MARCOS- based multi criteria optimization of cutting

parameter for Cast Alloy steel

SUBMITTED BY : UNDER THE GUIDANCE OF :

AMIT KUMARI Dr. LOKESWAR PATNAIK
ROLL NO. – ME22M01 ASSISTANT PROFESSOR
M.TECH (MANUFATURING ENGG.) NIAMT
3RD SEMESTER
INTRODUCTION
Multi-Criteria Decision-making (MCDM) has the potential for improving all areas of
•
decision-making in engineering, from design to manufacture, but is especially
beneficial for applications in high technology market sectors, where product
differentiation and competitive advantage are often achieved by just very small gains
in material performance. The full capability of MCDM methods are realized by their
ability to simultaneously consider material, process, and shape for complex materials
selection problems. It is essential therefore to expand the scope of MCDM methods
to a wide range of engineering applications and feedback the experience to improve
materials selection.
Quality responsive excellence is the most important business objective.
The purpose of undertaking cutting parameter optimization is two-
fold: Quality and Economics.
Turning is widely used industrial manufacturing process for circular
cross-section components. A manufacturing process involves a number
of process parameters (controllable and uncontrollable) which affects
the output (response). The basic idea of optimization is to increase
quality and reduce cost. Optimal process parameters are usually picked
by an experiences human technician (process planner or machine
operator) driven by wisdom, combination of material and size of work,
material and size of cutter, available range of machine variables and
machine accuracy limitations and data from standard industrial
handbooks. Reduced machining time, good tool life and good surface
finish are some of the important considerations during effective
machining.
Why Turning
• The turning method plays an important role in mechanical production. Normally,
for each product that needs to be machined by cutting methods, the machining
volumne of the turning method accounts for a large proportion. For the turning
method in particular and the other machining methods in general, they all have
the same purpose which is ensuring both economic and technical criteria. To
ensure both economic and technical goals, the highest productivity, the least
material consumption, the lowest labor cost, etc. To achieve multiple goals at the
same time, it is a need to solve the multi-objective optimization problem
• Turning is a widely used Industrial Manufacturing process for circular crosssection
components. A CNC Turn Center or a Conventional Lathe (like Engine lathe) is
used depending on market (external customers), manufacturing demands,
enterprise skills and monetary resources. A Manufacturing process involves a
number of process parameters (controllable and uncontrollable) which affect the
output (response variable). Turning Cutting Parameters (input cutting parameters
eg: cutting speed, feed rate, depth of cut, coolant, material and geometry of
insert used for cutting) have a bearing on Quality, Time and Cost (QTC) of the
resultant finished component (for a given work material grade).
LITERATURE REVIEW
• A brief review of status of research work carried out by various investigators is given below

• Abhang et L B al [2] utilize the regression modeling in turning process of EN-31 steel using
response surface methodology(RSM) with factorial design of experiments. From the analysis, it
is observed that feed rate is the most significant factor on the surface roughness followed by
cutting speed and depth of cut at 95% confidence level.

• Kalyanmoy Deb and Rituparna Datta [3] describe the use of an evolutionary multi-objective
optimization (EMO) algorithm and a suitable local search procedure to optimize the machining
parameters (cutting speed, feed rate, and depth of cut) in turning operations. EMO solutions
are modified using a local search procedure to achieve a better convergence property.
Cont..
• Meenu Sahu and Komesh Sahu [4] present an Optimization method of the cutting parameters (cutting
speed, depth of cut and feed) in dry turning of AISI D2 Steel to achieve minimum tool wear, low workpiece
surface temperature and maximum material removal rate.

• Suresh R K and Krishnaiah G [5] investigate and obtain an optimal setting of process parameters in turning
for maximizing the material removal rate of the manufactured component. The result of this analysis
identifies the optimal values of process parameters for effective and efficient machining.

• Dorigo M, Maniezzo V & Colorni A [6] describe the Ant System type of ACO implementation and the
features of the ACO algorithm. The procedure, utility and the steps to be followed are described.
WHY MARCOS
• MARCOS (Measurement Alternatives and Ranking according to
compromise solution) is a multi-criteria decision-making method
first proposed in 2020 . Although it has only been published for a
short time, this method has been applied in a number of studies
such as: selection of intermediate models of transport between
countries in the Danube region; solving multi-objective problems to
reduce risks in road traffic ; selection of loading/unloading
machines in small warehouses ; selection of employees for a
shipping company ; cost calculation in construction . However, up
to now, there have been no studies applying the MARCOS method
to multi-criteria decision making for cutting methods. This is the
first reason why this study was chosen.
Steps of MARCOS
• The steps to implement multi-criteria decision making according to the MARCOS method are as
follows
RESPONSE CHARACTERISTICS
• The following two response Characteristics were chosen.
1. Surface Roughness (SR)
Three main factors determine Surface Roughness.
• Rate of Feed
• Built Up Edge
• Vibrational Deflections (termed chatter) between tool and the work

2. Material Removal Rate (MRR)

• MRR using volume of material removed (mm3/ min) is also called
Volumetric Material Removal Rate (VMRR)
• Experiment will be performed at 27 levels with three process
parameters( i.e Cutting velocity, Feed rate, Depth of cut)
• Surface roughness and material removal rate will be taken as
response
• MARCOS one of MCDM methods will used to established relationship
between the response and factor affecting the response
Materials
• Material Selected :IT 90G
Chemical Composition
%C % Mn % Si %S %P % Cr %Ni %Mo
0.28-0.33 1.30 – 1.50 0.30 max 0.03 max 0.03 max 0.60-1.00 0.75-1.25 0.35-0.55

Mechanical Properties
UTS YS ELONGATION IZODE IMPACT VALUE HARDNESS
100 Kgf/Sq. mm 85 Kgf/Sq. mm 14 % 3.0 m Kgf Min 300-340 HB
Machine
• CNC HEC Lathe, Model LRT 65N

Tool Used :
1. TNGM- 160404-TN2000 (WIDIA MAKE)
2. SNMG- 120404-TN2000 (WIDIA MAKE)
3. RCMX-2507MOSN-SM-S40T1( WIDIA MAKE)
4. CNMG-120408-690
Tool
Cutting Tool Used
CNC Machine Test Piece Hardness
Testing M/c
Length of Shell – 1767
Thickness – 8 mm
Internal radius-R 1992
Problem :-
1. Vibration due to Boring bar length- 2000mm
2. Internal surface finish
3. MRR is very low
OBJECTIVES

• Objective 1. Low Surface Roughness is desirable

• Objective 2. High Material Removal Rate is desirable
• Objective 3. Optimization of Cutting parameters by using MARCOS
based multi criteria that leads to a scientific and quantifiable
improvement in manufacturing process which in turn leads to
increase quality/ profit.
EXPERIMENTAL DETAILS
• Experiment will be performed at 27 levels( By used of MINITAB)
• Selected Cutting Parameters. The 3 Selected Cutting Parameters (Controllable
Input Parameters)
cutting speed , feed rate and depth of cut
• Selected Response Characteristics. The 2 Selected Response Characteristics
(Output Parameters)
Surface Roughness and Material Removal Rate
• Need to include Surface Roughness as a Response Characteristic: Finish is a
functional necessity (friction, aesthetics etc) and an important customer
requirement. Therefore it is necessary to include SR as a response characteristic.
• Need to include Material Removal Rate as a Response characteristic: MRR directly
affects cycle time, an important parameter, hence MRR is included.
RESULT
SL. No. CUTTING VELOCITY FEED RATE DEPTH OF CUT Tool used SURFACE
(REVOLUTION PER (MM/Rev) (MM) ROUGHNESS
MIN) (μm)

1 190 0.4 0.8 TNGM- 160404- 1.321

TN2000
2 190 0.4 1.0 SNMG- 120404- 0.823
TN2000
3 190 0.4 1.2 RCMX- 1.559
2507MOSN-SM-
S40T1
4 190 0.4 0.8 CNMG-120408- 0.982
690
RESULT:
SL. No. CUTTING VELOCITY FEED RATE DEPTH OF CUT MATERIAL SURFACE
(REVOLUTION PER (MM/Rev) (MM) REMOVAL RATE ROUGHNESS
MIN) (mm3/Min) (μm)
1 190 0.4 0.8 1.013 0.823
2 190 0.4 1.0 1.267 1.657
3 190 0.4 1.2 1.52 1.459
4 190 0.8 0.8 2.027 0.992
5 190 0.8 1.0 2.533 0.817
6 190 0.8 1.2 3.04 1.523
7 190 1.0 0.8 2.533 1.449
8 190 1.0 1.0 3.167 0.873
9 190 1.0 1.2 3.8 1.645
10 320 0.4 0.8 1.707 1.456
FINDING:
• SNMG tool insert have better surface finishing compare to TNMG ,
RCMG and CNMG
• Better surface finish at low feed rate and cutting velocity.
• Better Material removal rate at high feed rate, high depth of cut and
high cutting velocity
• Requirement of MARCOS- based multi criteria optimization of cutting
parameter for this Cast Alloy Steel.
TO BE DONE
• Designing MARCOS model
• Calculating optimization of cutting parameter
• If the MARCOS model not form then again Redo the experiment.
THANK
YOU