APPLICATION OF TAGUCHI METHOD FOR

OPTIMIZATION OF PROCESS

PARAMETERS IN ANALYZING THE

CUTTING FORCES OF LATHE TURNING

OPERATION

Mathiselvan G∗ Sundaravel S† Sindiri Chaitanya‡

Kaja Bantha Navas R§

Abstract: A lathe tool dynamometer is a multi-component dynamometer thatis used to measure forces during the use of the machine tool. With advancementof technology, machine tool dynamometers are increasingly used for accuratemeasurement of forces and for optimization of the machining process parame-ters. The objective of this study is to illustrate the procedure adopted in usingTaguchi Method to a lathe turning operation. Depth of cut, Spindle speed,Feed rate and Tool Material were used as the process parameters where as theCutting force, Feed force and Thrust force are selected as performance charac-teristics. Orthogonal array based on design of experiments was used to conductexperiments. The degree of influence of each process parameter on individualperformance characteristic was analyzed from the experimental results obtainedusing Taguchi Method with the help of Minitab software. The signal-to-noiseratio and the analysis of variance are employed to study the performance char-acteristics on turning operation.

Keywords: Taguchi Method, Lathe Operation, Minitab, Orthoganal Array,S/N ratio

1 Introduction

In fact they have a fundamental role in the analysis, optimization and mon-itoring of a machine processes, selecting machines, tools and materials. Forces

∗mathiselvan@yahoo.com,Sathyabama University, Chennai, India†velsundarmech@gmail.com,Sathyabama University, Chennai, India‡Sathyabama University, Chennai, India§Sathyabama University, Chennai, India

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International Journal of Pure and Applied MathematicsVolume 109 No. 8 2016, 129 - 136ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu

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measurement is fundamental for the definition of optimum cutting conditions,the breakage behaviour of the process of chip formation and how they influencethe cutting forces and the machining process.

2 Literature Review

Srinivas Athreya et.al (2012) demonstrated the application of Taguchis Methodto improve the surface finish characteristics of faced components that were pro-cessed on a lathe machine. C. Velmurugan et.al(2011) investigated the effect ofparameters on metal removal rate (MRR),tool wear rate(TWR) as well as sur-face roughness(SR) with the help of Mathematical models which were developedusing the MINITAB R14 software. Mahendra J. Sable et.al(2011) fabricatedand Studied the Optimum Properties of Copper Alumina Metal Matrix Com-posites for High Temperature Applications. S. Rajakumar et.al(2011) carriedout sensitivity analysis and compared the relative impact of input parameterson tensile strength in order to verify the measurement errors on the values of theuncertainty in estimated parameters. Paulraj Sathiya et.al(2006) investigatedon the optimization and the effect of welding parameters on multiple perfor-mance characteristics (tensile strength and the metal loss) obtained by frictionwelded joints. Satyanarayana Kosaraju et.al(2012) investigating the effect ofprocess parameters on machinability performance characteristics and there byoptimization of the turning of Titanium (Grade 5) based on Taguchi method.Bala Murugan Gopalasamy et.al(2009) applied Taguchi method to find optimumprocess parameters for end milling which hard machining of hardened steel. Kr-ishankant et.al(2012) OptimizedTurning Process under the effects of MachiningParameters by the application of Taguchi Method.

3 Experimental Setup

Work piece is mounted in the chuck of the lathe headstock. The tool dy-namometer is mounted on the carriage at the place of tool holder. The toolholder is mounted on the dynamometer. Output of the dynamometer is shownin display. The natural frequency of the dynamometer is about 3 kHz and itsthreshold is smaller than 0.01 N. The output from this dynamometer is carriedby a connecting cable to the display monitor. The experiments are performedon aluminium, cutting speed (v) m/min, feed rate (f) mm/rev, depth of cut (d)and tool material to obtain the values of feed force, cutting force and thrustforce during turning in dry condition as well as minimum quantity of lubrica-tion technique. The measurements of forces were carried out using lathe tooldynamometer, shown in figure 1.

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Figure 1: Measurement of Forces using Lathe Tool Dynamometer.

4 Conducting Experiment

Taguchis L9 orthogonal array was used to design the experiments with Fourfactors and three levels. Experiments were conducted based on the Taguchismethod which is a powerful tool used in design of experiments. Taguchi ad-vocates use of orthogonal array designs to assign the factors chosen for theexperiment. The advantage of Taguchi method is that it uses a special design oforthogonal arrays to study the entire parameter space with only a small num-ber of experiments. Compared to the conventional approach of experimentation,this method reduces drastically the number of experiments that are required tomodel the response functions. The experimental results for L9 orthogonal arrayare given in table 1.

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Table 1: Experimental results for L9 Orthogonal array (Actual Values)

5 Analysis of results

5.1 Analysis of s/n ratio

Since the experimental design is orthogonal, it is then possible to separate outthe effect of each cutting parameter at different levels. For example, the meanS/N ratio for the spindle speed at levels 1, 2 and 3 can be calculated by averagingthe S/N ratios for the experiments 13, 46 and 79 respectively. The mean S/Nratio for each level of the other cutting parameters can be computed in a similarmanner. In addition, the total mean S/N ratio for all nine experiments are alsocalculated and listed in the following tables I,II,III. Regardless of the lower-the-better or the higher-the better quality characteristic, the greater the S/Nratio corresponds to the smaller variance of the output characteristics aroundthe desired value

Table 2: S/N response table for Cutting force

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Table 3: S/N response table for Feed force

Table 4: S/N response table for Thrust force

5.2 Analysis of variance

Analysis of variance (ANOVA) was introduced by Sir Ronald Fisher. Thisanalysis was carried out for a level of significance of 5Table 5. shows the resultsof ANOVA for Cutting Force. It is found that spindle speed and depth of cutare significant cutting parameters affecting cutting force. Therefore, based onS/N ratio and ANOVA analyses, the optimal cutting parameters for cuttingforce are the depth of cut at level 3, the spindle speed at level 3 and the feedrate at level 1.

Table 5: Results of ANOVA for Cutting force

Table 6. shows the results of ANOVA for Cutting Force. It is found thatdepth of cut is most significant cutting parameter and both spindle speed andfeed rate are less significant parameters affecting feed force. Therefore, based onS/N ratio and ANOVA analyses, the optimal cutting parameters for feed forceare the depth of cut at level 3, the spindle speed at level 2 and the feed rate atlevel 3.

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Table 6: Results of ANOVA for Feed force

Table 7. shows the results of ANOVA for Cutting Force. It is found thatspindle speed and depth of cut are equally significant and feed rate is the mostsignificant cutting parameter affecting thrust force. Therefore, based on S/Nratio and ANOVA analyses, the optimal cutting parameters for cutting forceare the depth of cut at level 3, the spindle speed at level 3 and the feed rate atlevel 1.

Table 7: Results of ANOVA for Thrust force

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Figure Graph1: Main effects plot for SN ratio.

Spindle Speed :- The effect of parameters spindle speed on the cutting forcesis shown above figure for S/N ratio. Its effect is increasing with increase inspindle speed upto 370 RPM beyond that it is decreasing. So the optimumspindle speed is level 3 i.e. 450 RPM.

Feed Rate :- The effect of parameters feed rate on the cutting forces is shownabove figure S/N ratio. Its effect is decreasing with increase in feed rate. So theoptimum feed rate is level 3 i.e. 0.53 mm/rev.

Depth of Cut :- The effect of parameters depth of cut on the cutting forces isshown above figure for S/N ratio. Its effect is decreasing with increase in depthof cut. So the optimum depth of cut is level 3 i.e.,1.0 mm.

6 Conclusion

This paper illustrates the application of the parameter design ”Taguchi method”in the optimization of turning operation. It is found that the parameter designof the Taguchi method provides a simple, systematic, and efficient methodologyfor optimizing the process parameters.

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7 References

[1] Bala Murugan Gopalasamy, Biswanath Mondal, Sukamal Ghosh, Taguchimethod and ANOVA : An approach for process parameters optimization of hardmachining while machining hardened steel.

[2] C.Velmurugan, R.Subramanian, S.Thirugnanam, B.Ananadavel, Exper-imental investigations on machining characteristics of Al 6061 hybrid metalmatrix composites processed by electrical discharge machining.

[3] Krishnaiah K and Shahabudeen (2012), Applied Design of Experimentsand Taguchi Methods, PHI learning Private Limited, New Delhi.

[4] Krishankant, Jatin Taneja, Mohit Bector, Rajesh Kumar, Application ofTaguchi Method for Optimizing Turning Process by the effects of MachiningParameters.

[5] Mahendra J. Sable, Vipin K. Tripathi, Fabrication and Study of OptimumProperties of Copper Alumina Metal Matrix Composites for High TemperatureApplications.

[6] Mantgomery D.C (2003), Design and Analysis of Experiments, John Wileyand Sons.

[7] Panneerselvam R (2004), Research Methodology, Prentice Hall of India,New Delhi, India.

[8] Paulraj Sathiya, S. Aravindan, A. Noorul Haq, Optimization for frictionwelding parameters with multiple performance characteristics.

[9] S. Rajakumar, C.Muralidharan, V.Balasubramanian, Optimisation andsensitivity analysis of friction stir welding process and tool parameters for joiningAA1100 aluminium alloy.

[10] Satyanarayana Kosaraju, Venu Gopal Anne and Bangaru Babu Popuri,Taguchi Analysis on Cutting Forces and Temperature in Turning Titanium Ti-6Al-4V.

[11] Srinivas Athreya, Dr Y.D.Venkatesh, Application Of Taguchi Method ForOptimization Of Process Parameters In Improving The Surface Roughness OfLathe Facing Operation.

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