Optimization of process parameters of Tool

Wear in turning operation

Submitted by:
Manik Barman
Roll No. 13101203002
Registration No. 131010410007 of 2013-2014

Guided by:

Prof. Dr. S. Mukherjee

Department of Mechanical Engineering
Jalpaiguri Government Engineering College

A thesis submitted in partial fulfillment

Of the requirement for a degree of
Master of Technology
In

Production Technology and Management

(Department of Mechanical Engineering)

Jalpaiguri Government Engineering College

Jalpaiguri 735102
2015
 Department of Mechanical Engineering

ACKNOWLEDGEMENT

The euphoria and joy, accompanying the successful completion of this task would be incomplete
without the special mention of those people whose guidance and encouragement made these efforts
successful.

I have opportunity to express my sincere heartfelt gratitude to my respected guide Prof. Dr.
S.Mukherjee who with zeal encouragement, benevolent and outstanding patience helped us in
making this endeavors grand success, his invaluable timely advice, enthusiasm, thought and guidance
are reflected on every aspects of this report.

I also wish to extend my thanks to Mr. Ashim Roy, Superintendent of Workshop, Department of
Workshop, JGEC for their insightful comments and constructive suggestions to improve the quality
of this work.

My gratitude to Dr. D.C.Roy (H.O.D) of Mechanical engineering for his cooperation.

Last but not the least we owe our sincere thanks to all those who helped us in many tangible and
intangible ways.

(MANIK BARMAN)
M-Tech ,(4th semester)
Roll No:13101203002
Registration No: 131010410007 of
2013-2014
 Department of Mechanical Engineering

FORWARD
I have immense pleasure in certifying that the project entitled “Optimization of process parameters
of Tool Wear in turning operation” submitted to the Department of Mechanical Engineering,
Jalpaiguri Govt. Engineering College MANIK BARMAN bearing roll no.-13101203002, registration
no.- 131010410007 of 2013-2014 final year student (M-TECH) of Mechanical Engineering,
Jalpaiguri Govt. Engineering College is a bonafide record of work performance by the student as a
result of his extensive and untiring effort under my guidance and supervision. The main purpose of
this is to help the students to activate their skills, most efficiently, in applying the knowledge they
have already acquired to reach a satisfactory solution of engineering problem, particularly those
involving the process “Optimization of process parameters of Tool Wear in a turning
operation”. I think he will be able to deal boldly with such problems in practical field in nature.

I wish him every success in life.

………………………………………….

Prof. (Dr.) Sudip Mukherjee

Department of Mechanical Engineering

 Government of West Bengal Phone :( 03561)255131
Department of Mechanical Engineering Fax :( 03561)255131
Jalpaiguri Government Engineering College Email: jgec@dte.vsnl.net.in
Jalpaiguri-735102
West Bengal

MESSAGE

I have immense pleasure in certifying SUBHAJIT DANGAR bearing roll no.-12101203004,

registration no.- 121010410003 of 2012-2013 final year student (M-TECH) of Mechanical
Engineering Department of Jalpaiguri Govt. Engineering College for his project “Optimization of
process parameters forminimization of surface roughness in a turning operation” under the
supervision of Dr. Sudip Mukherjee, a distinguished member faculty in the Department of
Mechanical Engineering of

Jalpaiguri Govt. Engineering College.

This is bonafide record of project work submitted by him towards partial fulfilment for obtaining the
degree of “Master of Technology” in Mechanical Engineering (Production Technology
&management) from “West Bengal University of Technology”, reflecting his sincere and
untiringefforts.

I do think that he will be able to deal efficiently with such problems in practice; I wish him all success
in all his future endeavours.

Prof. (Dr.) D.C. Roy

(Head of the Department)
Department of Mechanical Engineering
Jalpaiguri Govt. Engineering College.
 Government of West Bengal TELEGRAM: JALTECH
PRINCIPAL’S CHAMBER Phone :( 03561)255131
Jalpaiguri Government Engineering College Fax :( 03561)255131
Jalpaiguri-735102 Email: jgec@dte.vsnl.net.in
West Bengal

MESSAGE

It gives me great pleasure in certifying the authority of the project work and related report prepared
by MANIK BARMANbearing roll no.- 13101203002, registration no.- 131010410007 of 2013-
2014final year student (M-TECH) of Mechanical Engineering Department of Jalpaiguri Govt.
Engineering College for his project “Optimization of process parameters of Tool Wearin a
turning operation”, a distinguished member faculty in the Department of MechanicalEngineering
of Jalpaiguri Govt. Engineering College.

This project report has been prepared towards partial fulfillment of conditions that will enable them to
obtain the degree of “Master of Technology” in Mechanical Engineering (Production Technology
&Management) from “West Bengal University of Technology”, The report is not only a
bonafiderecordbut also bears true testimony of the potential and efforts put in by the student.

I have full faith that he will be able to deal efficiently with such problems in future endeavors and
hope he attain the pinnacle of glory.

Dr. J. Jhampati.
Principal
Jalpaiguri Govt. Engineering College.
Jalpaiguri.
 APPROVAL

The foregoing thesis is hereby approved as a creditable study of an engineering subject carried out
and presented in a manner satisfactory to warrant its acceptance as a pre-requisite to the degree for
which it has been submitted. It is to be understood that by this approval the undersigned does not
necessarily endorse or approve any statement mode, opinion expressed or conclusion drawn therein
but approved the thesis only for the purpose for which it is submitted.

Board of examiners:

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 CONTENTS
The Problem
Chapter 1
1.1 Introduction
1.2 Turning Operation
1.3 Adjustable Cutting Factors in Turning
1.4 Cutting Tool Materials
1.5 Factors Affecting the Tool Wear
1.6 Tool Wear in Machining
1.7 Turning Machine
Chapter 2: Literature Review
Chapter 3: Theoretical Analysis
3.1 Introduction
3.2 Control Parameters and Their Limits
3.3 Design of Experiments
3.4 Equipment used for Specimen Preparation
3.5 Work Piece Used
3.6 Tool Wear Measurement
3.7 Response Surface Methodology (RSM)
3.8 RSM Procedure
3.9 Mathematical Modeling
Chapter 4: Computer Simulation
Chapter 5: Results and Discussion
5.1 Introduction
5.2 Effect of Parameters on Tool Wear
5.2.1 Effect of Spindle Speed on Tool Wear
5.2.2 Effect of Feed Rate on Tool Wear
5.2.3 Effect of Depth of Cut on Tool Wear
5.3 Optimization
5.4 S/N Ration Calculation
5.5 Overall Mean of S/N Ration
5.6 ANOVA Calculation
Chapter 6: Conclusion and Scope for Further Work
Bibliography
 List of Figures

Figure 1.1 Adjustable Parameters in Turning Operation

Figure 1.2 Tool Wear in Machining
Figure 1.3 Lathe Machine
Figure 3.1 Digital vernier Caliper
Figure 3.2 Digital Vernier Caliper during tool wear measurement
Figure 3.3 Photographic view of Machined work piece
Figure 5.1 Variation of Tool Wear with Spindle Speed
Figure 5.2 Variation of Tool Wear with Spindle Speed
Figure 5.3 Variation of Tool Wear with Spindle Speed
Figure 5.4 Variation of Mean of S/N Ratio with Spindle Speed
Figure 5.5 Variation of Mean of S/N Ratio with Spindle Speed
Figure 5.6 Variation of Mean of S/N Ratio with Spindle Speed
 List of Tables
Table 1 : Limits and Levels of Control Parameters
Table 2 : Design of Experiment Combination Table
Table 3 : Experimental Data
Table 4 : S/N Ratio for Smaller the Better
Table 5 : Overall Mean of S/N Ratio
Table 6 : Effect of Each Parameter
Table 7 : ANOVA Calculation
 The Problem
The most crucial and determining factor for successful maximization of the manufacturing
process and its automation in any typical metal cutting process is tool wear. Here the work is
concerned with the optimization of High Speed Steel cutting tool wear undergoing turning
operation of a mild steel specimen. The parameters controlling the tool wear of the cutting tool
are spindle speed, feed rate and depth of cut. The experimental data are analyzed with the help
of a regression model and an attempt has been made to arrive at an optimum combination of the
control parameters, within their working ranges, which may provide the minimum wear of the
cutting tool undergoing turning operation of mild steel specimen.
 Chapter 1

Introduction
1.1 Introduction
Machining operations have been the core of the manufacturing industry since the
industrial revolution.Increasing the productivity and the quality of the machined parts are
the main challenges of metal-based industry; there has been increased interest in
monitoring all aspects of the machining process. Turning is most widely used among all
the cutting processes.The machining parameters (cutting speed, feed rate, depth of cut)
accelerate tool wear and it affects the surface finishing also. The tool wear is directly
related to the machining parameters. Optimum machining parameters, being the
objective of this work is planned for turning machines to minimize tool wear in order to
improve quality of machined products to improve the tool life.
Palanikumar developed a Response surface method (RSM) model for GFRP composites
to predict the surface roughness.The model uses a CCD based four factors five level
rotatable designs to carry out the experimental sequence of investigation and the model
was validated using analysis of variance (ANOVA). Response surface methodology is a
collection of mathematical and statistical techniques, which are useful for the modeling
and analyzing the engineering problems and developing, improving, and optimizing
processes. It also has important applications in the design, development, and
formulation of new products, as well as in the improvement of existing product designs,
and it is an effective tool for constructing optimization models.

1.2Turning operation
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit,
describes a helical tool path by moving more or less linearly while the work piece rotates.
Turning can be done manually, in a traditional form of lathe, which frequently requires
continuous supervision by the operator, or by using an automated lathe which does not. 
When turning, a piece of relatively rigid material (such as wood, metal, plastic, or stone)
is rotated and a cutting tool is traversed along 1, 2, or 3 axes of motion to produce
precise diameters and depths. Turning can be either on the outside of the cylinder or on
the inside (also known as boring) to produce tubular components to various geometries.
The turning processes are typically carried out on a lathe, considered to be the oldest
machine tools, and can be of four different types such as straight turning, taper
turning,profiling or external grooving. Those types of turning processes can produce
various shapes of materials such as straight, conical, curved, or grooved work piece. In
general, turning uses simple single-point cutting tools. Each group of work piece
materials has an optimum set of tools angles which have been developed through the
years.
 Figure 1.1: Adjustable parameters in turning operation
1.3 Adjustable cutting factors in turning
The three primary factors in any basic turning operation are speed, feed, and depth of
cut. Other factors such as kind of material and type of tool have a large influence, of
course, but these three are the ones the operator can change by adjusting the controls,
right at the machine.

Speed:
Speed always refers to the spindle speed and the work piece. When it is stated in
revolutions per minute it tells their rotating speed. But the important feature for a
particular turning operation is the surface speed, or the speed at which the work piece
material is moving past the cutting tool. It is simply the product of the rotating speed
times the circumference of the work piece before the cut is started. It is expressed in
meter per minute (m/min), and it refers only to the work piece. Every different diameter
on a work piece will have a different cutting speed, even though the rotating speed
remains the same.
V= m/min
Here, v is the cutting speed in turning, D is the initial diameter of the work piece in mm,
and N is the spindle speed in rpm.

Feed:
Feed always refers to the cutting tool, and it is the rate at which the tool advances along
its cutting path. On most power-fed lathes, the feed rate is directly related to the spindle
speed and is expressed in mm (of tool advance) per revolution (of the spindle).
Fm= f .N mm/min
Here, Fm is the feed in mm per minute, f is the feed in mm/rev and N is the spindle speed
in rpm.

Depth of Cut:
Depth of cut is practically self-explanatory. It is the thickness of the layer being removed
(in a single pass) from the work piece or the distance from the uncut surface of the work
to the cut surface, expressed in mm. It is important to note, though, that the diameter of
the work piece is reduced by two times the depth of cut because this layer is being
removed from both sides of the work.
= mm
Here, D and d represent initial and final diameter (in mm) of the job respectively.

1.4 Cutting tool materials

The classes of cutting tool materials currently in use for machining operation are high-
speed tool steel, cobalt-base alloys, cemented carbides, ceramic, and polycrystalline
cubic boron nitride and polycrystalline diamond. Different machining applications require
different cutting tool materials. The Ideal cutting tool material should have all of the
following characteristics:
 Harder than the work it is cutting
 High temperature stability
 Resists wear and thermal shock
 Chemically inert to the work material and cutting fluid
To effectively select tools for machining, a machinist or engineer must have specific
information about:
 The starting and finished part shape
 The work piece hardness
 The material's tensile strength
 The material's abrasiveness
 The type of chip generated
 The work holding setup
 The power and speed capacity of the machine tool

Some common cutting tool materials are described below:

Carbon steels:
HSS tools are so named because they were developed to cut at higher speeds.
Developed around 1900 HSS are the most highly alloyed tool steels. The tungsten (T
series) was developed first and typically contains 12 - 18% tungsten, plus about 4%
chromium and 1- 5% vanadium. Most grades contain about 0.5% molybdenum and most
grades contain 4- 12% cobalt.

It was soon discovered that molybdenum (smaller proportions) could be substituted for
most of the tungsten resulting in a more economical formulation which had better
abrasion resistance than the T series and undergoes less distortion during heat
treatment. Consequently about 95% of all HSS tools are made from M series grades.
These contain 5 - 10% molybdenum, 1.5 - 10% tungsten, 1 - 4% vanadium, 4%
Chromium and many grades contain 5 - 10% cobalt.
HSS tools are tough and suitable for interrupted cutting and are used to manufacture
tools of complex shape such as drills, reamers, taps, dies and gear cutters. Tools may
also be coated to improve wear resistance. HSS accounts for the largest tonnage of tool
materials currently used. Typical cutting speeds: 10 - 60 m/min.

Carbides:
Also known as cemented carbides or sintered carbides were introduced in the 1930s and
have high hardness over a wide range of temperatures, high thermal conductivity, high
Young's modulus making them effective tool and die materials for a range of
applications. The two groups used for machining are tungsten carbide and titanium
carbide; both types may be coated or uncoated.

Tungsten carbide particles (1 to 5 micrometer) are bonded together in a cobalt matrix

using powder metallurgy. The powder is pressed and sintered to the required insert
shape.

Titanium and niobium carbides may also be included to impart special properties. A wide
range of grades are available for different applications. Sintered carbide tips are the
dominant type of material used in metal cutting. The proportion of cobalt (the usual
matrix material) present has a significant effect on the properties of carbide tools. 3 - 6%
matrix of cobalt gives greater hardness while 6 - 15% matrix of cobalt gives a greater
toughness while decreasing the hardness, wear resistance and strength.
Tungsten carbide tools are commonly used for machining steels, cast irons and abrasive
non-ferrous materials.

Titanium carbide has a higher wear resistance than tungsten but is not as tough. With a
nickel-molybdenum alloy as the matrix, TiC is suitable for machining at higher speeds
than those which can be used for tungsten carbide. Typical cutting speeds are: 30 - 150
m/min or 100 - 250 when coated.

1.5 Factors Affecting Tool Wear

Whenever two machined surfaces come in contact with one another the quality of the
mating parts play an important role in the performance and wear of the mating parts. The
height, shape, arrangement and direction of these surface irregularities on the work
piece depend upon a number of factors such as:

A) The machining variable

The machining variables which include

I. Cutting speed: It is found that an increase of cutting speed generally improves tool
wear rate.

II. Feed: Experiments show that as feed rate increases tool wear alsoincreases due to
the increase in cutting force and vibration.

III. Depth of cut: Increasing the depth of cut increases the cutting resistance and
theamplitude of vibrations. As a result, cutting temperature also rises. Therefore, it is
expected that tool wear rate will be more.

B) The tool geometry

Some geometric factors which affect achieved tool wear include:
I. Nose radius
II. Rake angle
III. Side cutting edge angle, and
IV. Cutting edge.

C) Work piece and tool material combination and their mechanical properties
D) Quality and type of the machine tool used
E) Auxiliary tooling, and lubricant used, and
F) Vibrations between the work piece, machine tool and cutting tool
G) Use of cutting fluid: The cutting fluid is generally advantageous in regard to tool
wear because it affects the cutting process in three different ways.
Firstly, it absorbs the heat that is generated during cutting by cooling mainly the tool
point and the work surface. In addition to this, the cutting fluid is able to reduce the
friction between the rake face and the chip as well as between the flank and the
machined surface. Lastly, the washing action of the cutting fluid is considerable, as it
consists in removing chip fragments and wear particles. Therefore, the tool life with the
presence of cutting fluid is expected to be better than that obtained from dry cutting.
1.6 Tool Wear in Machining
Tool wear describes the gradual failure of cutting tools due to regular operation. It is a
term often associated with tipped tools, tool bits, or drill bits that are used
withmachinetools.
Types of wear include:
 Flank wear in which the portion of the tool in contact with the finished part erodes.
Can be described using the Tool Life Expectancy equation.
 Crater wear in which contact with chips erodes the rake face. This is somewhat
normal for tool wear, and does not seriously degrade the use of a tool until it
becomes serious enough to cause a cutting edge failure.
Can be caused by spindle speed that is too low or a feed rate that is too high.
In orthogonal cutting this typically occurs where the tool temperature is highest.
Crater wear occurs approximately at a height equaling the cutting depth of the
material. Crater wear depth ~ t0 t0= cutting depth
 Built-upedge in which material being machined builds up on the cutting
edge.Somematerials (notably aluminum and copper) have a
tendencytoannealthemselves to the cutting edge of a tool. It occurs most frequently
on softer metals, with a lower melting point. It can be prevented by increasing cutting
speeds and using lubricant. When drilling it can be noticed as alternating dark and
shiny rings.

1.7 Turning Machines

The turning machines are, of course, every kind of lathes. Lathes used in manufacturing
can be classified as engine, turret, automatics, and numerical control etc.
A lathe is a machine tool which rotates the work piece on its axis to perform various
operations such as cutting, knurling, facing, turning, with tools that are applied to the
work piece to create an object which has symmetry about an axis of rotation.
 Chapter 2

Literature Review
Literature review
One of the significant machining operations is metal cutting. Amongst them, turning is one of
the oldest machining processes. Variation during machining process due to tool wear,
surface roughness, temperature changes and other disturbances make it highly inefficient
for perfection, especially in high quality machining operations where product quality
specifications are very restrictive. Therefore, to assure the quality of machined products,
reduce costs and increase machining efficiency, cutting parameters must be optimized to
minimize various response variables such as tool wear.

Vishal S. Sharma · S. K. Sharma · Ajay K. Sharma carried out an experimental investigation

(2006) on cutting tool wear and developed a model for tool wear estimation. The changes in
the values of cutting forces, vibrations and acoustic emissions with cutting tool wear are
recoded and analyzed. On the basis of experimental results a model was developed for tool
wear estimation in turning operations using Adaptive Neuro fuzzy Inference system (ANFIS).
Acoustic emission (Ring down count), vibrations (Acceleration) and cutting forces along with
time have been used to formulate model. This model is capable of estimating the wear rate
of the cutting tool. The wear estimation results obtained by the model were compared with
the practical results and are presented. The model performed quite satisfactory results with
the actual and predicted tool wear values. The model can also be used for estimating tool
wear on-line but the accuracy of the model depends upon the proper training and section of
data points.

P. Chockalingam, Lee Hong Wee studied the effect of different coolant conditions on milling
of AISI 304 stainless steel. Cooling methods used in this investigation were flooding of
synthetic oil, water-based emulsion, and compressed cold air. Cutting forces and the
surface roughness were studied and tool flank wears observed. In this study, the
comparison between different coolants’ effect to the milling of AISI 304 stainless steel is
done and the results from the study can provide very useful information in manufacturing
field. The experiment results showed that water-based emulsion gave better surface finish
and lower cutting force followed by synthetic oil and compressed cold air. Different cooling
condition required different parameters in order to obtain lower surface roughness and
cutting force. Chipping was the initial wear mode in the milling of AISI 304 stainless steel.

Viktor P. Astakhov (Astakhov Tool Service, 3319 Fulham Dr., Rochester Hills, MI 48309,
USA) made an assessment (2003) of Flank wear of cutting tools. It is often selected as the
tool life criterion because it determines the diametric accuracy of machining, its stability and
reliability. This study argues that the existing criteria of flank wear are insufficient for its
proper characterization. Their existence is due to the lack of knowledge on the contact
conditions at the tool flank–work piece interface. Known attempts to evaluate the physical
processes at this interface do not help to resolve this issue. This study compares different
characteristics of the evaluation of flank wear. The contact process at the mentioned
interface is analyzed through the experimental assessment of the contact stresses, and the
full validity of Makarov’s law is confirmed, i.e. minimum tool wear occurs at the optimum
cutting speed. A new concept of tool resources is proposed and discussed. This resource is
defined as the limiting amount of energy that can be transmitted through the cutting wedge
until it fails.

J.A. Arsecularatnea,*, L.C. Zhanga, C. Montrossb (2005) carried out an investigation of

wear mechanism of cutting tools made of tungsten-carbide (WC), PCBN and PCD using the
tool life and Temperature results available in the literature. For tool/work combinations
WC/steel and PCBN/hardened-steel, under practical conditions, tool wear was found to be
greatly influenced by the temperature. It was concluded that the most likely dominant tool
wear mechanism for WC is diffusion and that for PCBN is chemical wear. For PCD, more
experimental results and hence further research is required to determine the dominant wear
mechanism.

Natarajan et al. (2007) presented the on-line tool wear monitoring technique in turning
operation. Spindle speed, feed, depth of cut, cutting force, spindle-motor power and
temperature were selected as the input parameters for the monitoring technique. For finding
out the extent of tool wear, two methods of Hidden Markov Model (HMM) such as the Bar-
graph Method and the multiple modeling Methods were used. A decision fusion center
algorithm (DFCA) was used for increasing the reliability of this output which combined the
outputs of the individual methods to make a global decision about the wear status of the
tool. Finally, all the proposed methods were combined in a DFCA to determine the wear
status of the tool during the operations.
 Chapter 3

Theoretical Analysis
3.1 Introduction
The present study has been carried out through the following phases:
a) Checking and preparing the lathe ready for performing the machining operation.
b) Preparing the work piece specimen ready for turning operation.
c) Measure the cutting tool dimension with a digital vernier caliper before the operation
and note it down.
d) Run the turning operation.
e) Again measure the cutting tool after the operation.
f) Calculate the tool wear for that single run of turning operation.
g) Experimental values are obtained by operating at the combination of process
variables are used to form 27 regression equations. Solving the set of equations for
the coefficients, the final equation for the system is constructed.

3.2 Control parameters and their limits

The working ranges of the parameters for subsequent design of experiment have been
selected in accordance with the normal working ranges for such operation. In the present
experimental study only spindle speed, feed rate and depth of cut have been considered
as process variables since these are the most important parameters affecting the tool
wear. The process parameters and their limits (and notations) are listed in Table 1:

Table 1: Limits and levels of control parameters

Limits
Control Parameters
Low( 1 ) Medium( 2 ) High( 3 )
Spindle Speed (v)
250 590 930
rpm
Feed Rate (f)
0.16 0.40 0.64
mm/rev
Depth of cut (d)
0.6 0.8 1.0
mm

3.3 Design of experiment

The experiments were designed by following full factorial design of experiments. Design
of experiments is an effective approach to optimize the parameters in various
manufacturing related process, and one of the best intelligent tool for optimization and
analyzing the effect of process variable over some specific variable which is an unknown
function of these process variables. The selection of such points in design space is
commonly called design of experiments (DOE). In this work related to turning of Mild
steel, the experiments were conducted by considering three main influencing process
parameters such as spindle speed, Feed Rate and Depth of Cut at three different levels
namely Low, Medium and High. So according to the selected parameters a three level
full factorial design of experiments (3 3 = 27) were designed and conducted. The level
designation of various process parameters are shown in table 2.
 Table 2: Design of Experiment Combination Table
Factorial Combination
Sl. No.
V f d
1. 1 1 1
2. 1 1 2
3. 1 1 3
4. 1 2 1
5. 1 2 2
6. 1 2 3
7. 1 3 1
8. 1 3 2
9. 1 3 3
10. 2 1 1
11. 2 1 2
12. 2 1 3
13. 2 2 1
14. 2 2 2
15. 2 2 3
16. 2 3 1
17. 2 3 2
18. 2 3 3
19. 3 1 1
20. 3 1 2
21. 3 1 3
22. 3 2 1
23. 3 2 2
24. 3 2 3
25. 3 3 1
26. 3 3 2
27. 3 3 3
3.4 Equipment used for specimen preparation
High Speed Precision Lathe NH 22 Manufactured by Hindusthan Machine Tools Limited.
 Model   NH22

Height of centers mm 220

Distance between centers mm 1000

Spindle Speed range rpm 16 from 40-2040 forward, 7 from 60-1430 reverse

Spindle power kW 11

Feed range (longitudinal) mm/rev 60 from 0.04-2.24

Feed range (cross) mm/rev 60 from 0.02-1.12

Tailstock sleeve travel mm 200

Main motor power kW 7.5 (std.) / 11.0 (opt.)

3.5 Work piece used:

Mild Steel bars of diameter 20mm and length 100mm are used for the purpose. For the
experiment 27 jobs of same diameter and length are taken for each factorial combination
according to full factorial design.

3.6 Tool Wear Measurement

Figure 3.1: Digital Vernier Caliper

 Figure 3.2: Digital Vernier Caliper during Tool Dimension Measurement

Figure 3.3: photographic view of machined work piece

Before and after each turning operation length of the cutting tool is measured by digital
vernier caliper and tool wear is calculated.

Machining conditions for full factorial design of experiments and the experimental output
values for tool wear at varying input parameters are listed in table 3.

Table 3: Experimental Data

Spindle Speed Depth of Cut
Exp. Feed Rate ( f ) Response (T =
(v) (d)
No. mm/rev Tool Wear) mm
RPM mm
1. 250 0.16 0.6 0.03
2. 250 0.16 0.8 0.06
3. 250 0.16 1.0 0.08
4. 250 0.40 0.6 0.05
5. 250 0.40 0.8 0.07
6. 250 0.40 1.0 0.09
7. 250 0.64 0.6 0.07
8. 250 0.64 0.8 0.08
9. 250 0.64 1.0 0.10
10. 590 0.16 0.6 0.04
11. 590 0.16 0.8 0.06
 12. 590 0.16 1.0 0.08
13. 590 0.40 0.6 0. 06
14. 590 0.40 0.8 0.08
15. 590 0.40 1.0 0.10
16. 590 0.64 0.6 0.08
17. 590 0.64 0.8 0.09
18. 590 0.64 1.0 0.11
19. 930 0.16 0.6 0.05
20. 930 0.16 0.8 0.08
21. 930 0.16 1.0 0.10
22. 930 0.40 0.6 0.07
23. 930 0.40 0.8 0.09
24. 930 0.40 1.0 0.12
25. 930 0.64 0.6 0.09
26. 930 0.64 0.8 0.11
27. 930 0.64 1.0 0.16

3.7 Development of Mathematical model

The general second order polynomial mathematical model, which analyses the
parametric influences on the various response criteria, can be described as follows:

k
k k
Tool Wear, T = B0+∑ ❑BiXi+∑ ❑BiiXi2+ i∑
, j=1
❑BijXiXj …………………….. (1)
i=1 i=1
i≠ j

Where T is Response and Xi(i, j =1, 2, . . . . , k) are levels of k quantitative variables. The
coefficient B0 is the constant term; the coefficients B i,Bij, Bijare for the Linear, Quadratic
and Interaction terms. After putting actual values from the experiments, 27 equations are
formed.

The general equation for this experiment,

T=B0+B1v+B2f+B3 d+ B11 v 2+B22f 2+B33d 2+ B12 vf+ B13 vd+ B23fd…….(2)

Here X1=v, X2=f,X3=d

Putting the value of process parameters in general equation, the above equations are
formed.
k
k k

Tool Wear, T = B0+∑ ❑Bi Xi +∑ ❑BiiXi +i∑ ❑B X X where i & j are from 1 to 3
2
, j=1
ij i j
i=1 i=1
i≠ j
B0 , Bi , Bii , Bijare the Co-efficient and Xi (X1, X2, X3) are the Parameter (Spindle Speed,
Longitudinal Feed & Cross Feed / Depth of Cut)
T1 = 0.03 = B0 + (B1 x 250+ B2 x 0.16+ B3 x 0.6) + (B11 x 2502+ B22 x 0.162+ B33 x 0.62) + (B12 x
250 x 0.16 + B13 x 250 x 0.6+ B23 x 0.16 x 0.6)
T2 = 0.06 = B0 + (B1 x 250+ B2 x 0.16+ B3 x 0.8) + (B11 x 2502+ B22 x 0.162+ B33 x 0.82) + (B12 x
250 x 0.16 + B13 x 250 x 0.8+ B23 x 0.16 x 0.8)
T3= 0.08 = B0 + (B1 x 250+ B2 x 0.16+ B3 x 1.0) + (B11 x 2502+ B22 x 0.162+ B33 x 1.02) + (B12 x
250 x 0.16 + B13 x 250 x 1.0+ B23 x 0.16 x 1.0)
T4 = 0.05 = B0 + (B1 x 250+ B2 x 0.40+ B3 x 0.6) + (B11 x 2502+ B22 x 0.402+ B33 x 0.62) + (B12 x
250 x 0.40 + B13 x 250 x 0.6+ B23 x 0.40 x 0.6)
T5= 0.07 = B0 + (B1 x 250+ B2 x 0.40+ B3 x 0.8) + (B11 x 2502+ B22 x 0.402+ B33 x 0.82) + (B12 x
250 x 0.40 + B13 x 250 x 0.8+ B23 x 0.40 x 0.8)

T6= 0.09 = B0 + (B1 x 250+ B2 x 0.40+ B3 x 1.0) + (B11 x 2502+ B22 x 0.402+ B33 x 1.02) + (B12 x
250 x 0.40 + B13 x 250 x 1.0+ B23 x 0.40 x 1.0)
T7 = 0.07 = B0 + (B1 x 250+ B2 x 0.64+ B3 x 0.6) + (B11 x 2502+ B22 x 0.642+ B33 x 0.62) + (B12 x
250 x 0.64 + B13 x 250 x 0.6+ B23 x 0.64 x 0.6)
T8= 0.08 = B0 + (B1 x 250+ B2 x 0.64+ B3 x 0.8) + (B11 x 2502+ B22 x 0.642+ B33 x 0.82) + (B12 x
250 x 0.64 + B13 x 250 x 0.8+ B23 x 0.64 x 0.8)
T9= 0.10 = B0 + (B1 x 250+ B2 x 0.64+ B3 x 1.0) + (B11 x 2502+ B22 x 0.642+ B33 x 1.02) + (B12 x
250 x 0.64 + B13 x 250 x 1.0+ B23 x 0.64 x 1.0)
T10 = 0.04 = B0 + (B1 x590+ B2 x 0.16+ B3 x 0.6) + (B11 x 5902+ B22 x 0.162+ B33 x 0.62) + (B12 x
590 x 0.16 + B13 x 590 x 0.6+ B23 x 0.16 x 0.6)

T11= 0.06 = B0 + (B1 x 590+ B2 x 0.16+ B3 x 0.8) + (B11 x 5902+ B22 x 0.162+ B33 x 0.82) + (B12 x
590 x 0.16 + B13 x 590 x 0.8+ B23 x 0.16 x 0.8)

T12= 0.08 = B0 + (B1 x 590+ B2 x 0.16+ B3 x 1.0) + (B11 x 5902+ B22 x 0.162+ B33 x 1.02) + (B12 x
590 x 0.16 + B13 x 590 x 1.0+ B23 x 0.16 x 1.0)
T13 = 0.06 = B0 + (B1 x 590+ B2 x 0.40+ B3 x 0.6) + (B11 x 5902+ B22 x 0.402+ B33 x 0.62) + (B12 x
590 x 0.40 + B13 x 590 x 0.6+ B23 x 0.40 x 0.6)
T14= 0.08 = B0 + (B1 x 590+ B2 x 0.40+ B3 x 0.8) + (B11 x 5902+ B22 x 0.402+ B33 x 0.82) + (B12 x
590 x 0.40 + B13 x 590 x 0.8+ B23 x 0.40 x 0.8)

T15= 0.10 = B0 + (B1 x 590+ B2 x 0.40+ B3 x 1.0) + (B11 x 5902+ B22 x 0.402+ B33 x 1.02) + (B12 x
590 x 0.40 + B13 x 590 x 1.0+ B23 x 0.40 x 1.0)

T16 = 0.08 = B0 + (B1 x 590+ B2 x 0.64+ B3 x 0.6) + (B11 x 5902+ B22 x 0.642+ B33 x 0.62) + (B12 x
590 x 0.64 + B13 x 590 x 0.6+ B23 x 0.64 x 0.6)
T17= 0.09 = B0 + (B1 x 590+ B2 x 0.64+ B3 x 0.8) + (B11 x 5902+ B22 x 0.642+ B33 x 0.82) + (B12 x
590 x 0.64 + B13 x 590 x 0.8+ B23 x 0.64 x 0.8)
T18= 0.11 = B0 + (B1 x 590+ B2 x 0.64+ B3 x 1.0) + (B11 x 5902+ B22 x 0.642+ B33 x 1.02) + (B12 x
590 x 0.64 + B13 x 590 x 1.0+ B23 x 0.64 x 1.0)

T19 = 0.05 = B0 + (B1 x930+ B2 x 0.16+ B3 x 0.6) + (B11 x 9302+ B22 x 0.162+ B33 x 0.62) + (B12 x
930 x 0.16 + B13 x 930 x 0.6+ B23 x 0.16 x 0.6)
T20= 0.08 = B0 + (B1 x 930+ B2 x 0.16+ B3 x 0.8) + (B11 x 9302+ B22 x 0.162+ B33 x 0.82) + (B12 x
930 x 0.16 + B13 x 930 x 0.8+ B23 x 0.16 x 0.8)
T21= 0.10 = B0 + (B1 x 930+ B2 x 0.16+ B3 x 1.0) + (B11 x 9302+ B22 x 0.162+ B33 x 1.02) + (B12 x
930 x 0.16 + B13 x 930 x 1.0+ B23 x 0.16 x 1.0)
T22 = 0.07 = B0 + (B1 x 930+ B2 x 0.40+ B3 x 0.6) + (B11 x 9302+ B22 x 0.402+ B33 x 0.62) + (B12 x
930 x 0.40 + B13 x 930 x 0.6+ B23 x 0.40 x 0.6)
T23= 0.09 = B0 + (B1 x 930+ B2 x 0.40+ B3 x 0.8) + (B11 x 9302+ B22 x 0.402+ B33 x 0.82) + (B12 x
930 x 0.40 + B13 x 930 x 0.8+ B23 x 0.40 x 0.8)
T24= 0.12 = B0 + (B1 x 930+ B2 x 0.40+ B3 x 1.0) + (B11 x 9302+ B22 x 0.402+ B33 x 1.02) + (B12 x
930 x 0.40 + B13 x 930 x 1.0+ B23 x 0.40 x 1.0)
T25 = 0.09 = B0 + (B1 x 930+ B2 x 0.64+ B3 x 0.6) + (B11 x 9302+ B22 x 0.642+ B33 x 0.62) + (B12 x
930 x 0.64 + B13 x 930 x 0.6+ B23 x 0.64 x 0.6)
T26= 0.11 = B0 + (B1 x 930+ B2 x 0.64+ B3 x 0.8) + (B11 x 9302+ B22 x 0.642+ B33 x 0.82) + (B12 x
930 x 0.64 + B13 x 930 x 0.8+ B23 x 0.64 x 0.8)
T27= 0.16 = B0 + (B1 x 930+ B2 x 0.64+ B3 x 1.0) + (B11 x 9302+ B22 x 0.642+ B33 x 1.02) + (B12 x
930 x 0.64 + B13 x 930 x 1.0+ B23 x 0.64 x 1.0)

To solve these 27 equations and find out the value of co-efficient the following
mathematical calculations needed to be performed. The flow chart of the calculation is
given below:

START

Input Matrix X= A, O,
S, T, F, P, R, W.
Find Transpose of X, Y = XT

Find (XT)*(X) = A

Find inverse of A, C = A-1

Input Matrix T, T represents tool wear

Find out Y*T = D

Find C*D =B
 Print B

END

These equations are solved by using Least Square Method in Matlab

software and the coefficients are found to be:
B0=-0.0233,
B1= -0.0001, B11= 0.0000, B12= 0.0001,
B2 =-0.0449, B22= 0.0133, B13=0.0001,
B3=-0.0030, B33= 0.0530, B23= -0.0174

So the mathematical model determined by the regression analysis is as

follows:
T=-0.0233 - 0.0001v + 0.0449 f - 0.0030d+0.0000v2 + 0.0133 f2 +
0.0530 d2+ 0.0001 vf + 0.0001vd - 0.0174 fd
Chapter 4

Computer
Simulation
Computer Simulation
The nonlinear 2nd order regression equation for tool wear involving control parameters is
obtained through regression analysis. The equation is found to be

T = - 0.0233 - 0.0001 v + 0.0449 f - 0.0030 d + 0.0000 v2 + 0.0133

f2 + 0.0530 d2 + 0.0001 v f + 0.0001 v d - 0.0174 f d

A computer program has been written in JAVA language on the basis of the above
mentioned proposed model. The program consists of three parts each for analyzing the
variation of control factor with the output parameter. While varying one control parameter
with the output, other two factors were kept constant.
The following program shows the variation of T with v, f & d respectively.
import java.io.*;

public class San1 {

static float T, v, f, d;

public static void fnChangeD() throws IOException {

floatTmin;
BufferedReaderbr = new BufferedReader(new
InputStreamReader(System.in));
System.out.println("First, the values of v and f remain
constant");
System.out.println("Enter the value for d within the range 0.5
to 1.0");
d = Float.parseFloat(br.readLine());
if (d < 0.5 || d > 1.0) {
System.out
.println("Sorry! You entered a value for d
which is out of range!");
} else {
System.out
.println("Keeping v=590 and f=0.4 and
incrementing the value of d by 0.01, the corresponding values of T are:");
Tmin = (float) (0.0233 + (-0.0001 * 590) + (0.0449 * 0.4)
+ (-0.0030*d)
+ (0.0000 * 590 * 590) + (0.0133 * 0.4 * 0.4) +
(0.0530 * d * d)
+ (0.0001 * 590 * 0.4) + (0.0001 * 590 * d) +
(-0.0174 * 0.4 * d));
for (; d <= 1; d = (float) (d + 0.01)) {
T = (float) (0.0233 + (-0.0001 * 590) + (0.0449 *
0.4) + (-0.0030*d)
+ (0.0000 * 590 * 590) + (0.0133 * 0.4 * 0.4) +
(0.0530 * d * d)
+ (0.0001 * 590 * 0.4) + (0.0001 * 590 * d) +
(-0.0174 * 0.4 * d));
fnTmin(T, Tmin);

System.out.print("d=" + d + " T=" + T);

System.out.println();

}
 System.out.println("The least value of T is " + Tmin);
}

public static void fnChangeF() throws IOException {

floatTmin;
BufferedReaderbr = new BufferedReader(new
InputStreamReader(System.in));
System.out.println("Next, the values of v and d remain
constant");
System.out
.println("Enter the value for f within the range
0.15 to 0.64");
f = Float.parseFloat(br.readLine());
if (f < 0.15 || f > 0.64) {
System.out
.println("Sorry! You entered a value for f
which is out of range!");
} else {
System.out
.println("Keeping v=590 and d=0.8 and
incrementing the value of f by 0.01, the corresponding values of T are:");
Tmin = (float) (0.0233 + (-0.0001 * 590) + (0.0449 * f) +
(-0.0030*0.8)
+ (0.0000 * 590 * 590) + (0.0133 * f * f) +
(0.0530 * 0.8 * 0.8)
+ (0.0001 * 590 * f) + (0.0001 * 590 * d) + (-
0.0174 * f * 0.8));
for (; f <= 0.64; f = (float) (f + 0.01)) {
T = (float) (0.0233 + (-0.0001 * 590) + (0.0449 * f)
+ (-0.0030*0.8)
+ (0.0000 * 590 * 590) + (0.0133 * f * f) +
(0.0530 * 0.8 * 0.8)
+ (0.0001 * 590 * f) + (0.0001 * 590 * d) + (-
0.0174 * f * 0.8));
fnTmin(T, Tmin);

System.out.print("f=" + f + " T=" + T);

System.out.println();

}
System.out.println("The least value of T is " + Tmin);
}

public static void fnChangeV() throws IOException {

floatTmin;
BufferedReaderbr = new BufferedReader(new
InputStreamReader(System.in));
System.out.println("Last, the values of f and d remain
constant");
System.out.println("Enter the value for v within the range 250
to 930");
v = Float.parseFloat(br.readLine());
if (v < 250 || v > 930) {
System.out
 .println("Sorry! You entered a value for v
which is out of range!");
} else {
System.out
.println("Keeping f=0.4 and d=0.4 and
incrementing the value of vf by 10, the corresponding values of T are:");
Tmin = (float) (0.0233 + (-0.0001 * v) + (0.0449 * 0.4) +
(-0.0030*0.8)
+ (0.0000 * v * v) + (0.0133 * 0.4 * 0.4) +
(0.0530 * 0.8 * 0.8)
+ (0.0001 * v * 0.4) + (0.0001 * v * 0.8) + (-
0.0174 * 0.4 * 0.8));
for (; v <= 930; v = (float) (v + 10)) {
T = (float) (0.0233 + (-0.0001 * v) + (0.0449 * 0.4)
+ (-0.0030*0.8)
+ (0.0000 * v * v) + (0.0133 * 0.4 * 0.4) +
(0.0530 * 0.8 * 0.8)
+ (0.0001 * v * 0.4) + (0.0001 * v * 0.8) + (-
0.0174 * 0.4 * 0.8));
fnTmin(T, Tmin);

System.out.print("v=" + v + " T=" + T);

System.out.println();

}
System.out.println("The least value of T is " + Tmin);
}

public static void fnTmin(float a, float b) {

if (a < b)
b = a;

public static void main(String[] args) throws IOException {

fnChangeD();
fnChangeF();
fnChangeV();
}

}
 Chapter 5

Results and
Discussion
5.1 Introduction
The regression equation developed and simulated in computer to find out the
effect of each control parameters on tool wear of the specimen undergoing turning
operation within the considered ranges. This is done by using a computer
programming which gives the responses for each input and this is done by varying
one parameter at a time within its considered range and keeping other parameters
constant at their mid-level values.

5.2 Effect of Parameters on Tool Wear

Each of the control parameters and their effects on tool wear are discussed below:

5.2.1 Effect of Spindle Speed on Tool Wear

Figure 5.2.1 shows the variation of tool wear with the change of Spindle speed.
Spindle Speed is made to vary from 250 RPM to 930 RPM and Feed Rate & Depth
of Cut are kept constant at mid values within their ranges, which are 0.4 mm/rev &
0.8 mm respectively. Figure 5.2.1 shows that the tool wear increases with increase
of Spindle Speed. It has been found from the graph that tool wear is minimum at
Spindle Speed of 250 RPM.

Variation of Tool Wear (mm) with Spindle Speed (rpm)

0.0875

0.0850
Tool Wear (mm)

0.0825

0.0800

0.0775

0.0750

200 300 400 500 600 700 800 900 1000

Spindle Speed (rpm)

Last, the values of f and d remain constant

Enter the value for v within the range 250 to 930
Keeping f=0.4 and d=0.4 and incrementing the value of v by 10, the corresponding values of T are:
v=250.0 T=0.07434 v=330.0 T=0.07594 v=410.0 T=0.07754
v=260.0 T=0.07454 v=340.0 T=0.07614 v=420.0 T=0.07774
v=270.0 T=0.07474 v=350.0 T=0.07634 v=430.0 T=0.07794
v=280.0 T=0.07494 v=360.0 T=0.07654 v=440.0 T=0.07814
v=290.0 T=0.07514 v=370.0 T=0.07674 v=450.0 T=0.07834
v=300.0 T=0.07534 v=380.0 T=0.07694 v=460.0 T=0.07854
v=310.0 T=0.07554 v=390.0 T=0.07714 v=470.0 T=0.07874
v=320.0 T=0.07574 v=400.0 T=0.07734 v=480.0 T=0.07894
 v=490.0 T=0.07914 v=640.0 T=0.08214 v=790.0 T=0.08514
v=500.0 T=0.07934 v=650.0 T=0.08234 v=800.0 T=0.08534
v=510.0 T=0.07954 v=660.0 T=0.08254 v=810.0 T=0.08554
v=520.0 T=0.07974 v=670.0 T=0.08274 v=820.0 T=0.08574
v=530.0 T=0.07994 v=680.0 T=0.08294 v=830.0 T=0.08594
v=540.0 T=0.08014 v=690.0 T=0.08314 v=840.0 T=0.08614
v=550.0 T=0.08034 v=700.0 T=0.08334 v=850.0 T=0.08634
v=560.0 T=0.08054 v=710.0 T=0.08354 v=860.0 T=0.08654
v=570.0 T=0.08074 v=720.0 T=0.08374 v=870.0 T=0.08674
v=580.0 T=0.08094 v=730.0 T=0.08394 v=880.0 T=0.08694
v=590.0 T=0.08114 v=740.0 T=0.08414 v=890.0 T=0.08714
v=600.0 T=0.08134 v=750.0 T=0.08434 v=900.0 T=0.08734
v=610.0 T=0.08154 v=760.0 T=0.08454 v=910.0 T=0.08754
v=620.0 T=0.08174 v=770.0 T=0.08474 v=920.0 T=0.08774
v=630.0 T=0.08194 v=780.0 T=0.08494 v=930.0 T=0.08794
The least value of T is 0.07434
5.2.2 Effect of feed rate on tool wear
Figure 5.2.2 shows the variation of tool wear with the change of Feed Rate. Feed Rate is
made to vary from 0.16 mm/rev to 0.64 mm/rev and Spindle Speed & Depth of Cut are
kept constant at mid values within their ranges, which are 590 RPM & 0.8 mm
respectively. Figure 5.2.2 shows that tool wear increases with increase of Feed Rate. It
is has been found from the graph that tool wear is minimum at Feed Rate of 0.16
mm/rev.

Variation of Tool Wear (mm) with Feed Rate (mm/rev)

0.12

0.11
Tool Wear (mm)

0.10

0.09

0.08

0.07

0.1 0.2 0.3 0.4 0.5 0.6

Feed Rate (mm/rev)

Next, the values of v and d remain constant

Enter the value for f within the range 0.15 to 0.64
Keeping v=590 and d=0.8 and incrementing the value of f by 0.01, the corresponding values of T are:
f=0.16 T=0.07014726 f=0.17 T=0.07109095 f=0.18 T=0.0720373
f=0.19000001 T=0.07298631 f=0.33999994 T=0.08754066 f=0.4899998 T=0.10269349
f=0.20000002 T=0.07393798 f=0.34999993 f=0.4999998 T=0.10372496
f=0.21000002 T=0.07489231 T=0.088532224 f=0.5099998 T=0.10475909
f=0.22000003 T=0.0758493 f=0.35999992 T=0.08952645 f=0.5199998 T=0.105795875
f=0.23000003 T=0.07680895 f=0.36999992 T=0.09052334 f=0.5299998 T=0.10683533
f=0.24000004 T=0.07777126 f=0.3799999 T=0.09152289 f=0.5399998 T=0.10787743
f=0.25000003 T=0.07873623 f=0.3899999 T=0.092525095 f=0.5499998 T=0.108922206
f=0.26000002 T=0.07970386 f=0.3999999 T=0.09352997 f=0.55999976 T=0.10996963
f=0.27 T=0.08067415 f=0.40999988 T=0.0945375 f=0.56999975 T=0.11101972
f=0.28 T=0.0816471 f=0.41999987 T=0.09554768 f=0.57999974 T=0.11207247
f=0.29 T=0.08262271 f=0.42999986 T=0.09656053 f=0.58999974 T=0.11312788
f=0.29999998 f=0.43999985 f=0.5999997 T=0.11418595
T=0.083600976 T=0.097576044
f=0.6099997 T=0.115246676
f=0.30999997 f=0.44999984 T=0.09859421
f=0.6199997 T=0.11631007
T=0.084581904 f=0.45999983 T=0.09961504
f=0.6299997 T=0.11737612
f=0.31999996 T=0.08556549 f=0.46999982 T=0.10063853
f=0.6399997 T=0.11844482
f=0.32999995 T=0.08655174 f=0.4799998 T=0.10166468
The least value of T is 0.07014726

5.2.3 Effect of depth of cut on tool wear

Figure 5.2.3 shows the variation of tool wear with the change of Depth of Cut. Depth of
Cut is made to vary from 0.6 mm to 1.0 mm and Spindle Speed & Feed Rate is kept
constant at mid values within their ranges, which are 590 RPM & 0.40 mm/rev
respectively. Figure 5.2.3 shows that tool wear increases with increase of Depth of Cut. It
is has been found from the graph that tool wear is minimum at Depth of Cut of 0.6 mm.

Variation of Tool Wear (mm) with Depth of Cut (mm)

0.11

0.10
Tool Wear (mm)

0.09

0.08

0.07

0.06

0.05
0.6 0.7 0.8 0.9 1.0
Depth of Cut (mm)

First, the values of v and f remain constant

Enter the value for d within the range 0.5 to 1.0
Keeping v=590 and f=0.4 and incrementing the value of d by 0.01, the corresponding values of T are:
d=0.6 T=0.056492005 d=0.98999965
d=0.61 T=0.057623703 T=0.108482845
d=0.62 T=0.058766 d=0.99999964 T=0.11002795
d=0.63 T=0.0599189
d=0.64 T=0.061082397
d=0.65 T=0.062256496
d=0.65999997 T=0.063441195
d=0.66999996 T=0.06463649
d=0.67999995 T=0.06584239
d=0.68999994 T=0.06705889
d=0.6999999 T=0.068285994
d=0.7099999 T=0.06952369
d=0.7199999 T=0.07077199
d=0.7299999 T=0.07203089
d=0.7399999 T=0.073300384
d=0.7499999 T=0.07458048
d=0.7599999 T=0.075871184
d=0.76999986 T=0.07717248
d=0.77999985 T=0.07848438
d=0.78999984 T=0.07980688
d=0.79999983
T=0.081139974
d=0.8099998 T=0.08248368
d=0.8199998 T=0.08383797
d=0.8299998 T=0.08520287
d=0.8399998 T=0.08657837
d=0.8499998 T=0.08796447
d=0.8599998 T=0.08936117
d=0.86999977
T=0.090768464
d=0.87999976 T=0.09218637
d=0.88999975 T=0.09361486
d=0.89999974 T=0.09505396
d=0.9099997 T=0.09650366
d=0.9199997 T=0.09796396
d=0.9299997 T=0.09943486
d=0.9399997 T=0.100916356
d=0.9499997 T=0.102408454
d=0.9599997 T=0.103911154
d=0.9699997 T=0.10542445
d=0.97999966
T=0.106948346
The least value of T is 0.056492005
5.3 Optimization
Analysis of the variation of Tool Wear against individual control parameters
shows that Tool Wear of the specimen will be best at three distinct values of the
control parameters. Hence combination of these control parameters for Tool
Wear within considered range is
Spindle Speed = 250 RPM
Feed Rat = 0.16 mm/rev
Depth of Cut = 0.6 mm

5.4 S/N ratio calculation

Taguchi uses the loss function to measure the performance characteristic
deviating from the desired value. The value of loss function is then further
transformed to S/N ratio. Usually, there are three categories of the performance
characteristic in the analysis of the S/N ratio, that is, the lower-the-better, the
higher-the-better, and the nominal-the-better. The S/N ratio for each level of
process parameters is computed based on the S/N analysis and the smaller S/N
ratio corresponds to the better performance characteristic for minimum tool wear
calculation. Therefore, the optimal level of the process parameter is the level with
the lowest S/N ratio. S/N ratio calculation is done to find influence of the control
parameters.

For Calculating S/N Ratio for Smaller-the-Better for Tool Wear, the Equation is
[ Yi] = - 10 log 10[ ( Xi2 )/ n ] Where Yi = S/N Ratio for Respective Result
Xi = Total Tool Wear for each experiment I = 1 to
27
n = no. of results for each experiment for
experiment no i

For experiment no.1

Y1= - 10 log 10[ X12 / n ] = - 10 log 10 [ 0.032/ 1 ] = 30.4576

For experiment no.2

Y2 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.062/ 1 ] = 24.4370

For experiment no.3

Y3 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.082/ 1 ] = -21.9382

For experiment no.4

Y4 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.052/ 1 ] = 26.0206

For experiment no.5

Y5 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.072/ 1 ] = 23.0980

For experiment no.6

Y6 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.092/ 1 ] = 20.9151

For experiment no.7

Y7 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.072/ 1 ] = 23.0980

For experiment no.8

Y8 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.082/ 1 ] = 21.9382

For experiment no.9

Y9 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.102/ 1 ] = 20.00

For experiment no.10

Y10 = - 10 log 10[ X12 / n ] = - 10 log 10 [ 0.042/ 1 ] = 27.9588

For experiment no.11

Y11 = - 10 log 10[ X12 / n ] = - 10 log 10 [ 0.062/ 1 ] = 24.4370

For experiment no.12

Y12 = - 10 log 10[ X12 / n ] = - 10 log 10 [ 0.082/ 1 ] = 21.9382

For experiment no.13

Y13 = - 10 log 10[ X12 / n ] = - 10 log 10 [ 0.062/ 1 ] = 24.4370

For experiment no.14

Y14 = - 10 log 10[ X12 / n ] = - 10 log 10 [ 0.082/ 1 ] = 21.9382

For experiment no.15

Y15 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.102/ 1 ] = 20.00

For experiment no.16

Y16 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.082/ 1 ] = 21.9382

For experiment no.17

Y17 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.092/ 1 ] = 20.9151

For experiment no.18

Y18 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.112/ 1 ] = 19.1721

For experiment no.19

Y19 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.052/ 1 ] = 26.0206
For experiment no.20
Y20 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.082/ 1 ] = 21.9382

For experiment no.21

Y21 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.102/ 1 ] = 20.00

For experiment no.22

Y22 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.072/ 1 ] = 23.0980

For experiment no.23

Y23 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.092/ 1 ] = 20.9151

For experiment no.24

Y24 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.122/ 1 ] = 18.4164

For experiment no.25

Y25 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.092/ 1 ] = 20.9151

For experiment no.26

Y26 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.112/ 1 ] = 19.1721

For experiment no.27

Y27 = - 10 log 10 [ X12 / n ] = - 10 log 10 [ 0.162/ 1 ] = 15.9176
 Table 5: S/N Ratio for Smaller the Better
Exp Spindle Feed Depth of Response (T S/N Ratio
. Speed (v) Rate ( f ) Cut (d) = Tool for Smaller
No. RPM mm/rev mm Wear) mm is Better
1. 250 0.16 0.6 0.03 30.4576
2. 250 0.16 0.8 0.06 24.4370
3. 250 0.16 1.0 0.08 21.9382
4. 250 0.40 0.6 0.05 26.0206
5. 250 0.40 0.8 0.07 23.0980
6. 250 0.40 1.0 0.09 20.9151
7. 250 0.64 0.6 0.07 23.0980
8. 250 0.64 0.8 0.08 21.9382
9. 250 0.64 1.0 0.10 20.00
10. 590 0.16 0.6 0.04 27.9588
11. 590 0.16 0.8 0.06 24.4370
12. 590 0.16 1.0 0.08 21.9382
13. 590 0.40 0.6 0. 06 24.4370
14. 590 0.40 0.8 0.08 21.9382
15. 590 0.40 1.0 0.10 20.00
16. 590 0.64 0.6 0.08 21.9382
17. 590 0.64 0.8 0.09 20.9151
18. 590 0.64 1.0 0.11 19.1721
19. 930 0.16 0.6 0.05 26.0206
20. 930 0.16 0.8 0.08 21.9382
21. 930 0.16 1.0 0.10 20.00
22. 930 0.40 0.6 0.07 23.0980
23. 930 0.40 0.8 0.09 20.9151
24. 930 0.40 1.0 0.12 18.4164
25. 930 0.64 0.6 0.09 20.9151
26. 930 0.64 0.8 0.11 19.1721
27. 930 0.64 1.0 0.16 15.9176

5.5 Overall mean of S/N ratio

The Calculation of overall mean is done by the following process:

K11 = Mean of low level values of spindle speed

K11= ( Y1+ Y2 + Y3 + Y4 + Y5 + Y6 + Y7 + Y8 + Y9) / 9 = (30.4576 + 24.4370 + 21.9382
+ 26.0206 + 23.0980 + 20.9151 + 23.0980 + 21.9382 + 20.00)/9 = 23.5447

K21 = Mean of medium level values of spindle speed

K21 = ( Y10+ Y11 + Y12 + Y13 + Y14 + Y15 + Y16 + Y17 + Y18 ) / 9 = (27.9588 + 24.4370 +
21.9382 + 24.4370 + 21.9382 + 20.00 + 21.9382 + 20.9151 + 19.1721)/9 =
22.5261

K31 = Mean of high level values of spindle speed

K31= ( Y19+ Y20 + Y21 + Y22 + Y23 + Y24 + Y25 + Y26 + Y27 ) / 9 = (26.0206 + 21.9382 +
20.00 + 23.0980 + 20.9151 + 18.4163 + 20.9151 + 19.1721 + 15.9176)/9 =
20.7159

K12 = Mean of low level values of feed rate

K12 = ( Y1+ Y2 + Y3 + Y10 + Y11 + Y12 + Y19 + Y20 + Y21) / 9 = (30.4576 + 24.4370 +
21.9382 + 27.9588 + 24.4370 + 21.9382 + 26.0206 + 21.9382 + 20.00 )/9 =
24.3473

K22 = Mean of medium level values of feed rate

K22= ( Y4+ Y5 + Y6 + Y13 + Y14 + Y15 + Y22 + Y23 + Y24) / 9 = (26.0206 + 23.0980 +
20.9151 + 24.4370 + 21.9382 + 20.00 +23.0980 + 20.9151 + 18.4163 )/9 =
22.0987

K32 = Mean of high level values of feed rate

K32= ( Y7+ Y8 + Y9 + Y16 + Y17 + Y18 + Y25 + Y26 + Y27 ) / 9 = (23.0980 + 21.9382 +
20.00 + 21.9382 + 20.9151 + 19.1721 + + 20.9151 + 19.1721 + 15.9176 )/9 =
20.3407

K13 = Mean of low level values of depth of cut

K13= ( Y1+ Y4 + Y7 + Y10 + Y13 + Y16 + Y19 + Y22 + Y25) / 9 = (30.4576 + 26.0206 +
23.0980 + 27.9588 + 24.4370 + 21.9382 + 26.0206 + 23.0980 + 20.9151)/9 =
24.8827

K23 = Mean of medium level values of depth of cut

K23 = ( Y2+ Y5 + Y8 + Y11 + Y14 + Y17 + Y20 + Y23 + Y26 ) / 9 = (24.4370 + 23.0980 +
21.9382 + 24.4370 + 21.9382 + 20.9151 + 21.9382 + 20.9151 + 19.1721) / 9 =
22.0877

K33 = Mean of high level values of depth of cut

 K33 = ( Y3+ Y6 + Y9 + Y12 + Y15 + Y18 + Y21 + Y24 + Y27) / 9 = (21.9382 + 20.9151 +
20.00 + 21.9382 + 20.00 + 19.1721 + 20.00 + 18.4164 + 15.9176) / 9 = 19.8108

Table 6: Overall Mean of S/N Ratio

Average SN Ratio by Factor Level Overall
Level Spindle Feed Depth of Mean of S/N
Speed (v) Rate (f) cut (d) Ratio (Y0)
Low 23.5447 24.3473 24.8827
Medium 22.5261 22.0987 22.0877
High 20.7159 20.3407 19.8108
22.2622
Delta =
2.8288 4.0066 5.0719
Larger - Smaller
Rank 3 2 1

The values obtained in the above table 6 are represented graphically in figure
5.2.1, figure 5.2.2 and figure 5.2.3

Variation of Mean of S/N Ratio with Spindle Speed (rpm)

23.5

23.0
Mean of S/N Ratio

22.5

22.0

21.5

21.0

200 300 400 500 600 700 800 900 1000

Spindle Speed (rpm)
 Figure 5.2.1: variation of mean of S/N ratio with spindle speed

Variation of Mean of S/N Ratio with Depth Of Cut (mm)

25

24
Mean of S/N Ratio

23

22

21

20

0.6 0.7 0.8 0.9 1.0

Depth Of Cut (mm)

Fig5.2.2: variation of mean of S/N ratio with depth of cut

Variation of Mean of S/N Ratio with Feed Rate (mm/rev)

24
Mean of S/N Ratio

23

22

21

20
0.1 0.2 0.3 0.4 0.5 0.6 0.7
Feed Rate (mm/rev)

Fig 5.2.3: variation of mean of S/N ratio with feed rate

From the calculations and the graphs it is found Depth of cut is the most
influencing parameter followed by feed rate and Spindle Speed.
5.6 ANOVA Calculation

The test results analyzed using Computer Simulation and S/N Ratio were again analyzed
by using ANOVA (Analysis of Variance) for identifying the significant factors and their
relative contribution on the outcome or results. By using S/N Ratio and Computer
simulation it is not possible to judge and determine the effect of individual parameter
where by using ANOVA percentage contribution of individual parameters can be
determined. The analysis was carried out with a confidence level of 95% (α=0.05) which
means we are 95% sure that our prediction is right or in the other hand there is a chance
of type-1 error is only 5% which means rejecting null hypothesis while it is true. Our null
hypothesis is that the control parameters are not significant. Therefore alternative
hypothesis is that they are influencing the outcome.

The decision rule for accepting the null hypothesis or rejecting is that – at a α level
of confidence, rejectH0 if P (Fk−1,n−k> F computed)¿ α . Do not reject if H0 if P ¿ α

Statistically the two hypotheses can be written as-

H0=null hypothesis= control factors are not significant=0
HA=alternative hypothesis =control factors are significant≠ 0

The sum of squares computing technique was discussed earlier. To calculate

mean squares ratio we need to know the degrees of freedom of various
parameters. The rule is that-
D.O.F.(degree of freedom) of total sum of squares= total number of experiment –
one(n-1).
D.O.F. associated with each factors = number of levels – one (k-1)
D.O.F for the error will be the difference between the degree of freedom of total
sum of squares and the summation of degree of freedom of the factors. Where k=
number of levels, n= number of test runs. Now the F ratio can be calculated as-

Mean square of factor

F factor =
mean square of the error

Another term appeared in the ANOVA table is percentage contribution of each

factor. The formula for percentage contribution= (

∑ of square of factor )×100
total ∑ of squres

Effect of each parameter can be determined by subtraction of each value of

table no.6 to the overall average of S/N ratio (22.2622).After subtraction, the
effect of each parameter obtained as follows:
 Table 6: Effect of each parameter
Spindle Speed Feed Rate Depth of Cut
(r.p.m) (mm/rev) (mm)
Low 1.2825 2.0851 2.6205

Medium 0.2639 -0.1635 -0.1745

High -1.5463 -1.9215 -2.4514

SS= Sum of square of each parameter = Σ (Kij - YO) 2 *n

Kij =Average S/N ratio values from table 5 for each parameter (low, medium
and high level)

YO = Overall mean of S/N

ration= 9

SSspindle speed=[(1.28252)*9 +(0.26392)*9 +(-1.54632)*9]=36.8367

SSfeed rate=[(2.08512)*9 +(-0.16352)*9 +(-1.92152)*9] = 72.5988

SSdepth of cut=[(2.62052)*9 +(-0.17452)*9 +(-2.45142)*9]= 116.1615

Total sum of square(TSS)=[ ( Yi ) 2 ] – [ ( Σ Yi ) 2 / 27]

Yi=S/N ratio values for each experiment

Where i= varies from 1…… 27
= (30.45762 + 24.43702 + 21.93822 + 26.02062 + 23.09802 + 20.91512 +
23.09802 + 21.93822 + 20.002 + 27.95882 + 24.43702 + 21.93822 + 24.43702 +
21.93822 + 20.002 + 21.93822 + 20.91512 + 19.17212 + 26.02062 + 21.93822 +
20.002 + 23.09802 + 20.91512 + 18.41642 + 20.91512 + 19.17212 +15.91762) -
(30.4576 + 24.4370 + 21.9382 + 26.0206 + 23.0980 + 20.9151 + 23.0980 +
21.9382 + 20.00 + 27.9588 + 24.4370 + 21.9382 + 24.4370 + 21.9382 + 20.00
+ 21.9382 + 20.9151 + 19.1721 + 26.0206 + 21.9382 + 20.00 + 23.0980 +
20.9151 + 18.4164 + 20.9151 + 19.1721 +15.9176)2/27 = 13620.6854 -
(601.03042/ 27) = 13620.6854 – (361237.5417/27) = 13620.6854 – 13379.1682
= 241.5172
Sum of squared error(SSE) = TSS – Σ (SSspindle speed + SSfeed rate +
SSdepth of cut) = 241.5172 – (36.8367 + 72.5988 + 116.1615) =
241.5172 – 225.597 = 15.9202
DOFtotal = total no. of experiment – 1 = 27-1 = 26
DOFspidle speed = no. of level -1 = 3-1 =2
DOFfeed rate = no. of level -1 = 3-1 =2
DOFdepth of cut = no. of level -1 =3-1 =2
DOFerror =DOFtotal –( Σ DOFdepth of cut + DOFfeed rate + DOFspindle speed )= 26- (2+2+2)
= 20

Mean square error (MSE)=SSeach factor / DOFeach factor

F value =MSEeach factor / SSE

The analysis was carried out in MINITAB software. The following table shows
ANOVA table-
Table 5.6.1 ANOVA Results
Contributio
Factors DOF Seq. SS Adj. SS Adj. MS F Value P
n
Spindle
Speed 2 0.0033852 0.0033852 0.0016926 30.88 0.000 18.06 %
(rpm)
Feed
Rate 2 0.0053407 0.0053407 0.0026704 48.72 0.000 28.50 %
(mm/rev)
Depth of
2 0.0089185 0.0089185 0.0044593 81.35 0.000 47.59 %
Cut (mm)

Error 20 0.0010963 0.0010963 0.0000548 5.85%

Total 26 0.0187407

S = 0.00740370 R-sq = 94.15% R-sq (Adj.) = 92.40%

From the above table it can be seen that the percentage contribution of the factor d
i.e. depth of cut as high as 47.59%. The next contributing factor is Feed Rate with
percentage of contribution 28.50%. Spindle Speedhas a relatively low contribution.
From the values of F ratios it can be concluded that Depth of Cut is (p=0.000) is
more significant factor than the Feed Rate (p=0.000) and Spindle Speed (p=0.000),
which again validate the findings of Taguchi S/N ratio conclusions. As the p value of
the factor all three factor (p=0.000) is less than the α (0.05) value so it can be said
that all the three factors are statistically significant.Another term appeared in the
ANOVA table is R-Sq& R-Sq (adj) where R-sq is a statistical measure of how close
the data are to the fitted regression line. This is also known as co-efficient of
determination or the co-efficient of determination for multiple regressions. R-sq. is
always between 0% to 100%. 0% indicates that the model explains none of the
variability of the response data around its mean and 100% indicates that the model
explains all the variability of the response data around its mean. In general higher
the R-sq. better the model fits your data. R-Sq(adj) is the modified version of R-sq.
that has been adjusted in for the number of predictors in the model. The adjusted R-
sq increases only if the new term improves the model more than would be expected
by chance. It decreases when a predictor improves the model by less than expected
by chance. The R-squared can be negative, but usually not. It is always lower than
the R-squared.
Conclusion
From the present study it can be concluded that Tool Wear of a High Speed Steel
cutting tool undergoing turning operation of a Mild Steel Specimen can be optimized
with proper combination of control parameters within their working ranges. Also an
insight into the influence of individual control parameters along with their percentage
contribution will help in selecting the optimum combination.
 From the Taguchi S/N Ratio calculation and graph analysis the optimum set of
combination for tool wear is Spindle Speed (v) = 250 RPM, Feed Rate (f) = 0.16
mm/rev & Depth of Cut (d) = 0.6 mm. This optimality has been proposed within
the experimental working range of v (250 rpm to 930 rpm), f (0.16 mm/rev to
0.64 mm/rev) & d (0.60 mm to 1.0 mm).
 From the computer simulation of the regression equation and respective graph
also it has been proposed that the optimum set of combination for tool wear is
Spindle Speed (v) 250 RPM, Feed Rate (f) 0.16 mm/rev & Depth of Cut (d) 0.6
mm. this optimality has been proposed within the experimental working range of
v (250 rpm to 930 rpm), f (0.16 mm/rev to 0.64 mm/rev) & d (0.60 mm to 1.0
mm).
 It has also been found by Taguchi S/N Ratio calculation that Depth of Cut (d) is
the most influencing parameter on Tool Wear followed by Feed Rate (f) and
Spindle Speed (v).
 ANOVA analysis also indicates that Depth of Cut is the most influencing Control
factor on Tool Wear with 47.59% contribution followed by Depth of Cut (d) with
28.50% contribution & Spindle Speed with 18.06% contribution.
 Results obtained from Taguchi S/N Ratio analysis and ANOVA analysis bear
the same trend.

Scope for further work

Here in this work while analyzing the experimental data for optimization of control
parameters the process is simplified by consideration of the most significant
parameters spindle speed, feed rate and depth of cut. There are other parameters
which also contribute to the Wear of Tool such as Rake Angle, Cutting Too Nose
Radius, Cutting Speed, use of Cutting Fluid and Tool Geometry.

The study can be extended by considering the effect of all this parameter onTool
Wear.

Furthermore other analytical methods such as Genetic Algorithm and Neural

Network can be employed for optimization of Tool Wear parameters.