20.1

Total 17 1.44715 100

62
Table 5.6, have the ANOVA results for MRR. It shows the significant factors and their
contribution in increasing the MRR. The significance can check through the F and P values.
The Factors have the higher F-values and lower P-values up to 5% will be the significant
parameter for MRR. So, the most significant parameter is feed rate, depth of cut is the
significant, tool type and speed are insignificant factors for MRR.

The percentage contribution of parameters on MRR is shown in Figure 5.6.

Percentage Contribution of Parameters on MRR

1 2 3 4 5
Tool Type, 6.07% Speed, 2.1%
Error, 20.1%

Feed, 39.84%
Depth of Cut,
31.89%

Figure 5.6: Percentage Contribution of Parameters on MRR

Response table is obtained by averaging S/N values of parameters at each level.

Table 5.7: Response Table for MRR Based on Average S/N Ratio

S/N Ratio Process Parameters

Depth
Level Tool Type Speed Feed of Cut
1 0.5405 0.5148 0.2471 0.2590

MRR 2 0.4008 0.4812 0.4796 0.5067

3 0.4159 0.6852 0.6462
Delta 0.1397 0.0989 0.4381 0.3872
Rank 3 4 1 2

The Table 5.7 is the response table which is obtained by averaging S/n ratio values of factors
at each level of MRR. To get the first level of tool type value, add all the S/N values of tool
type of HSS divided by 9; for second level of speed, add all the S/N values of speed of
63
second level i.e. 800 rpm divided by 6. We achieved all the remaining values by the above
procedure.

From S/N response table and Main effects plot, the optimal level of parameters that will
achieve maximum MRR is T1, S1, F3, DC3;
Table 5.8: Optimal Level of Parameters for MRR

Optimal Levels of Parameters for MRR

Depth
Tool Type Speed Feed of Cut
HSS 500 rpm 180 mm/min 1 mm

In Table 5.8 we see that which level of factors is significant for MRR. The first level of tool
type HSS, low level speed 500 rpm, high level of feed rate 180 mm/min, and depth of cut 1.0
mm (T1, S1, F3, and DC3) are the significant level of factors.

5.2 Microsoft Excel

Microsoft Excel is a full-featured spreadsheet program that allows you to arrange and
organize data, complete calculations, transform data to graph, and also develop professional
looking reports. Three mega parts of Excel are:

a) Worksheets: Worksheets allow you to enter, calculate, manipulate and

analyze data such as numeric and text.
b) Charts: It pictorially represents data. Excel cans also draw two-dimensional
and three dimensional column charts, pie charts and other types of charts.
c) Databases: Databases manage data. For example, once you enter data onto a
worksheet, Excel can sort the data, search the particular data, and select data
that meets certain criteria.

64
Excel has cells. Each cell is represented by rows and columns. The types of data that a cell
can hold include:

❖ Numbers
❖ Text
❖ Dates and times
❖ Boolean values
❖ Formulas

5.2.1 History of Microsoft Excel

Microsoft originally marketed a spreadsheet program called Multiplan in 1982, which was
very famous on CP/M systems, but on MS-DOS systems it lost popularity to Lotus 1-2-3.
This promoted development of a new spreadsheet called Excel which starts with the intention
to 'do everything 1-2-3 does and do it better'. First version of Excel was released for the Mac
in 1985 and the first windows version was released in November 1987. Lotus was slow to
bring 1-2-3 to Windows and by 1988 Excel had started to outsell 1-2-3 and helped Microsoft
achieve the position of leading PC software developer. This accomplishment, dethroning the
king of the software world, solidified Microsoft as a valid competitor and showed its future
of developing graphical software.
Microsoft pushed its advantage with regular new releases, every two years or so. The current
version for the Windows platform is Excel 11, also called Microsoft Office Excel 2003. The
current version for the Mac OS is Microsoft Excel 2004.

5.2.1.1 Features of Microsoft Excel

1. Add Header and Footer: MS Excel allows us to keep the header and footer in
spreadsheet document.
2. Find and Replace Command: MS Excel allows us to find the required data (text and
numbers) in the workbook and also substitute the existing data with a new one.
3. Password Protection: It allows the user to protect their workbooks by using a
password from unauthorized access to their information.

65
 4. Data Filtering: Filtering is a quick and easy way to find and work with a subset of
data in a range. A filtered range displays only the rows that meet the criteria you
specify for a column. MS Excel provides two commands for filtering ranges:
• AutoFilter; which includes filter by selection, for simple criteria
• Advanced Filter; for more complex criteria
5. Data Sorting: Data sorting is the process of arranging data in some logical order. MS
Excel allows us to sort data either in ascending or descending order.
6. Built-in formulae: MS Excel has got many built-in formulae for sum, average,
minimum, etc. We can use those formulae as per our needs.
7. Create different charts (Pivot Table Report): MS Excel allows us to create different
charts such as bar graph, pie- charts, line graphs, etc. This helps us to organize,
analyze and compare data very easily.
8. Automatically edits the result: MS Excel automatically varies the result if any
changes are made in any of the cells.
9. Formula Auditing: Using formula auditing we can graphically display or trace the
relationships between cells and formulas with blue arrows. We can trace the
precedents (the cells that provide data to a specific cell) or the dependents (the cells
that depend on the value in a specific cell).

5.2.2 Why We Use Microsoft Excel Software in Our Project

We use Microsoft excel to analyze the data by use of gray relational analysis technique to
find out and check the main effect of factors on the response variables all at a time.

5.2.2.1 Grey Relational Analysis

Multi factors optimization process makes use of GRA technique. GRA technique is part of
theory proposed by Julong called is Grey System Theory. This theory is used when there are
incomplete, poor, and uncertain information’s. GRA technique is appropriate to solve
problems by means of complex relationship among variables and multi factors. Grey
relational analysis transforms optimization of multiple performance features into single
objective optimization. GRA technique performed analysis through four steps:

66
Normalization of S/N ratios: In normalization step we apply the preprocessing technique
on the S/N ratio data for both the response variables within the range of zero to one. All the
data now become positive. To normalize the data for smaller the better criteria i.e. Ra, with
the help of following formula;

(5.7)
Where;
Xi* (k) = indicates the normalization of Ra
MaxYi (k) = maximum value in the column of S/N ratio of Ra
Yi (k) = the individual value from the top to bottom in the column of S/N ratio of Ra
MinYi (k) = minimum value in the column of S/N ratio of Ra
To normalize the data for larger the better criteria i.e. MRR, with the help of following
formula;

(5.8)
Where;
Zij = shows the normalization of MRR
Yij = the individual value from the top to bottom in the column of S/N ratio of MRR
Min (Yij) = minimum value in the column of S/N ratio of MRR
Max (Yij) = maximum value in the column of S/N ratio of MRR
Deviation Sequence: We calculate the deviation sequence for Ra and MRR by the
following formulas respectively;
DSi = MaxXi* (k) – Xi (5.9)
Where;
DSi = indicates the deviation sequence of Ra
Xi = is the normalization value of Ra and i = 1, 2, 3……….. 18

67
 DSij = MaxZij – Zij (5.10)
Where;
DSij = shows the deviation sequence of MRR
Zij = is the normalization value of MRR and ij = 1, 2, 3……….. 18

Generation of grey relational coefficient: We can generate the grey relational

coefficient for Ra and MRR by using the following formulas respectively;
GRCi = 0.5/ (DSi + 0.5) (5.11)
Where;
GRCi = grey relational coefficient for Ra and i = 1, 2, 3………18
DSi = indicates the deviation sequence of Ra
GRCij = 0.5/ (DSij + 0.5) (5.12)
GRCij = grey relational coefficient for MRR and i = 1, 2, 3………18
DSij = indicates the deviation sequence of MRR
Table 5.9: Values of S/N Ratio of Ra and MRR
S.No. Cutting Spindle Feed Depth Ra MRR S/N Ratio S/N Ratio
Tool Speed Rate of Cut of Ra of MRR
1 HSS 500 60 0.4 1.01 0.2396 -0.08643 -12.4103
2 HSS 500 120 0.7 0.395 0.5948 8.068058 -4.51258
3 HSS 500 180 1 0.49 1.0211 6.196078 0.181366
4 HSS 800 60 0.4 0.755 0.2433 2.441061 -12.2772
5 HSS 800 120 0.7 0.535 0.573 5.432924 -4.83691
6 HSS 800 180 1 0.35 1.019 9.118639 0.163484
7 HSS 1000 60 0.7 0.68 0.2958 3.349822 -10.58
8 HSS 1000 120 1 0.245 0.7514 12.21668 -2.48258
9 HSS 1000 180 0.4 0.495 0.1262 6.107896 -17.9788
10 Carbide 500 60 1 0.29 0.3979 10.75204 -8.00452
11 Carbide 500 120 0.4 0.37 0.1559 8.635966 -16.1431
12 Carbide 500 180 0.7 0.525 0.6795 5.596814 -3.35621
13 Carbide 800 60 0.7 0.31 0.1006 10.17277 -19.948
14 Carbide 800 120 1 0.125 0.4824 18.0618 -6.33185
15 Carbide 800 180 0.4 0.435 0.4688 7.230215 -6.58025
16 Carbide 1000 60 1 0.165 0.2053 15.65032 -13.7522
17 Carbide 1000 120 0.4 0.3 0.32 10.45757 -9.897
18 Carbide 1000 180 0.7 0.195 0.7967 14.19931 -1.9741

68
In Table 5.9, we have all the levels of factors values, Ra and MRR values achieved from
experiments and testing, and their corresponding S/N ratio values got from the equations 5.1
and 5.3 using Excel respectively. First we squared each value of Ra and MRR and then using
the above equations for calculations.
Generation of grey relational grade and Rank: To generate the grey relational grade
we use the following formula;
GRGi = (GRCi + GRCij) /2 (5.13)
Here;
GRGi = grey relational grades for i = 1, 2, 3……….18

Table 5.10: GRA Overall Results

Data Deviation Grey Relational Grey Rank
Normalization Sequence Coefficient Relational
Ra MRR Ra MRR Ra MRR Grade
1 0.374466 0 0.625534 1 0.444233553 0.72211678 3
0.550673 0.766811 0.449327 0.233189 0.526688996 0.681952851 0.60432092 9
0.653823 1 0.346177 0 0.590892652 1 0.79544633 1
0.860731 0.381078 0.139269 0.618922 0.782143153 0.446858848 0.614501 6
0.695874 0.750699 0.304126 0.249301 0.621792928 0.667288931 0.64454093 5
0.492784 0.999112 0.507216 0.000888 0.496417974 0.998226462 0.74732222 2
0.810656 0.465389 0.189344 0.534611 0.725327773 0.483273416 0.60430059 10
0.322077 0.867659 0.677923 0.132341 0.424475861 0.790712854 0.60759436 7
0.658682 0.097828 0.341318 0.902172 0.594305334 0.356589734 0.47544753 14
0.402781 0.593337 0.597219 0.406663 0.455697509 0.551472754 0.50358513 12
0.51938 0.189025 0.48062 0.810975 0.509881732 0.381395551 0.44563864 16
0.686843 0.824258 0.313157 0.175742 0.614887532 0.739927682 0.67740761 4
0.4347 0 0.5653 1 0.469351338 0.333333333 0.40134234 17
0 0.676433 1 0.323567 0.333333333 0.607114852 0.47022409 15
0.59684 0.664093 0.40316 0.335907 0.55361166 0.598152484 0.57588207 11
0.132877 0.307799 0.867123 0.692201 0.36573149 0.419392514 0.392562 18
0.419006 0.499321 0.580994 0.500679 0.462537463 0.499660851 0.48109916 13
0.21283 0.892919 0.78717 0.107081 0.388449158 0.823613845 0.6060315 8

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The Table 5.10 contains overall calculations of GRA technique. In first step data is
normalized through using equation 5.7 and 5.8 for Ra and MRR respectively. All the S/N
values of Ra and MRR are become within 0 and 1 range and gives positive results. Next, we
calculated the deviation sequence by equation 5.9 and 5.10 for Ra and MRR respectively. In
third step we determined the grey relational coefficient for Ra and MRR using equation 5.11
and 5.12 respectively. In last step, we calculated the grey relational grade of both response
variables using equation 5.13. In Table 5.10 we see that in Rank column third row got 1. It
means that the setting of sample third gives the optimal results to increase productivity and
reduce surface roughness.

Table 5.11: Optimal Combination of Factor Levels

S.No. Milling Grey Relational Grade Main Rank

Parameters Effect
Level 1 Level2 Level 3 (max min)

1 Tool Type 0.646177 0.505975 0.140202 1

2 Spindle Speed 0.492178 0.575635 0.527839 0.083457 3

2
3 Feed Rate 0.539735 0.542236 0.646256 0.106521

4 Depth of Cut 0.552448 0.589657 0.586122 0.037209 4

Tool type is found to be most significant parameter followed by feed rate, spindle speed, and
depth of cut. The optimal setting is first level of tool type, medium setting of spindle speed
and depth of cut, and highest level of feed rate.

5.3 Summery
In this chapter we analyze the data got from the experimentation and testing through three
techniques i.e. Taguchi S/N ratio, ANOVA, and GRA. We made probability plots to check
the validity of data for further analysis. We have made analysis through Taguchi S/N ratio
and ANOVA to check the main effect one at a time and significances of the parameters on
response variables respectively. We also used GRA technique to check main effect of factors
on output all at a time.
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CHAPTER 6 SUSTAINABILITY OF PROJECT

6.1 Introduction
Sustainability is the capability of any organization or a project to carry on their goals and
objectives remain throughout into the future. Ultimately, the project has to end, but their
effect should be remained. Sustainability of project means that the project should be planned,
monitored and controlled, while contemplating the environmental, social and economic
features of life cycle keep in mind. We planned our final year project, visited to the different
industries and select Daud Son’s Armor industry for project, select process parameters,
response variables, machining process and material, monitored the whole experimentation
and testing, and get the results for the analysis and conclude it.

6.2 Environmental, Economic, and Social Benefits of the Project

The following are the environmental, economic, and social benefits of our FYP:

1) Environmental benefits
2) Economic benefits
3) Social benefit

6.2.1 Environmental Benefits

For the welfare of human being the environmental safety is necessary, because all the
somatic resources come out from the environment. Though, we reduce resources and uses
more resources than the earth have produced by waning and humiliating the environment.
The environmental benefit of our project is to reduce wastes and defects of the raw material
due to process parameters by getting the optimal combination of the factors and to reduce
surface roughness and to increase productivity. It also decreased the emissions, pollutions
and wastes.

Another environmental benefit of our project is we used low carbon steel alloy material AISI
4140 for milling machining not use any other things like chemicals, gasoline, plastics, natural
gases, coal, or air is a raw material because its create pollution which is not beneficial after
the cutting operations for both human beings and environments. Also if we use air for cutting

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then we add different other gases which will be toxic for the environment. The awesome
benefit of the project is that the environment can succeed and carry on withstanding people
and all life forever.

6.2.2 Economic Benefits

The quality of economy is just improved, not the size of it by sustainability growth. Any
organization needs a best economy, not a big economy. The economic benefits of our project
are to reduce the overall consumptions, labor costs, maintenance costs, raw material costs,
rework and inspection costs etc. and distribution of wealth equally. Due to reducing the
different types of costs and manufacturing best quality of products gives the prosperity and
money to the peoples of organization and customers.
In our project we use Taguchi method which works on reducing the number of experiment by
the help of Minitab software. This Taguchi technique save time, reduce material, and money.
Also this Taguchi method is used to identify the factors that affect the response variables in
the process. To use AISI 4140 material we achieve our final product substantial and use less
material within operation as compere to use of any other material.

6.2.3 Social Benefits

As we all know about the fact that waste and defects of any manufacturing process like
cutting process either it is in the form of wasting energy, extra chip, power, cost, time or any
other resources etc. have bad impact on society when the cutting parameters are not
optimized properly.
In our project we have four cutting parameters that is cutting speed, feed rate, depth of cut
and cutting tool type are optimized and found the best combination of parameters in order to
improve surface roughness and material removal rate that are socially beneficial for human
beings either directly in the form of owner and worker in any organization and also indirectly
to remaining society also containing animal etc.
One of the social benefits of our project is when an organization provides a good quality and
of accuracy part in short time with low cost which best for manufacturer and customers and
consumer. When a company work with optimum cutting parameters will have good quality
of products which in turn increase the conformance of the company and by increasing the
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conformance more customers are willing to buy the goods and hence increase sale of the
company then company will be hiring more to run it. By this creating jobs and unemployment
will reduced which is other social benefit of the project.

6.3 Role and Advantage of the Project

The following is the role and advantage of our FYP for economy, society, and environment:

6.3.1 Economically
Economically the role and advantages of our project are as we resolved with the problem of
surface roughness and material removal rate in our project by optimization of process
parameter such as spindle speed, depth of cut, feed rate, and cutting tool type. So by
optimization we reduced defects, costs, time, and other resources and increasing the material
removal rate, profit, accuracy of the parts and finally found the optimum combination of
process parameter which is economically beneficial for any organization.

6.3.2 Socially
Our project is not much related with society but little bit from social perspective of our
project as we already discussed that like any other manufacturing process cutting process
might be create a problem of low productivity, waste in the form of chips are harmful for
society when it is not optimized properly. Here we optimized the process parameters that are
good for the worker health and society also.

6.3.3 Environmentally
The cutting process great impact on environment when consider the energy, efficiency, noise
pollution etc. when the process parameters is not optimum. Our project has also positive
impact on environment by minimizing the unwanted process like noise pollution, energy
wastage, efficiency and hence optimization of cutting parameters for environmental impact.

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CHAPTER 7 CONCLUSIONS AND RECOMMENDATIONS

In this chapter we will conclude the results and then recommend it for the future work by
comparing the main achievements with objectives of the research. This research is
concentrating on the surface roughness and the material removal rate to decrease and increase
respectively. We want to achieve best quality of surface finishing of work piece and improve
MRR.

7.1 Project Conclusion

We concluded from the main effect plot for S/N ratio and ANOVA of Ra that cutting tool
types and depth of cut are the most significant and feed rate is significant factors among
parameters. The most significant factors among input parameters are the cutting tool types
and depth of cut with percentage contribution of 32.91% and 28.64% respectively. We also
get the results from the main effects plot that is it best to select the first level of cutting tool
types, low level of spindle speed, feed rate, and depth of cut. Additional, the selected low
level of spindle speed is originated to be insignificant. The levels which we achieved through
analysis of factors that will minimize the Ra are HSS, 500 rpm, 60 mm/min, and 0.4 mm for
AISI 4140 low carbon steel.

We further concluded from the main effect plot for S/N ratio and ANOVA of MRR that feed
rate is the most significant and depth of cut is the significant factors among parameters. The
most significant factors among input parameters is feed rate with percentage contribution of
39.84%. We also get the results from the main effects plot that is it best to select the first
level of cutting tool types, low level of spindle speed, high level of feed rate, and depth of
cut. Additional, the selected low level of toll types and spindle speed is originated to be
insignificant. The levels which we achieved through analysis of factors that will minimize the
Ra are HSS, 500 rpm, 180 mm/min, and 1.0 mm for AISI 4140 low carbon steel.

From ANOVA analysis it is shown that cutting tool type is the most effective and persuading
factor in achieving the best quality of surface finish, followed by depth of cut. And also from
ANOVA analysis it is shown that feed rate is the most effective and significant factor in
achieving the high productivity, followed by depth of cut. Multi optimization of factors is

74
done through the using of integrated Taguchi based grey relational analysis (TGRA). Grey
relational analysis recognized that a cutting tool type of HSS, spindle speed of 500 rpm, feed
rate of 180 mm/min, and depth of cut of 1.0 mm is the optimal combination of milling
parameters.

7.2 Future Work Recommendation

In this research we used the L18 Taguchi mixed model for the experimentation and take four
factors i.e. spindle speed, cutting tool type, feed rate, and depth of cut and two response
variables or outputs i.e. Ra and MRR. So for the future students we recommend that use L36
Taguchi mixed model for the experimentation and take four factors with replacement of one
factor like coolant type and two or three response variables with addition or replacement of
factors such as cutting forces, metal surface and tool wear. L36 model because when number
of experiments increases, it gives best results, if you can afford it.

75
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