ABSTARCT

The main objective of today's manufacturing industries is to produce low

cost, high quality products in short time. This paper investigates the machining of
EN8 to find optimal parameters for CNC Hard turning process. The Taguchi’s L9
Orthogonal array is used to formulate the experimental layout, to analysis the effect
of each parameter on the machining characteristics and to predict the optimal
choice for each turning parameters such as Speed, Feed and Depth of cut. The
optimal factor for Surface Roughness was Speed-1500, Feed -0.20 mm/rev DOC
-0.2 . The Percentage of contribution for surface finish majorly influenced with
speed 67%

• R.GOWTHAM -820717114307
• R.GUNASEKARAN-820717114309
• R.MANIKANDAN-820717114314
 LITERATURE SURVEY
Title Author Published year & Work piece Input parameter Conclusion
journal & tool & responses
material
A surface roughness Dilbag Singh . International AISI 52100 1.Cutting speed Study shows that
prediction model for hard P. Journal of 2. Feed the feed is the
turning process Venkateswara Advanced 3. Effective dominant factor
Rao Manufacturing rake angle determining the
Technology · April 4. Nose radius surface finish
2007 & surface followed by nose
roughness, radius and cutting
velocity

Effects of cutting edge Tugrul O¨ zel Int J Adv Manuf AISI H13 feed rate, and study shows that the
geometry, workpiece · Tsu-Kong Technol (2005) 25: steel the cutting effects of workpiece
hardness, feed rate Hsu · Erol 262–269 speed hardness, cutting
and cutting speed on Zeren and feed rate & edge geometry, feed
surface roughness and surface rate and cutting
forces in finish turning hardness and speed on
of hardened AISI H13 honed edge surface roughness
steel geometry are statistically
significant
 Title Author Published year Work piece & Input parameter Conclusion
& journal tool material & responses

Surface roughness B. Fnides, M. A. ISSN 1392 - hardened hot cutting speed, The results revealed
model in turning Yallese, T. 1207. work steel feed rate and that feed rate seems to
hardened hot work Mabrouki, J-F. MECHANIKA. depth of cut & influence
steel using Rigal 2009. Nr.3(77) surface surface roughness
mixed ceramic tool roughness more significantly
criteria than cutting
speed

Empirical modeling of developed the second-

hard turning process Dr. G.Harinath Volume 2, Issue INCONEL speed, feed order polynomial
of inconel using Gowd1, M. 10, October 600. and depth of models for the Feed
response surface Gunasekhar 2012) cut & force Thrust force
methodology Reddy2, Bathina Response (Fy), Cutting force
Sreenivasulu3 Surface (Fz) and Surface
Methodology roughness (Ra) by
using the
Experimental data.
 Title Author Published year Work piece Input parameter & Conclusion
& journal & tool responses
material

[IJESAT , To improve the

Optimization Of K. Adarsh Volume-2, Issue- EN-8 cutting speed, feed surface
Surface Roughness In Kumar1 4, 807 – 812 rate and depth of cut roughness, a good
Face Turning Operation & Surface combination of
In Machining Of En-8 roughness cutting speed and
feed rate needs to
be selected

Analysis Of Surface S.B.SALVI (IJEST),Vol. 5 20 MnCr5 Cutting speed, feed The results
Roughness No.02 February Steel and Depth of Cut indicate that feed
In Hard Turning By 2013 &surface roughness. rate has
Using significant role to
Taguchi Method play in producing
lower surface
roughness
followed by
cutting speed.
 Title Author Published year & Work piece & Input parameter Conclusion
journal tool material & responses

Optimization Of Hard Franko Tehnički vjesnik AISI 4142 (cutting The results
Turning Process Puh 19, 2(2012), 415- speed, feed and indicate that feed
Parameters With Pcbn 419 depth of cut & rate has
Tool surface roughness significant role to
Based On The Taguchi play in producing
Method lower surface
roughness
followed by
cutting speed.
The Optimization Of Ali Riza Journal of AISI 8660 cutting speed, Interaction of
Machining Parameters Motorcu Mechanical Hardened feed rate, depth of feed rate/depth of
Using The Engineering Alloy Steel cut &surface cut
Taguchi Method For 56(2010)6, 391-401 roughness model, was found to be
Surface Roughness Of Taguchi method significant on the
AISI 8660 surface finish due
Hardened Alloy Steel to surface
hardening of steel
 Title Author Published Work piece Input parameter & Conclusion
year & journal & tool responses
material

Taguchi Multi- R. Journal of Al-15%SiCp cutting speed, feed Al-SiC(15p) metal

machining Ramanuja Studies on Composites rate and depth of cut matrix composites
Characteristics m Manufacturing & Taguchi method. such as surface
Optimization in (Vol.1- roughness and power
Turning of 2010/Iss.2-3) consumption are
Al-15%SiCp improved together by
Composites using using the method
Desirability Function proposed in this
Analysis study.

The Effects Of A. D. (IJERT) Vol. 1 AISI 52100 cutting speed, feed feed rate contributes
Cutting Conditions On Bagawade1 Issue 10, Steel rate and depth of cut largely to the
Chip Area Ratio And December- 2012 & evolution of surface
Surface Roughness In surface roughness roughness
Hard Turning Of AISI
52100 Steel
 HARD TURNING

Hard turning is a process which eliminates the requirements of grinding operation.

A proper hard turning process gives surface finish Ra 0.4 to 0.8 microns, roundness
about 2-5 microns and diameter tolerance +/-3-7microns. Hard turning can be
performed by that machine which soft turning is done. The starting point of hard
turning is the material hardness 40 HRC but regularly hard turning is done on the
material having hardness 60HRC and higher.
 BENEFITS OF HARD TURNING

1. Complex part contours can be easily machined by this process

2. Metal removal rate is very high
3. The CNC Lathe which is used for soft turning process can be used for this process
4. No coolant is required in many cases.
5. Tool inventory required is small.
 OBJECTIVE

The objective of the present work is to find the responses, their interaction with
input variables, and to find combination of input variables to find optimum value of the
response variables using Cryo treated TNMG carbide cermets on EN8 as work piece in
CNC turning machine with various hardened work piece. The input variables selected
are various hardness level of steel, DOC and speed . To find the significant value
through Taguchi’s design process optimize through MINITAB 17 software.
 PROBLEM STATEMENT

The generation of heat during machining increases the temperature in the cutting zone.
Increase in the temperature may

1. Affect the strength, hardness, wear resistance and life of the cutting tool,

2. Cause difficulty in controlling the accuracy due to dimensional changes in the part
being machined and on the machined surface integrity

3. Cause thermal damage to the workpiece and affect its properties and service life
 MATERIAL-EN8

COMPOSITION IN WEIGHT %
SL.NO ELEMENT
MIN MAX
1 Carbon, C 0.36 0.44
2 Manganese, Mn 0.45 0.70
3 Silicon, Si 0.10 0.35
4 Molybdenum, Mo 0.20 0.35
5 Chromium,Cr 1.00 1.40
6 Sulphur - 0.04
7 phosphorous - 0.035
 APPLICATION

EN8 is suitable for the manufacture of parts such as general-purpose axles and
shafts, gears, bolts and studs, stressed pins, keys etc. It can be further surface
hardened by induction processes, producing components with enhanced wear
resistance.
 METHDOLOGY
PROJECT OBJECTIVE

DATA COLLECTION AND LITRATURE REVIEW

STUDING AND PROPOSING A METHOD & HARDENING PROCESS

CNC TURNING PROCESS & OUTPUT RESPONCES ANALYSIS

OPTIMIZATION PROCESS

CONCLUSION
 HARDENING PROCESS
Material is heated up to the suitable temperature and then quenched in water
or oil to harden to full hardness according to the kind of steel. Material is heated to
the suitable temperature for hardening, then cooled rapidly by immersing the hot
part is water, oil or another suitable liquid to transform the material to a fully
hardened structure. In this process with the help of AAA medium type of oil and
End quenching process used for increase the hardness of the EN8.
 MEASURING MEHODS

Surface roughness : surface roughness tester

Machining time : CNC machine

Material removal rate : weight calculation

COMPARISION OF BEFORE AND AFTER HEAT
TRAETMENT

BEFORE AND AFTER TREATED

60
50
40
30
20

HARDNESS
10
0
T A B C
EA T T T
TR
REA REA R EA
E T T T
OR R R R
F TE TE TE
BE AF AF AF
PROCESS PARAMETERS AND THEIR
LEVELS

PROCESS PARAMETERS
LEVEL SPINDLE SPEED
S FEED (mm/Rev) DOC
(N) (RPM)
1 1500 0.10 0.1
2 1750 0.15 0.2
3 2000 0.20 0.3
PROCESS PARAMETERS AND VARIABLES
SPINDLE SPEED (N)
S.NO FEED (mm/Rev) DOC
(RPM)

1 1500 0.10 0.1

2 1500 0.15 0.2

3 1500 0.20 0.3

4 1750 0.10 0.2

5 1750 0.15 0.3

6 1750 0.20 0.1

7 2000 0.10 0.3

8 2000 0.15 0.1

9 2000 0.20 0.2

 EXPERIMENTAL DATA ANALYSIS AND
OPTIMIZATION

SPEED
FEED MT RA
SL.NO DESIGN (N) DOC MRR
(mm/Rev) SEC micron
(RPM)
A 1 B 1 C1 0.140
1 1500 0.10 0.1 21 0.645
A 1 B 2 C2 0.201
2 1500 0.15 0.2 14 0.574
A 1 B 3 C3 0.350
3 1500 0.20 0.3 11 0.803
4 A 2 B 1 C2 1750 0.10 0.2 18 0.921 0.157

A 2 B 2 C3 0.342
5 1750 0.15 0.3 12 1.090
A 2 B 3 C1 0.185
6 1750 0.20 0.1 9 1.364
A 3 B 1 C3 0.184
7 2000 0.10 0.3 16 0.927
A 3 B 2 C1 1.026
8 2000 0.15 0.1 11 0.784
A 3 B 3 C2 0.385
9 2000 0.20 0.2 8 0.656
MACHINING TIME (ANALYSIS OF RESULT )
TRIAL DESIGN SPEED FEED DOC MT SNRA1

1 A1B1C1 1500 0.10 0.1 21 -26.4444

2 A1B2C2 1500 0.15 0.2 14 -22.9226

3 A1B3C3 1500 0.20 0.3 11 -20.8279

4 A2B1C2 1750 0.10 0.2 18 -25.1055

5 A2B2C3 1750 0.15 0.3 12 -21.5836

6 A2B3C1 1750 0.20 0.1 9 -19.0849

7 A3B1C3 2000 0.10 0.3 16 -24.0824

8 A3B2C1 2000 0.15 0.1 11 -20.8279

9 A3B3C2 2000 0.20 0.2 8 -18.0618

OPTIMUM CONTROL FACTOR –MT

LEVEL SPEED FEED DOC

-23.40 -25.21 -22.12
1
-21.92 -21.78 -22.03
2
-20.99 -19.32 -22.16
3
2.41 5.89 0.13
DELTA
2 1 3
RANK
ANALYSIS OF VARIANCE FOR MT

%OF
SOURCE DF SEQ SS ADJ MS F P
CONTRIBUTION
2 20.667 10.3333 31.00 0.031 14
Speed
2 126.000 63.0000 189.0 0.005
Feed 85
0
2 0.667 0.3333 1.00 0.500 0
Doc
2 0.667 0.3333     1
Error
8 148.000       100
Total
SURFACE ROUGHNESSES (ANALYSIS OF
RESULT)

TRIAL DESIGN SPEED FEED DOC RA SNRA1

1 A1B1C1 1500 0.10 0.1 0.645 3.80881

2 A1B2C2 1500 0.15 0.2 0.574 4.82176

3 A1B3C3 1500 0.20 0.3 0.803 1.90569

4 A2B1C2 1750 0.10 0.2 0.921 0.71481

5 A2B2C3 1750 0.15 0.3 1.090 -0.74853

6 A2B3C1 1750 0.20 0.1 1.364 -2.69629

7 A3B1C3 2000 0.10 0.3 0.927 0.65841

8 A3B2C1 2000 0.15 0.1 0.784 2.11368

9 A3B3C2 2000 0.20 0.2 0.656 3.66192

OPTIMAL CONTROL FACTOR –RA

LEVEL SPEED FEED DOC

1 3.5121 1.7273 1.0754

2 -0.9100 2.0623 3.0662

3 2.1447 0.9571 0.6052

DELTA 4.4221 1.1052 2.4610

RANK 1 3 2
ANALYSIS OF VARIANCE FOR RA

SOURC % OF
DF SEQ SS ADJ MS F P
E CONTRIBUTION

Speed 2 0.32952 0.16476 8.11 0.110 67

Feed 2 0.02795 0.01398 0.69 0.593 6

Doc 2 0.09561 0.04780 2.35 0.298 19

Error 2 0.04065 0.02032     8

Total 8 0.49372       100

 MRR (ANALYSIS OF RESULT)

TRIAL DESIGN SPEED FEED DOC MRR SNRA1

1500 0.10 0.1 0.140 -17.0774

1 A1B1C1
1500 0.15 0.2 0.201 -13.9361
2 A1B2C2
1500 0.20 0.3 0.350 -9.1186
3 A1B3C3
1750 0.10 0.2 0.157 -16.0820
4 A2B1C2
1750 0.15 0.3 0.342 -9.3195
5 A2B2C3
1750 0.20 0.1 0.185 -14.6566
6 A2B3C1
2000 0.10 0.3 0.184 -14.7036
7 A3B1C3
2000 0.15 0.1 1.026 0.2229
8 A3B2C1
2000 0.20 0.2 0.385 -8.2908
9 A3B3C2
 MRR FORMULA
Before weight-After weight/Time taken X Density
DENSITY-7.85/gmcc

B.Weight 482 484 508 496 488 478 487 485 498

A.Weight 459 462 478 474 456 465 464 453 474
OPTIMAL CONTROL FACTOR –MRR

LEVEL SPEED FEED DOC

1 -13.377 -15.954 -10.504

2 -13.353 -7.678 -12.770

3 -7.590 -10.689 -11.047

DELTA 5.787 8.277 2.266

RANK 2 1 3
ANALYSIS OF VARIANCE FOR MRR

%OF
SOURCE DF SEQ SS ADJ MS F P
CONTRIBUTION
2 0.18302 0.09151 1.13 0.470
Speed 30
2 0.19974 0.09987 1.23 0.448
FEED 33
2 0.06811 0.03405 0.42 0.704
Doc 11
2 0.16213 0.08106    
Error 26
8 0.61300      
Total 100
 RESULT

OPTIMAL CONTROL FACTOR

Surface Roughness-A1 (Speed - 1500) B3 (Feed – 0.20) C2 (DOC –0.2)

Machining Timing- A2 (Speed - 1750) B1 (Feed – 0.10) C3 (DOC – 0.3)

Material Removal Rate- A2 (Speed - 1750) B1 (Feed – 0.10) C3 (DOC – 0.3)

PERCENTAGE OF CONTRIBUTION OF PROCESS PARAMETER

Surface Roughness- Speed- 67%

Machining Timing- feed- 61%

Material Removal Rate-Feed- 33%
 CONCLUSION

The present study investigates extensively on the aspects

related to surface roughness, parametric optimization and Taguchi
analysis in hard turning using coated carbide inserts.
• Good surface quality of roughness about 0.574 micron is
obtained during hard turning operation.
• The Minimum surface finish was obtained when depth of cut of
0.2mm, Spindle speed of 1500 RPM and feed 0.15 mm.
 REFERENCE
[1] Dilbag Singh and P.Venkateswara Rao “ A surface roughness prediction model for
hard turning process” int. J. Adv. Manuf. Technol(2007) 32 : 1115-1124
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piece hardness, feed rate and cutting speed on surface roughness and forces in finish
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[3] B. Fnides, M.A Yallese, T. Mabrouki, J. F Rigal “Surface roughness model in turning
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[4] Dr. G . Harinath Gowd, M. Gunasekhar Reddy, Bathina Sreenivasulu “ Empirical

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[5] K. Adersh Kumar et all “ Optimisation of surface roughness in face turning operation
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[6] S.B.Salvi et all “ Analysis of surface roughness in hard turning by using Taguchi
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[7] F. Puh et all “ optimization of hard turning process parameters with PCBN tool based on
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for surface roughness of AISI 8660 hardened alloy steel” Journal of mechanical
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[9] R. Ramanujam ET all “Taguchi multi machining characteristics optimization in turning

of Al-15 SiCp composites using desirability function analysis” Journal of studies of
manufacturing vol-1-2010/Iss2-3 pp120-125.
[10] A.D.Bagawade ET all “The cutting conditions on chip area ratio and surface roughness
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