International Review of Mechanical Engineering (I.RE.M.E.), Vol. 6, N.

6
ISSN 1970 - 8734 September 2012

Experimentation and Prediction of Vibration Amplitude

in End Milling with Reference to Radial Rake Angle

G. Mahesh1, S. Muthu2, S. R. Devadasan3

Abstract – Reducing the vibration during end milling operation improves the surface finish and
reduces tool wear. Experiments are conducted as per the Design of Experiments (DoE) of
Response Surface Methodology (RSM) to predict the spindle and work table vibration by varying
the tool geometry parameter i.e., radial rake angle and cutting conditions (Spindle speed, feed
rate, radial and axial depth of cut) in the end mill cutter. The experiment was conducted on
Aluminium Al 6063 by HSS end mill cutter. LabviewTM was used to develop a data acquisition
platform to acquire and analyze the vibrations occurring in the X and Y axes. Current vibration
was obtained with two unidirectional piezoelectric accelerometers. A second order mathematical
model, in terms of machining parameters, was developed for vibration amplitude prediction using
RSM. This model gives the factor effects of the individual process parameters. Values of Prob > F
less than 0.05 indicate model terms are significant. The Spindle Speed, Axial depth of cut and
Radial depth of cut were the most important parameters that causes the vibration of the end
milling process compared to the other factors such as Radial Rake angle and Feed Rate. Test
results show good agreement between the actual process output and the predicted Vibration
amplitude. Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved.

Keywords: Radial Rake Angle, Vibration Amplitude, RSM, Doe, Vertical Milling Machine

I. Introduction A lot of testing techniques are currently used to

The present scenario in industries is to increase their
rate of production in order to meet the increase in
demand. The major problems faced by manufacturers are
machine idle time. The problems lead to increase in the
idling time of production machines thereby causing
considerable decrease in the rate of production [1].
Mechanical vibrations are produced by the cyclic
variations in the machine components and due to
dynamic interactions between the cutting tool and the
work piece which results in reduced productivity, poor
surface finish and reduced tool life and deteriorated
quality [2].
Vibration analysis is a reliable technique to monitor
the operating conditions of a machine without
intervening the process [3]. In any machining operation,
the tool removes the chip from a surface. For some
combination of spindle speed and depth of cut, vibration
level can be high. These vibrations lead to poor surface
quality, increase cutting forces, accelerate tool wear and
increase tool breakage risk [4]. Feed rate, cutting speed
and tool geometry are controllable factors, whereas
factors such as tool wear, work piece and machine
vibrations, and material variability of the tool and the
work piece are uncontrollable [5].
Vibration in the cutting process is significantly
affected by the amount of feed rate [6]. Helix angle of an
end mill cutter is the significant parameter, which
reduces the vibration amplitude [7], [8].
measure vibrations [9], [10]. The sensors used are
accelerometers and dynamometers to calculate the
vibration [11]. These sensors measure acceleration, they
are adequate for traditional frequency analyses. The
accelerometer, which is used to measure surface
vibration, is also used to detect the tool condition.
Vibration signals between the tool and work piece are
measured by a PCB accelerometer mounted on the vice
of the Fadal machine on which the work piece was
placed [12]. Accelerometer and a proximity sensor
employed as in-process surface recognition sensors
during cutting to collect the vibration and rotation data
[13].
Vibration measuring using a micro electro mechanical
system accelerometer, and experimental tests were
carried out to characterize the device [14]. The
preliminary tests proved that the developed measurement
unit was capable of sensing, measuring, and condition
monitoring.
Experiment by using piezo transducer is used to check
the spindle vibration [15]. A pole/ zero cancellation
technique based on analytical model are used to measure
the forced vibration in an end milling process, and
verified the same for selecting the cutting conditions to
suppress the forced vibration [16]. Tool wear in the end
milling process using spindle shaft torsion vibration.
Their vibration measurement system includes a laser
Doppler velocimeter [17].

Manuscript received and revised August 2012, accepted September 2012 Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved

1164
 G. Mahesh, S. Muthu, S. R. Devadasan
Tool condition monitoring in end milling based on the
vibration signal collected through microcontroller-based
data acquisition [18]. Vibration analysis on the cutter
path orientations employed in rough and finish milling
via the use of fast Fourier transform (FFT) analysis [19].
II. Influence of Radial Rake Angle
in End Mill Cutter
Rake angle is the angle between the leading edge of a
cutting tool and perpendicular to the surface being cut.
Rake angles for milling cutters are specified in two
directions, axial and radial rake angle.
Axial rake is the cutting insert’s angle with respect to
the central axis of the cutter/spindle assembly. Radial
rake is the cutting insert’s angle with respect to the
periphery of the cutter.
Common configurations include (a) Positive in both
directions (b) Negative in both directions and (c) Positive
in one direction and negative in the other. The rake and
clearance angles are the most important among the
design factors and that an end mill with a positive rake
angle improves machining ability, thereby producing
lower cutting force and cutting temperature [20].
Experimental studies has been conducted to predict
the effects of rake and helix angles on the cutting forces
variations during milling of hard materials and integrated
it into a cutting relation. Rake angle becomes higher, the
cutting forces components become lower [21].
Experimental studies has been conducted to find the
effect of tool geometry (radial rake angle and nose
radius) and cutting conditions (cutting speed and feed
rate) on the machining performance during end milling of
medium carbon steel [22]. An attempt has been made to
predict the process parameters such as tool wear and
vibration by considering the significant parameters such
as tool diameter, number of flutes, rake and clearance
angle, and work piece material [23] and the larger
positive rake angle is desirable for burr reduction [24].
Among various parameters of tool geometry, radial
rake angle is one of the most important parameters,
which determines the tool and chip contact area and
hence affects the power consumption [25].
In this present work, the main objective is to develop a
mathematical model to predict the vibration amplitude in
terms of machining parameters such as radial rake angle
of cutting tool (E), spindle speed(A), feed rate(B),
axial(C) and radial depth of cut (D). During milling, the
vibration amplitude is measured by using two
piezoelectric accelerometers; one is placed near the
spindle and the other on work table in both cutting and
feed direction in work. Tool vibration is not taken into a
account because it requires high expensive non contact
type equipment.
To find best optimize cutting working conditions of
the process parameters the use of non-linear techniques
like Design of Experiments (DoEs) is best suitable under
such circumstances and DoE is the most effective and
economical technique to evaluate the main and
Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved
1165
interaction effects of input factors on an output response
[26], [27]. The DoE method was used in the present work
to explore the non-linear relationship between the
machining parameters and vibration. Design Expert 6.0
package is used to analyze the data and develop the
model.
III. Response Surface Methodology (RSM)
Response surface method (RSM) adopts the
combination of experimental, mathematical and
statistical techniques which are useful for the modeling
and analysis of problems in which a response of interest
is influenced by several variables [28]. RSM saves cost
and time by reducing the number experiments required
for investigation.
In this technique, the main objective is to optimize the
responses that are influencing by various parameters. In
modeling of the manufacturing processes using RSM, the
sufficient data is collected through designed
experimentation. A second order regression model is
developed. The study uses the following steps as per the
methodology of Central Composite Design (CCD) in the
optimization of experiments using RSM to understand
the effect of important parameters:
1. Identifying the important process parameter
2. Development of design matrix
3. Conducting the experiments as per the design matrix
4. Recording the responses
5. Development of the mathematical model
6. Checking the adequacy of the models developed
7. Conducting the conformity test runs and comparing
the results.
The design matrix selected for conducting the
experiment at five levels, five factor central composite
rotatable designs consists of 32 set of coded conditions
and comprising a half replication 24 =16 factorial design
plus 6 centre points and 10 star points.
The upper (+2) and lower (-2) levels of all the five
variables as shown in Table I had been established by
trial runs prior to the actual pre defined parameters to
establish the exact predicted values. The intermediate
levels of -1, 0, +1 of all the variables had been calculated
by interpolation.
Thus the 32 experimental runs allow the estimation of
the linear, quadratic and two way interactive effects of
the process parameters. Experiments are conducted at
random to avoid sickening errors indulging into the
experimental procedure.
IV. Development of the
Mathematical Model
The general form of a quadratic polynomial, which
gives the relation between response y and the process
variable x under investigation, is given by:
Y=f (A,B,C,D,E)
International Review of Mechanical Engineering, Vol. 6, N. 6
 G. Mahesh, S. Muthu, S. R. Devadasan

y'' = β0 x0 + β1 x1 + β 2x2 + β3 x3 + β11 x12 + β22 x22+ prepared from aluminum alloy (Al 6063) square block to
(1)
+β33 x32 + β11 x1 x2 + β12 x1 x3 + β14 x2x3 perform the experimental trials. The chemical
composition and mechanical properties of the base
where: material are presented in Table II and Table III,
y'' is the estimated response based on the second order respectively. The experiments are conducted on
equation, MAKINO CNC Vertical Machining Center (Model-S33)
β0 is the free term of the regression equation, the with high-speed steel end mill cutter under dry condition.
coefficients, LabviewTM is used to develop a data acquisition platform
x0, x1... are linear terms, to acquire and analyze the vibrations occurring in the X
x11, x22... are the quadratic terms, and Y axes.
x12, x13... are the interaction terms. The vibration amplitude is measured by using two
The Values of the coefficients of the polynomials are unidirectional piezoelectric accelerometers, one is placed
calculated by using multiple regression method. A near the spindle (channel I) and the other on work table
statistical software Minitab-16 was used to calculate the (channel II) and the setup are shown in Fig. 1. The data
values of these coefficients. acquired in the LabviewTM simulation via the personal
computer and the output is shown in Fig. 2; the
V. Experimental Set Up corresponding readings are tabulated in Table IV.

The test plates of size 50 mm × 50 mm × 50mm are

TABLE I
PROCESS FACTORS AND THEIR LEVELS
Parameter Factor Level
Units
(Input Variables) -2 -1 0 1 2
Spindle Speed rpm 1500 2000 2500 3000 3500
Feed Rate mm/rev 0.04 0.06 0.08 0.1 0.12
Axial depth of cut mm 0.5 0.6 0.7 0.8 0.9
Radial depth of cut mm 0.5 0.6 0.7 0.8 0.9
Radial Rake angle Degrees 12 15 18 21 24

Fig. 1. MAKINO CNC Vertical Machining Center (Model-S33)

TABLE II
CHEMICAL COMPOSITION OF AL 6063 ALLOY (AS PER ASM AEROSPACE SPECIFICATION METAL INC)
Others Others
Weight (%) Al Si Fe Cu Mn Mg Cr Zn Ti
each Total
6063 Bal 0.2-0.6 0.35 0.1 0.1 0.45-0.9 0.1 max 0.10 max 0.10 max 0.05 0.15 max

TABLE III
MECHANICAL PROPERTIES OF AL 6063 ALLOY (AS PER ASM AEROSPACE SPECIFICATION METAL INC)
Ultimate Tensile Ultimate Bearing
Hardness Hardness Modulus of Poission’s Shear
Tensile Yield Bearing Yield
Brinell Vickers Elasticity Ratio Strength
Strength Strength Strength Strength
73 83 241 MPa 214 MPa 68.9 GPa 434 MPa 276 MPa 0.33 152 MPa

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 6

1166
 G. Mahesh, S. Muthu, S. R. Devadasan

Fig. 2. Vibration amplitude output

TABLE IV
EXPERIMENTAL DESIGN MATRIX AND RESPONSE
Control factors Response
A: spindle B: Feed Rate- C: Axial D: Radial E:
Trail Channel 1- Channel 2
Speed- (Rpm) (mm/rev) Depth- (mm) Depth - (mm) Radial Rake Angle-
(mm/s2) (mm/s2)
(-2) (-1) (0) (1) (Degree) (2)
1 -1 -1 -1 -1 1 0.019 0.0038
2 1 -1 -1 -1 -1 0.021 0.0043
3 -1 1 -1 -1 -1 0.018 0.0035
4 1 1 -1 -1 1 0.018 0.0041
5 -1 -1 1 -1 -1 0.018 0.0042
6 1 -1 1 -1 1 0.019 0.0040
7 -1 1 1 -1 1 0.021 0.0041
8 1 1 1 -1 -1 0.020 0.0038
9 -1 -1 -1 1 -1 0.018 0.0040
10 1 -1 -1 1 1 0.021 0.0041
11 -1 1 -1 1 1 0.019 0.0040
12 1 1 -1 1 -1 0.021 0.0044
13 -1 -1 1 1 1 0.020 0.0041
14 1 -1 1 1 -1 0.024 0.0032
15 -1 1 1 1 -1 0.018 0.0030
16 1 1 1 1 1 0.023 0.0040
17 -2 0 0 0 0 0.021 0.0042
18 2 0 0 0 0 0.025 0.0046
19 0 -2 0 0 0 0.015 0.0032
20 0 2 0 0 0 0.015 0.0031
21 0 0 -2 0 0 0.017 0.0042
22 0 0 2 0 0 0.019 0.0039
23 0 0 0 -2 0 0.018 0.0039
24 0 0 0 2 0 0.022 0.0041
25 0 0 0 0 -2 0.015 0.0039
26 0 0 0 0 2 0.016 0.0039
27 0 0 0 0 0 0.015 0.0035
28 0 0 0 0 0 0.015 0.0036
29 0 0 0 0 0 0.015 0.0034
30 0 0 0 0 0 0.015 0.0035
31 0 0 0 0 0 0.014 0.0036
32 0 0 0 0 0 0.015 0.0035

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 6

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 G. Mahesh, S. Muthu, S. R. Devadasan

VI. Results and Discussion
A rigorous analysis were carried out with the
experimental data using Design Expert 6.0 software of
state ease.
A second order quadratic model was developed for the
prediction of spindle speed and work table vibration.
The model was checked for its adequacy using
ANOVA (analysis of variance).
Tables V & VI show ANOVA table for the prediction
of spindle speed and work table vibration respectively. It
is observed from the Tables V and VI that models are
significant and the lack of fit are not significant which
infer the significance of the model. Values of Prob > F
less than 0.05 indicate model terms are significant and
values greater than 0.10 indicate the model terms are not
significant. The p-value < 0.0001 represents that there is
only a 0.01% chance that such model could occur due to
noise. To illustrate the relationship between the response
and the process parameters the fitted polynomial
equation is expressed in the form of surface plots.
The Tables V & VI also show the other adequacy
measures R2, Adj R2 and Pred R2.
The coefficient of determination R2 indicates that the
goodness of fit for the models is nearer to 1. The
regression equation obtained from the Design Expert
software in terms of actual factors are given below for
spindle vibration and work table vibration.
VI.1. Effect of Spindle Vibration
VI.1.1. Interaction Effect of Spindle Speed
and Feed Rate on Spindle Vibration
From the Fig. 3 it is noticed that feed rate has the
direct influence on spindle vibration at lower spindle
speed. This may be due to the fact that as the feed rate
increases, the speed of cutting tool movement relative to
the work piece also increases resulting in higher spindle
vibration:

Spindle Vibration = + 0.22624 - 4.26591E-005 × A -0.16610 × B -0.17261 × C - 0.24886 × D +

- 1.25126E-003 × E-2.50000E-005 × A × B + 2.50000E-006 × A × C +
+1.50000E-005 × A × D -5.00000E-007 × A × E+ 0.12500 × B× C+- 0.062500 × B× D+ (2)
+ 6.25000E-003 × B× E + 0.025000 × C × D + 8.33333E-004 × C × E ++ 4.16667E-004 × D × E +
+8.68182E-009× A2 +0.42614 × B2 + 0.092045 × C2 + 0.14205 × D2 +3.28283E-005 × E2
TABLE V
ANOVA TABLE FOR THE PREDICTION OF SPINDLE VIBRATION
Sum of Mean F p-value
Source
Squares df Square Value Prob > F
Model 0.000266 20 1.33E-05 37.12870192 < 0.0001 significant
A-spindle Speed 0.000024 1 0.000024 67.01538462 < 0.0001
B-Feed Rate 1.67E-07 1 1.67E-07 0.465384615 0.5092
C-Axial Depth 0.000006 1 0.000006 16.75384615 0.0018
D-Radial Depth 1.35E-05 1 1.35E-05 37.69615385 < 0.0001
E-Radial Rake Angle 6.67E-07 1 6.67E-07 1.861538462 0.1997
AB 0.000001 1 0.000001 2.792307692 0.1229
AC 2.50E-07 1 2.50E-07 0.698076923 0.4212
AD 9.00E-06 1 9.00E-06 25.13076923 0.0004
AE 9.00E-06 1 9.00E-06 25.13076923 0.0004
BC 0.000001 1 0.000001 2.792307692 0.1229
BD 2.50E-07 1 2.50E-07 0.698076923 0.4212
BE 2.25E-06 1 2.25E-06 6.282692308 0.0292
CD 0.000001 1 0.000001 2.792307692 0.1229
CE 0.000001 1 0.000001 2.792307692 0.1229
DE 2.50E-07 1 2.50E-07 0.698076923 0.4212
A^2 0.000138 1 0.000138 385.8567308 < 0.0001
B^2 8.52E-07 1 8.52E-07 2.379807692 0.1512
C^2 2.49E-05 1 2.49E-05 69.39519231 < 0.0001
D^2 5.92E-05 1 5.92E-05 165.2644231 < 0.0001
E^2 2.56E-06 1 2.56E-06 7.15 0.0216
Residual 3.94E-06 11 3.58E-07
Lack of Fit 3.11E-06 6 5.18E-07 3.106060606 0.1171 not significant
Pure Error 8.33E-07 5 1.67E-07
Cor Total 0.00027 31
R-Squared 0.9854
Adj R-Squared 0.9588

Worktable vibration = +0.014144 - 4.11318E-006×A+8.25095E-003 × B + 7.06061E-004 × C +

-0.01176 × D -2.78011E-004 × E +9.43750E-006 × A × B - 3.61250E-006 × A × C +
+8.62500E-007 × A × D + 4.62500E-008 × A × E + 0.015313 × B × C +
+ 3.43750E-003 × A × D - 7.39583E-004 × B × E - 1.81250E-003 × C× D +
+ 1.02083E-004 × C × E - 3.93750E-004 × D × E + 9.18636E-010 × A2 +
- 0.20710 × B2 + 5.34091E-003 × C2 + 0.012966 × D2 + 1.16288E-005× E2

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 G. Mahesh, S. Muthu, S. R. Devadasan

TABLE VI
ANOVA TABLE FOR THE PREDICTION WORK TABLE VIBRATION
Mean p-value Prob >
Source Sum of Squares df F Value
Square F
Model 3.99E-06 20 2.00E-07 40.29684 < 0.0001 significant
A-spindle Speed 1.22E-07 1 1.22E-07 24.602 0.0004
B-Feed Rate 2.10E-08 1 2.10E-08 4.24126 0.0639
C-Axial Depth 2.15E-07 1 2.15E-07 43.35407 < 0.0001
D-Radial Depth 5.13E-08 1 5.13E-08 10.36631 0.0082
E-Radial Rake Angle 1.08E-08 1 1.08E-08 2.188359 0.1671
AB 1.43E-07 1 1.43E-07 28.77553 0.0002
AC 5.22E-07 1 5.22E-07 105.4059 < 0.0001
AD 2.98E-08 1 2.98E-08 6.008521 0.0322
AE 7.70E-08 1 7.70E-08 15.54946 0.0023
BC 1.50E-08 1 1.50E-08 3.030132 0.1096
BD 7.56E-10 1 7.56E-10 0.152706 0.7034
BE 3.15E-08 1 3.15E-08 6.361889 0.0284
CD 5.26E-09 1 5.26E-09 1.061367 0.325
CE 1.50E-08 1 1.50E-08 3.030132 0.1096
DE 2.23E-07 1 2.23E-07 45.08095 < 0.0001
A^2 1.55E-06 1 1.55E-06 312.4051 < 0.0001
B^2 2.01E-07 1 2.01E-07 40.64813 < 0.0001
C^2 8.37E-08 1 8.37E-08 16.89589 0.0017
D^2 4.93E-07 1 4.93E-07 99.57648 < 0.0001
E^2 3.21E-07 1 3.21E-07 64.87909 < 0.0001
Residual 5.45E-08 11 4.95E-09
Lack of Fit 2.61E-08 6 4.36E-09 0.768895 0.6257 not significant
Pure Error 2.83E-08 5 5.67E-09
Cor Total 4.05E-06 31
R-Squared 0.9865
Adj R-Squared 0.9621

The spindle vibration was lowered between 2000 and
3000 r.p.m. However, the spindle vibration was increased
beyond these ranges. This may be due to the fact that at
lower spindle speeds the spindle rotates slowly and there
is more contact between the tool and work piece resulting
in more vibration.
between the tool and the work piece and the chance of
vibration is more. Similarly for higher axial depth, the
tool will advance more towards the work piece producing
more vibration. At a medium range of axial depth, the
spindle vibration will be damped and results in lesser
vibration frequency.

Fig. 4. Interaction effect of spindle speed and axial depth

Fig. 3. Interaction effect on of spindle speed and feed
over spindle vibration
rate over spindle vibration

VI.1.2. Interaction Effect of Spindle Speed and Axial
Depth on Spindle Vibration
The interaction effect of spindle speed and axial depth
on spindle vibration plot of fig.4 showed that the spindle
vibration converged to a minimal value at the range of
0.6 and 0.7 mm of axial depth and 2000 and 2500 r.p.m.
of spindle speed. The spindle vibration increased at the
extremities of both axial depth and spindle speed
revolution. This may be due to the reason that, for small
axial depth of cut there will only be a small contact
VI.1.3. Interaction Effect of Spindle Speed and Radial
Depth on Spindle Vibrations
The Interaction effect (Fig. 5), of spindle speed and
radial depth on spindle vibration showed that at higher
spindle speed, the rise in radial depth increased the
spindle vibration. This trend is inverse in relationship
compared to the axial depth of cut.
This may be due to the reason that at higher speeds the
spindle vibration will be more. In addition to it the radial
depth is increased,and there will be more hindrance for
the movement of tool into the work piece which may

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 G. Mahesh, S. Muthu, S. R. Devadasan

result in more spindle vibrations. Otherwise it was interesting to note that at lower radial rake angle the
noticed that the radial depth of cut and axial depth of cut increase in feed rate decreased the spindle vibration
have similar interaction effect with that of spindle where as at higher radial rake angle increase in feed rate
vibration. decreased the spindle vibration.

Fig. 5. Interaction effect of spindle speed and Fig. 7. Interaction effect of feed rate and axial depth
radial depth on spindle vibrations on spindle vibration

VI.1.4. Interaction Effect of Spindle Speed and

Radial Rake Angle on Spindle Vibrations
From the figure (Fig. 6), it was noticed that the
increase of radial rake angle from 150 to 210 increased
the spindle vibration both at lower as well as higher
spindle speed revolution. This may be due to the fact
that, when the rake angle increases, the contact area
between the tool and the work piece also increases
resulting in the formation of more chips and thus more
vibration in the spindle. For reducing the spindle
vibration, it can be noticed from the results that the radial Fig. 8. Interaction effect of feed rate and radial depth
rake angle should be minimum in the range of 150 to 170 on spindle vibration
where as the speed should be between 2000 and 2500
r.p.m.

Fig. 9. Interaction effect of feed rate and radial rake angle

Fig. 6. Interaction effect of spindle speed and radial rake angle
on spindle vibrations
The interaction effects of feed rate and axial depth of
cut, feed rate and radial depth of cut on spindle vibration
are less significant. The Fig. 7 and Fig. 8 shows the
interaction effects of feed rate and axial depth of cut,
feed rate and radial depth of cut on spindle vibration.
VI.1.5. Interaction Effect of Feed Rate and Radial Rake
Angle on Spindle Vibrations
From the Interaction effect plot shown in Fig. 9, it is
on spindle vibrations
This may be due to the fact that at lower rake angle,
the spindle vibration will be less. In addition to this if the
feed rate is increased, lesser the vibration on the spindle.
This showed there was a tradeoff between radial rake
angle and feed rate on spindle vibration. Hence these
studies suggested that a lower rake angle between 12 and
17 degrees would be preferred to reduce spindle
vibration.
The results of analysis through DOE also suggested
that there was a significant interaction on spindle
vibration observed between feed rate and radial rake
angle.

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 G. Mahesh, S. Muthu, S. R. Devadasan

VI.2. Effect of Work Table Vibration Whereas higher spindle speed, if we increase the axial
depth of cut, the vibration frequencies will be arrested,
VI.2.1. Interaction Effect of Spindle Speed and Feed
because of more contact between the tool and work
Rate on Work Table Vibrations
piece.
From the Fig. 10 it was evidenced that, the spindle
speed had more significant effect compared to the feed
rate on work table vibration. The work table vibration
was found to be reduced between spindle speed of 2000
and 2750 r.p.m. and it was increased beyond these limits.
This may be due to the fact that at lower and higher
speed the spindle vibrations will be more resulting in
more work table vibrations as mentioned earlier. These
spindle vibrations will be transferred to the work table
causing, work table vibrations. As far as the feed rate was
concerned, the work table vibration was more between
0.06 and 0.1 mm/rev.
This may be due to the reason that at lower and higher Fig. 11. Interaction effect of spindle speed and axial depth
feed rates most of the vibration frequencies are damped on worktable vibration
by the spindle and only small vibration will occur in the
worktable, whereas at an intermittent stage of feed rate, VI.2.3. Interaction Effect of Spindle Speed and Radial
the vibrations transferred to the spindle will be less and Depth on Worktable Vibration
most of the vibrations will be transferred to the
worktable. The spindle speed between 2000 to 2750 r.p.m and
radial depth between 0.6 and 0.8 mm are found to be
significant in decreasing the work table vibration as
shown in Fig. 12.
This may be due to the reason that at lower and higher
radial depths, the spindle will vibrate more transferring
this effect to the worktable also. But at an intermediate
value of the radial depth, the vibrations will get damped
resulting in low worktable vibrations.

Fig. 10. Interaction effect of spindle speed and feed rate

on work table vibrations

VI.2.2. Interaction Effect of Spindle Speed and Axial

Depth on Worktable Vibration
It was noticed from Fig. 11 that, at lower axial depth,
with increase in spindle speed, the work table vibration Fig. 12. Interaction effect of spindle speed and
radial depth on worktable vibration
increased. This may be due to the fact that at lower axial
depth and higher speed, the spindle will vibrate more and
these vibrations will be transferred to the worktable VI.2.4. Interaction Effect of Spindle Speed and Radial
causing worktable vibrations. However, there was no Rake Angle on Worktable Vibration
significant effect at the higher axial depth. When spindle
The work table vibration was found to be, influenced
speed is minimum, the change in axial depth doesn’t
by increasing spindle speed as shown in Fig. 13. Unlike,
influence the work table vibration.
spindle speed vibration, the work table vibration was
Whereas with the maximum spindle speed of 3500
found to be higher at lower radial rake angle compared to
r.p.m , the increase in axial depth, decreased the work
higher radial rake angle. However this trend was not
table vibration. This may be due to the reason that at
significant at lower spindle speed. The effect of spindle
lower spindle speeds, even if the axial depth is increased,
speed on work table vibration was found to be more
the tool will continue to remove the material from the
significant when it is interacted with radial rake angle.
work piece at a steady constant rate only. This will cause
This is due to the fact that at higher spindle speed and
only less vibration on the worktable.
lower rake angles, the spindle vibration will be more.

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 6

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 G. Mahesh, S. Muthu, S. R. Devadasan

Unlike spindle speed vibration, the work table vibration

was found to be higher between 0.06 and 0.1. Similarly,
at higher feed rate and lower rake angle, the work table
vibration was found to be lowered.

Fig. 16. Interaction effect of radial rake angle and

feed rate on worktable vibration

Fig. 13. Interaction effect of spindle speed and

radial rake angle on worktable vibration

Fig. 14, Fig. 15, Fig. 16, Fig. 17 and Fig. 18 represent
less significant plots showing the interaction effects of
axial depth and feed rate, radial depth and feed rate,
radial rake angle and feed rate and axial depth and radial
depth respectively on the worktable vibration.

VI.2.5. Interaction Effect of Radial Depth and Radial

Rake Angle Over Worktable Vibration
From, the Fig. 19 it was found that both the radial rake Fig. 17. Interaction effect of axial depth and
radial depth on worktable vibration
angle and the radial depth had significant effect on work
table vibration. The work table vibration was found to be
reduced between rake angle of 150 to 170 and for the
radial depth between 0.70 and 0.80 mm.

Fig. 18. Interaction effect of axial depth and radial rake angle on
worktable vibration

Fig. 14. Interaction effect of axial depth and
feed rate on worktable vibration
Fig. 15. Interaction effect of radial depth and
feed rate on worktable vibration
For higher rake angle, it was found that there was a
significant increase in work table vibration with the
increase in radial depth. This may be attributed to the fact
that at higher rake angle there will be more contact
between the tool and the work piece resulting in the
formation of more chatter. In addition to it, if the radial
depth increases, the tool will be subjected to more
vibrations and as a result, the worktable will also vibrate
more. Similarly, for higher radial depth, it was found a
significant increase in work table vibration with increase
in rake angle. This may be due to the fact that at higher
radial depth, the tool will be in more contact with the
work piece. If we increase the rake angle, at this time, the
chance of vibration of the tool will be more resulting in
more worktable vibrations.

Copyright © 2012 Praise Worthy Prize S.r.l. - All rights reserved International Review of Mechanical Engineering, Vol. 6, N. 6

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 G. Mahesh, S. Muthu, S. R. Devadasan

TABLE VII
VALIDATION OF THE MODEL
Response Response
Trial Control Factors
Channel -1 (mm/s2) Channel -2 (mm/s2)
A: B: C: D: E: Observed Predicted Observed Predicted
% Error % Error
(-2) (-1) (0) (1) -2 value value value value
1 2000 0.04 0.6 0.5 21 0.056 0.058 -0.2 0.0035 0.0032 0.03
2 3000 0.08 0.7 0.7 18 0.043 0.044 -0.1 0.0044 0.0046 -0.02
3 2000 0.1 0.6 0.6 15 0.065 0.063 0.2 0.0036 0.0035 0.01

vibration: Feed rate should be minimum below 0.08 mm,

Spindle speed should be between 2000 and 2500 r.p.m.
Axial depth of cut should be between 0.6 and 0.7 mm
Radial depth of cut should be between 0.7 and 0.8 mm.
Radial rake angle should be minimum in the range of 150
to 170.

Acknowledgements
The authors are grateful to the Management,
Department of Mechanical Engineering and Department
of Production Engineering, PSG College of Technology,
Coimbatore, India for extending the facilities to measure
vibration amplitude in FIST laboratory and Tool and die
Fig. 19. Interaction effect of radial depth and
design centre to carry out this investigation.
radial rake angle on worktable vibration

VII. Validation of the Model References

Table VII shows that a regression model developed
using CCD by RSM of DoE was verified using
confirmatory test. Table VII shows the comparison of
predicted vs experimental value of Vibration of both
spindle speed and work table. The percentage of error is
found to be within ±2% which shows the validity of the
model.
VIII. Conclusion
Based on the experimental investigation, application
of Response Surface Methodology (RSM) and central
composite rotatable design (CCRD) for modeling and
optimization of spindle and work table vibration of end
milling process has been discussed. Mathematical model
equations were derived for both spindle and work table
vibration by using mathematical software package
DESIGN EXPERT 6.0. The confirmatory test shows the
predicted values from the model equations were found to
be good agreement with observed values and the
percentage of error is found to be within
±2%.Considering the factors such as spindle Speed, feed
Rate, axial depth of cut, radial depth of cut and radial
Rake angle using design of experiments concept, the
following conclusions are drawn:
The Spindle Speed, Axial depth of cut and Radial
depth of cut were the most important parameters to be
considered for reducing the spindle and work table
vibration of the end milling process compared to the
other factors such as Radial Rake angle and Feed Rate.
For reducing the spindle vibration and work table
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Vol. 35, pp.150–158,
p 20099. E-maail: devadasan_srrd@yahoo.com
[15] Ching-Fenng Chang. and Jiin-Jia Chen., “Viibration monitoriing of
motorized spindles using spectral analysis a techniqques”, Mahesh G. received his Bachelor off
Mechatronnics Vol.19, pp. 726–734,
7 2009. Engineering deegree in Mechan nical Engineeringg
[16] Huang, C.Y. and Wang, J.JJ.J., “A pole/zeroo cancellation appproach from P.S.N.A A College of Engineering
E andd
to reducingg forced vibrationn in end milling”, International Joournal Technology, Kamaraj Univeersity, Madurai,,
of Machine Tools and Manufacture Vol.50, pp.601–610, 20110. India in 1998, Master of Enginneering degree inn
[17] Kim,S. annd Klamecki, B.E., “Milling cuutter wear monittoring Production E Engineering fro om Thiagarajarr
using spinndle shaft vibratioon”, Journal of Manufacturing
M Sccience College of Enngineering, Kam maraj University,,
and Enginneering-Transactions of the ASM ME, Vol. 119,pp..118 - Madurai, India in 2003. Hee is currently a
120, 1997.. Reseearch Scholar in the department oof Mechanical En ngineering, Annaa
[18] Zhang, J.ZZ. and Chen, J.C., “Tool conditionn monitoring in an a end Univ versity, Chennai, India. He has 144 years of academ
mic experience att
milling operation based on the vibration signnal collected throough a varioous capacities. Currently he is woorking as an Assisstant Professor inn
microcontrroller-based dataa acquisition syystem “, Internaational the department of Mechanical Enngineering, EASA College off
Journal of o Advanced Manufacturing
M T
Technology, Voll. 39, Engineering and Techhnology, Coimbaatore, India. His areas of interestt
pp.118–1228, 2008. are Production
P Enginneering, Optimizaation techniques, Vibration, TPM M
[19] Toh, C.K.., “Vibration anaalysis in high sppeed rough and finish etc.
milling harrdened steel”, Jouurnal of Sound and Vibration, Vool. 278,
pp.101–1115, 2004. Muthu S. receeived his Bachelo or of Engineeringg
[20] Young-Hyyun Kim., and Suung-Lim Ko., “D Development of design
d degree in Production Engineeering from PSG G
and manuufacturing technnology for end mills in machhining College of Tecchnology, Coimbatore, Universityy
hardened steel”,
s Journal off Materials Processsing Technologyy, Vol of Madras,, Inddia in 1978, Masteer of Engineeringg
130, pp. 6553-661,2002. degree in Inddustrial Engineerring from PSG G
[21] Bissey, S.., Poulachon, G., and Lapujoulade, F., “Modelliing of College of Tecchnology, Coimbatore, Universityy
Tool geom metry in predictiion of cutting foorce during milliing of of Madras, Inddia in 1980, a Ph.D. degree inn
hard matterials, Machiniing Science and a Technologyy: an Mechanical Enggineering. He is a Life member off
Internationnal Journal, Vol. 9, pp. 101-115, 2007.
2 ISTEE, IE and Fellow w member in IIIIE. He had 30yeears of academicc
[22] Reddy, N. S. K. and Raoo, P. V, “Selectiion of Optimum m Tool experience at variouss capacities. Currrently he is serving as a principall
Geometry and Cutting Coonditions Using a Surface Rougghness in Srri Vidya Collegee of Engineeringg and Technology y; Virudhunagar..
Prediction Model for End Milling”, Inteernational Journnal of He published
p 5 Interrnational Journalls and presented 47 national andd
Advanced Manufacturing Technology, Vol.26, V pp.1202--1210, Interrnational Confereences. He has beeen guiding 14 Research
R scholarss
2005. and his areas of interest are Prroduction Engin neering, Qualityy
[23] Yesilyurt, I., “End mill breeakage detection using mean frequency Management, Maintennance Managemeent etc.
analysis of scalogram”, Innternational Jourrnal of Machine Tools
and Manuffacture, Vol.46, pp.p 450–458, 20006. Devadasan S S. R. is a Prrofessor in thee
[24] Partchapoll Sartulvanich., Hakan
H Sahlan, and
a Taylan Altann., “A Production Enngineering Depaartment of PSG G
Finite elem
ment analysis of burr
b formation inn face milling of a cast College of Tecchnology, Coimb batore, India. Hee
aluminiumm alloy”, Machhining Science and Technologyy: an holds a Bachelor’s degree in Mechanicall
Internationnal Journal, Vol.11,pp. 157-181,22007. Engineering, a Master’s degrree in Industriall
[25] Reddy, N.. S. K. and Rao,, P. V, “Experim mental investigatiion to Engineering, a Ph.D. degree in Mechanicall
study the effect of solid luubricants on cuttiing forces and suurface Engineering annd a Doctor of Science
S degree inn
quality in end milling”, Inteernational Journal of Machine Toools & Mechanical Enngineering. He has h 20 years off
Manufactuure, Vol. 46, pp.189–198, 2006. hing and researchh experience. Hee has published over
teach o 85 papers inn
[26] Santhakum mar. J. and Aruunkumar.G., “O Optimization of Deep intern
national journals. He is an editoriial advisory boarrd member of thee
Drawing Process Parameters Using Desiign of Experim ments”, Euroopean Journal off Innovation Management. His researchr interestss
Internationnal Review of Mechanical Engineeering (IREME), Vol. V 6, inclu
ude Agile Manufaacturing, Six Sigmma, Total Producttive Maintenancee
no. 5, 20122. and Total
T Quality Maanagement.
[27] Ramesh. T. and Senthhilvelan., “Statiistical Modeling of
Aluminium m Based Compoosites and Alum minium Alloys Using U
Design off Experiments”, International ReviewR of Mechaanical
Engineerinng (IREME), Vool. 4, No. 7, pp.7999-804, 2010.
[28] Montgomeery, D.C, “Desiggn and Analysis of o Experiments”.. John
Wiley andd Sons, New Yorkk, pp.427–450, 20001.

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