Materials Today: Proceedings 47 (2021) 6285–6290

Contents lists available at ScienceDirect

Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

Optimization of cutting temperature in machining of titanium alloy

using Response Surface Method, Genetic Algorithm and Taguchi method
Bhagyashree Jayarjun Kadam ⇑, K.A. Mahajan
Mechanical Department, MES College of Engineering, Pune, India

a r t i c l e i n f o a b s t r a c t

Article history: Cutting temperature during machining plays a very important role in the overall performance of machin-
Available online 25 May 2021 ing processes. Since, it was a very difficult task to measure the tool temperature correctly, Finite Element
Modeling was used as a modeling tool to predict cutting temperature in the current investigation.
Keywords: Titanium alloys have been generally defined as difficult to cut materials due to their natural properties.
Titanium alloys The main drawback in machining titanium alloys is high cutting temperature due to high adhesion of tool
Cutting temperature work interface. This paper presents a finite-element modeling of cutting tool temperature during turning
Taguchi analysis
of Titanium alloy Ti-6Al-4 V under dry machining. The ANSYS software was used to determine the cutting
Research Surface Method (RSM)
Thermal modelling
temperature at tool nose. The Design of Experiments (DOE) was carried out in Minitab 2018 software. The
Genetic Algorithms (GA) process parameters considered for design of experiments are cutting speed, feed rate, and depth of cut
used for operation. Response Surface Method (RSM) and Taguchi analysis was used to analyse the
machining effect on tool material in this study. The purpose of performing an orthogonal array experi-
ment is to determine the optimum level for each of the process parameters and to establish the relative
significance of each parameter. An attempt has also been made to optimize the cutting temperature pre-
diction model using Genetic Algorithms (GA) to optimize the objective function. The outcomes acquired
through RSM are likewise similar to the outcomes of Genetic Algorithm. The results showed that cutting
speed of 120 m/min, feed rate of 0.10 mm/rev and depth of cut of 0.5 mm are desirable for getting optimal
conditions.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Technology Innovation
in Mechanical Engineering-2021.

1. Introduction
Titanium alloys are indexed as difficult-to-cut materials. These
materials having applications in biomedical, aerospace owing to
properties: light weight, more strength, have excellent fatigue
performance and provide high resistance to harsh condition [1].
The newer aircraft designs are increasingly making use of tita-
nium and titanium alloys. These types of alloy pose an utmost
challenge to engineers due to generation of the high temperatures
and stresses during machining. Because of lower thermal conduc-
tivity heat generated remains close to cutting interface that result
in lesser tool life and precise workpiece measurements [2]. Ti-
6Al-4 V which is among the most highly utilized alpha–beta
(a + b) titanium alloys for manufacturing compressor blades [3].
Tool temperature is a major concern considered when turning
this kind of difficult-to-cut metals because this affects the perfor-
mance. In machining processes, the temperature is known as one
of the most important keypoint in the cutting zone that affects
machinability [4].
Finite Element Modeling (FEM) proves to be powerful tool for
modeling. The analysing turning process is tough task, FEM yield
right solution to this complex problem [5]. On account of growth
in numerical method analysis, the potential of finite element
model is modified to anticipate cutting forces, temperatures and
chip morphology [6].
In this study, the focus was to find the predicted cutting tool
temperature using regression method and to form equation for
response. Then plotting graph to recognize the impact of process
parameters visually and also finding optimum parameters for turn-
ing of Titanium alloy using RSM, GA and a Taguchi S/N analysis.

⇑ Corresponding author.
E-mail address: bhagyashreekadam05@gmail.com (B. Jayarjun Kadam).

https://doi.org/10.1016/j.matpr.2021.05.252
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Technology Innovation in Mechanical Engineering-2021.
B. Jayarjun Kadam and K.A. Mahajan Materials Today: Proceedings 47 (2021) 6285–6290

2. Experimental work Total Heat ¼ Q ¼ Q S þ Q f ¼ ðF S  V S Þ þ ðF f  V f Þ ð1Þ

The force and velocity formed due to shear and friction can be
For the present work Ti-6Al-4 V (grade 5) is selected as material
given by Equation (2) below::
for workpiece. The grade 5 alloy is widely used among all the tita-
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
nium alloys. PVD TiAlN coated tungsten carbide insert is used in
F s ¼ ð ½ðF P cosi þ F R siniÞcosu  F Q sinu þ ðF P sini  F R cosiÞ Þ
2 2
turning. These types of inserts are utilized regularly in metal cut-
an
ting operation because of wear resistance, excessive hardness V s ¼ ðcoscos ðuan Þ
Þ  ðcos gs Þ  V
cosi

and chemical stability [7,8]. Insert having ISO specification TNMG
16 04 08 is used in turning operations. Under dry machining con-
dition, all the tests were carried out with combination of different
operating parameters like feed rate, cutting speed and depth of cut
(Table 1).
Table 2 shows turning experiments of 27 runs determined by
design of experiments and the response parameters are cutting
and feed forces measured by Neelesh Kumar Sahu et al [9]. The
same cutting and feed forces are used as an input for analytical
model in equation (1&2) to calculate total heat.
3. Finite element Machining simulation
In turning operations, during the material removal process heat
generation takes place in three regions named as Primary Defor-
mation Zone (PDZ), Secondary Deformation Zone (SDZ) and Ter-
tiary Deformation Zone (TDZ) (Table 3).
Total Heat Generation = Heat Generated in (PDZ + SDZ + TDZ)
The heat in the tertiary zone is negligible as compare to heat in
first and second zones that is similar to 99% of overall heat
generated. The heat generation in turning is calculated from Equa-
tion (1) [10]:
Table 1
Selected process parameters.
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ffi
F f ¼ ð ½ðF P cosi þ F R siniÞsinan þ F Q cosan  þ ðF P sini  F R cosiÞ Þ
2 2
u
V f ¼ ðcosðsin
uan ÞÞ  V
ð2Þ
The overall heat evaluated in Equation (1) is considered as load
to get cutting temperature on insert while performing steady state
thermal analysis in ANSYS Workbench software.
Temperature views and distribution of temperature on different
faces of the insert for some combination of process parameters in
dry machining are shown in Figs. 1, 2 and 3 given below:
4. Optimisation
4.1. Development of prediction model by response Surface method
(RSM).
With the simulation value a regression equation is obtained
using RSM. RSM is defined as gathering of mathematical and statis-
tical methods, used in modeling and analysis of problems, where
responses is impacted by various parameters and target is to opti-
mize responses [11]. Regression Analysis is performed using MINI-
TAB 18 software. RSM also specifies the correlation of the
controllable inputs and the evaluated response surfaces [12].
Model Equations from Regression Analysis,

Process Parameters Unit Level 1 Level 2 Level 3 Temperature (T) = 306—0.39 V  94f + 812 d + 46.35 V f2.58 V d4251f d
Cutting speed m/min 120 180 240
Feed rate mm/rev 0.1 0.15 0.2 The main effect plot and ANOVA helped to study effect of
Depth of cut mm 0.5 0.75 1 parameters on output. ANOVA tells the importance of input param-
eter impacting the output responses. When the F value is larger,

Table 2
Experimental results.

Experiment No. Speed (V) Feed (f) Depth of cut (d) (mm) Feed Force (FQ) (N) Cutting Force (FP) (N)
(m/min) (mm/rev)
1 180 0.15 1 234.6 256.3
2 180 0.1 0.75 101.9 146.1
3 120 0.2 1 296.5 336.4
4 180 0.2 0.75 214.6 375.7
5 120 0.1 1 148 139.4
6 240 0.1 0.75 117 156.3
7 120 0.2 0.5 196 365.1
8 180 0.2 1 323 379.8
9 180 0.1 1 169.4 145.7
10 180 0.15 0.75 156.2 264.3
11 180 0.1 0.5 90.2 182.3
12 120 0.2 0.75 215.4 328.2
13 240 0.15 0.5 135.8 333.3
14 180 0.15 0.5 132.4 306.1
15 120 0.15 0.75 155.7 234.6
16 240 0.2 0.5 157.6 438.1
17 120 0.15 1 229.2 245.7
18 240 0.15 1 270.3 299
19 240 0.2 0.75 210.8 445.8
20 120 0.15 0.5 137.7 272.6
21 180 0.2 0.5 189.6 415
22 120 0.1 0.75 91.2 166.8
23 120 0.1 0.5 101.4 165.2
24 240 0.2 1 332.7 456.1
25 240 0.1 0.5 87.8 186.3
26 240 0.15 0.75 156.4 287.1
27 240 0.1 1 183.6 169

6286
B. Jayarjun Kadam and K.A. Mahajan Materials Today: Proceedings 47 (2021) 6285–6290

Table 3
Orthogonal array and Simulation results.

Expt. No. Feed (f) DOC (d) Speed (V) Temperature (oC)
(mm/rev) (mm) (m/min)
1 0.1 0.5 120 255.04
2 0.1 0.75 120 248.16
3 0.1 1 120 234.55
4 0.15 0.5 120 454.13
5 0.15 0.75 120 341.5
6 0.15 1 120 360.4
7 0.2 0.5 120 559.53
8 0.2 0.75 120 455.49
9 0.2 1 120 470.09
10 0.1 0.5 180 424.59
11 0.1 0.75 180 298.26
12 0.1 1 180 455.49
13 0.15 0.5 180 760.46
14 0.15 0.75 180 566.08
15 0.15 1 180 543.37
16 0.2 0.5 180 1019.2
17 0.2 0.75 180 780.57
18 0.2 1 180 769.45
19 0.1 0.5 240 615.91
20 0.1 0.75 240 428.41
21 0.1 1 240 551.18
22 0.15 0.5 240 1083.1
23 0.15 0.75 240 854.91
24 0.15 1 240 831.99
25 0.2 0.5 240 1511.3
26 0.2 0.75 240 1341.6
27 0.2 1 240 1158.5

Fig. 1. Temperature distribution of tool at Cutting Speed = 120 m/min, Fig. 3. Temperature distribution of tool at Cutting Speed = 240 m/min,
Feed = 0.1 mm/rev, Depth of Cut = 1 mm. Feed = 0.2 mm/rev, Depth of Cut = 0.5 mm.

the change of turning parameter has a remarkable outcome on per-

formance. If P-value is less than 0.05, then parameters are consid-
ered as statistical significance on outputs [13]. There is a great
influence on the performance for a parameter with a high contribu-
tion. The percentage contributions of each cutting parameters and
it’s interactions on the cutting temperature are shown in Table 4.

4.2. Genetic algorithm (GA)

GA known as artificial intelligent system is established to

acquire the optimum value [15].
In this investigation, approach is used to produce mathematical
model from the simulated value for predicting the cutting temper-
ature (T) by Response surface method. The developed temperature
model is solved using GA to get optimal value. In this optimization
is solved by combining RSM temperature equation with GA. In
Fig. 2. Temperature distribution of tool at Cutting Speed = 240 m/min, turning titanium alloy, optimization problem is formulated as
Feed = 0.1 mm/rev, Depth of Cut = 1 mm. below:
6287
B. Jayarjun Kadam and K.A. Mahajan Materials Today: Proceedings 47 (2021) 6285–6290

Table 4
ANOVA Results for cutting temperature.

Source DF Seq SS Contribution Adj SS Adj MS F-Value P-Value

Model 6 2,919,004 97.41% 2,919,004 486,501 125.17 0.000
Linear 3 2,635,099 87.93% 2,635,099 878,366 225.98 0.000
V 1 1,387,784 46.31% 1,387,784 1,387,784 357.04 0.000
f 1 1,152,233 38.45% 1,152,233 1,152,233 296.44 0.000
d 1 95,083 3.17% 95,083 95,083 24.46 0.000
2-Way Interaction 3 283,905 9.47% 283,905 94,635 24.35 0.000
V*f 1 232,002 7.74% 232,002 232,002 59.69 0.000
V*d 1 18,017 0.60% 18,017 18,017 4.64 0.044
f*d 1 33,885 1.13% 33,885 33,885 8.72 0.008
Error 20 77,737 2.59% 77,737 3887
Total 26 2,996,741 100.00%

Fig. 4. Main Effects Plot for Temperature (T).

Fig. 6. Optimization Plot.

Table 5
Response table for S/N ratio of temperature.

Level Cutting speed (m/min) Feed (mm/rev) DOC (mm)

1 51.11 51.32 56.29
2 55.37 55.56 54.22
3 58.71 58.30 54.68
Delta 7.61 6.98 2.08
Rank 1 2 3

Main Effects Plot for SN ratios

Data Means
Cuttting Speed (m/min) Feed (min/rev) DOC (mm)
-51

-52
Fig. 5. Contour Plot of Temperature (T) vs Speed (V), Feed rate (f) and Depth of cut
-53
Mean of SN ratios

(d).
-54

-55
Find: V (Cutting speed, m/min), f (feed, mm/rev), d (Depth of
-56
cut, mm).
Minimum: T (V, f, d) -57

Subjects to constraints: 120  V  240. -58

0.1  f  0.2. -59

0.5  d  1. 120 180 240 0.10 0.15 0.20 0.50 0.75 1.00

Signal-to-noise: Smaller is better

4.3. Taguchi analysis Fig. 7. Main effects plot for S/N ratio of temperature.

Taguchi method is a statistical and improves the quality [16].

The main things considered are orthogonal array and the S/N ratio. eter having the highest value of signal to noise ratio. Smaller the
Total runs are notably reduced and experimental work is expedited better characteristic was selected to achieve minimum cutting
using Taguchi’s analysis [17,18]. The optimal setting is the param- temperature on tool insert.

6288
B. Jayarjun Kadam and K.A. Mahajan
Fig. 8. Typical GA Plots for cutting temperature (T).
Fig. 9. Predicted optimal values from genetic algorithm (GA).
Table 6
Predicted optimal parameters for the turning operations.
Cutting Speed
RSM 120
Taguchi Analysis 120
GA 120
5. Result and discussion
5.1. Optimization of Machining condition using response surface
method (RSM)
The influences of parameters on responses were studied using
ANOVA. For turning with this insert, cutting speed (46.31%) is
the most influential on cutting temperature followed by feed rate
(38.45%) and depth of cut (3.17%). It was found through main effect
plot (Fig. 4) that the resultant value of cutting temperature raises
with rise in value of cutting speed.
The cutting speed was the major factor whereas feed rate and
depth of cut were second and third listed factors affecting the cut-
ting temperature respectively. At larger value of cutting speed, cut-
ting temperature is abundant to ease the workpiece and narrows
shear strength of material [14].
From the response contour plots (Fig. 5), observation says cut-
ting speed increases cutting temperature also increases exceed-
ingly, and rise in feed and depth of cut will help to get more
temperature. Fig. 6 shows the combined desirability at the opti-
mum conditions.
5.2. Optimization of Machining condition using Taguchi analysis
Figures show graphically the reaction of three parameters on
temperature. The signal to noise ratio response table of cutting
Materials Today: Proceedings 47 (2021) 6285–6290
Feed DOC Temperature Value
Predicted Experimental
0.1 0.5 232.6166 255.04
0.1 0.75 206.535 248.16
0.1 0.5 232.994 255.04
temperature is evaluated (Table 5). Using MINITAB 18 software,
analysis was made followed by generation of response table and
main effect plot (Fig. 7). Based on this analysis, results obtained
are: factors at levels V = 120 m/min (Level 1), f = 0.1 mm/rev (Level
1) and d = 0.75 mm (Level 2), which results in minimum T.
5.3. Optimization of Machining condition using Genetic algorithm
GA is performed to optimize the measured cutting temperature
in turning of Titanium alloy. Fig. 8(a) shows the values of best and
mean for individual generation. The total number of generations,
population size and crossover effects to achieve the value of best
fitness. Fig. 8(b) show vertical lines that range from smaller to lar-
ger fitness value and mean value at each generation. The validation
of the optimization has been examined by confirmation experi-
ments. The optimal machining parameters and response obtained
from genetic algorithm is shown in Fig. 9 below.
5.4. Validation
Confirmation test is done to check model developed by RSM,
Taguchi analysis and GA. The optimal levels for turning Ti-6Al-
4 V to calculate minimum temperature is possible at cutting speed
of 120 m/min, depth of cut of 0.5 mm and feed rate of 0.1 mm/rev.
The outcomes of the validation test and it’s comparisons with
6289
B. Jayarjun Kadam and K.A. Mahajan
actual values for the cutting temperatures are listed in Table 6
below.
6. Conclusion and future scope
1. Finite element simulations proved to be very useful in predict-
ing temperature distribution on cutting tool in turning as mea-
surement of actual temperature is not possible.
2. From the ANOVA, the study concludes that cutting speed is sig-
nificant on the temperature distribution, also confirms that
mathematical model obtained for cutting temperature is well
fitted with the data.
3. The outcomes acquired through RSM are likewise similar to the
outcomes of Genetic Algorithm and it was found that it gives
closer values of parameters as compared to results obtained
with the Taguchi Analysis.
4. It is clear from the plot for overall desirability function that cut-
ting speed of 120 m/min, feed rate of 0.10 mm/rev and depth of
cut of 0.5 mm are desirable for getting optimal conditions.
5. The procedure can be used for the prediction of cutting temper-
ature at various points of cutting tool.
6. The parameters i.e. cutting speed, feed rate and the depth of cut
were considered for the experimentation, for calculating the
responses. The research study can be extended with increased
number of variables. The new variables may be spindle speed
and the tool nose radius.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
References
[1] Salman Pervaiz, Amir Rashid, Ibrahim Deiab, Cornel Mihai Nicolescu, ‘‘An
experimental investigation on effect of minimum quantity cooling lubrication
(MQCL) in machining titanium alloy (Ti6Al4V)”, in: Springer-Verlag London
2016.
[2] Salman Pervaiz, Saqib Anwar, Imran Qureshi, Naveed Ahmed, Recent Advances
in the machining of titanium alloys using minimum quantity lubrication
(MQL) based techniques, Korean Soc. Precision Eng. 2019.
[3] J. Paulo Davim, Aveiro, Portugal, ‘‘Machining of Titanium alloys”; Springer.
6290
Materials Today: Proceedings 47 (2021) 6285–6290
[4] Vikas Upadhyay, P.K. Jain, N.K. Mehta, Machining with minimum quantity
lubrication: a step towards green manufacturing, Int. J. Machining
Machinability Mater. 13(4) 2013 349.
[5] C. Ezilarasan, V.S.S. Kumar, A. Velayudham, Theoretical predictions and
experimental validations on machining the Nimonic C-263 super alloy,
Simul. Model. Pract. Theory 40 (2014) 192–207.
[6] J. Ning, S.Y. Liang, Predictive modeling of machining temperatures with force-
temperature correlation using cutting mechanics and constitutive relation,
Materials 12 (2019) 284.
[7] Che Haron, J.A. Ghani, G.A. Ibrahim, Surface integrity of AISI D2 when turned
using coated and uncoated carbide tools” in, International Journal of Precision
Technology 106-114 (2007).
[8] Narasimhulu Andriya, P Venkateswara Rao, Sudarsan Ghosh, Dry Machining of
Ti-6Al-4V using PVD Coated TiAlN Tools, Proceedings of the World Congress on
Engineering 2012 Vol III
[9] Neelesh Kumar Sahu, Atul B. Andhare, Sandip Andhale, Roja Raju Abraham,
Prediction of surface roughness in turning of Ti-6Al-4V using cutting
parameters, forces and tool vibration, IMMT (2017).
[10] V.C. Venkatesh, S. Izman. Precision Engineering. Tata McGraw-Hill Publishing
Company Limited: New Delhi, India, 2010; pp. 99–101.
[11] D.C. Montogomery, Design and Analysis of Experiments, 5th edition., John
Wiley & Sons Inc, 2001.
[12] S. Chauhan, Kali Dass, Optimization of machining parameters in turning of
titanium (Grade-5) alloy using response surface methodology, Mater. Manuf.
Processes 27 (5) (2012) 531–537.
[13] Kuldeep A. Mahajan, Raju Pawade, Effect of machining parameters and
vibration on polymethylmethacrylate curved surface in single-point
diamond turning, Journal of Micromanufacturing 4 (1) (2021) 74–83,
https://doi.org/10.1177/2516598420941728.
[14] A.S. More, W. Jiang, W.D. Brown, A.P. Malshe, Tool wear and machining
performance of cBN–TiN coated carbide inserts and PCBN compact inserts in
turning AISI 4340 hardened steel, J. Mater. Process. Technol. 180 (2006) 253–
262.
[15] K. Manoj, M. Husian, N. Upreti, D. Gupta, Genetic algorithm: review and
application, Int. J. Inform. Technol. Knowl. Manage. 2 2010.
[16] Ross P.J. Taguchi, ‘‘Techniques for quality Engineering”, USA: McGraw-Hill;
1996.
[17] G. Taguchi, Introduction to Quality Engineering, Asian Productivity,
Organization Tokyo, 1990.
[18] Kuldeep A. Mahajan, Raju Pawade, and R. Balasubramaniam, ‘‘Experimental
Study of Effect of Machining Parameters on PMMA in Diamond Turning” :
Advances in Manufacturing Processes. Lecture Notes in Mechanical
Engineering. Springer, Singapore. December 2020, https://doi.org/10.1007/
978-981-15-9117-4_2
Further Reading
[1] M.A. Sulaiman, M.S. Asiyah, R. Shahmi1, E. Mohamad, N.A. Mohamad, M.A. Md
Ali1, D. Yuniawan, T. Ito. Effect of cutting parameter on the tool life of the
uncoated carbide tool during turning using minimum quantity lubrication
(MQL). Special Issue AMET 2017.
[2] Alborz Shokrani, Ihsan Al-Samarrai, Stephen T. Newman, Hybrid cryogenic
MQL for improving tool life in machining of Ti-6Al-4V titanium alloy, J. Manuf.
Processes 43 (2019) 229–243.