Prod. Eng. Res. Devel. (2009) 3:3140 DOI 10.

1007/s11740-008-0132-2

PRODUCTION PROCESS

Estimating the effect of cutting parameters on surface nish and power consumption during high speed machining of AISI 1045 steel using Taguchi design and ANOVA
Anirban Bhattacharya Santanu Das P. Majumder Ajay Batish

Received: 16 April 2008 / Accepted: 12 August 2008 / Published online: 2 September 2008 German Academic Society for Production Engineering (WGP) 2008

Abstract The present paper outlines an experimental study to investigate the effects of cutting parameters on nish and power consumption by employing Taguchi techniques. The high speed machining of AISI 1045 using coated carbide tools was investigated. A combined technique using orthogonal array and analysis of variance was employed to investigate the contribution and effects of cutting speed, feed rate and depth of cut on three surface roughness parameters and power consumption. The results showed a signicant effect of cutting speed on the surface roughness and power consumption, while the other parameters did not substantially affect the responses. Thereafter, optimal cutting parameters were obtained. Keywords High speed machining Surface roughness Power consumption Taguchi design ANOVA

1 Introduction 1.1 High speed machining Development of machine tools and cutting tools during the last few decades have given the scope to opt for high speed machining not only for higher material removal rate but also for the reduction of machining cost, lead time, number
A. Bhattacharya (&) A. Batish Mechanical Engineering Department, Thapar University, Patiala 147004, Punjab, India e-mail: anb90_bank@yahoo.co.in; abhattacharya@tiet.ac.in S. Das P. Majumder Mechanical Engineering Department, Kalyani Government Engineering College, Kalyani 741235, West Bengal, India

of necessary machine tools, improvement in surface quality and complete elimination of nishing operations in most cases. The manufacturing industry is constantly striving to decrease its cutting costs and increase the quality of the machined parts as the demand for high tolerance manufactured goods is rapidly increasing. Several experimental investigations have been carried out over the years in order to study the effect of cutting parameters, tool geometries and cutting uids on the workpiece surface integrity using several workpiece materials. Modeling of cutting processes for surface nish and tool wear has also been carried out by the researchers [1]. The effect of cryogenic cooling has been investigated [24] for different steels with coated and uncoated carbide tools under normal cutting conditions. Investigations of orthogonal turn-milling towards a better surface nish have also been studied [5]. Economic benets of nish turning using coated carbide tools [6] have been investigated to identify the most cost effective combination of cutting speed, feed and tool material for a nish turning operation, with useful tool life being taken when the surface roughness deteriorated beyond a predetermined level. Today, following the trends in development of high speed machining, dry machining is often considered desirable to avoid the extra costs and environmental problems associated with cutting uids. Furthermore, at high cutting speeds, the cutting uid is thrown outside the cutting area because of the high rotational speed of the job or the tool. High speed machining of hardened steel has the potential to give a sufciently high quality of the machined surface to make nishing operations such as grinding and polishing unnecessary [7, 8]. Both cases tend to intensify the heat generation along the tool surfaces, and consequently the tools must possess enhanced thermal and chemical stability. Therefore, high speed machining is not only ideal for higher metal removal but also for favorable

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chip formation, reduced burr formation and desired surface quality [9]. Increased speed is often needed for reducing the cutting force, which aids in the machining of especially small parts with less dimensional deviation and vibration [10]. On the contrary, high speed machining will lead to a demand for the development of improved cutting materials [11], rigid and high power machine tools and a reduction in the heat generated at the cutting surface. High speed machining will also cause rapid tool wear [12], increased vibration, and higher power consumption. But a signicant advantage of high speed machining is that at high speed and feed, the chip is cut and removed so fast that it tends to transfer no or little heat to the work piece, leading to little possibility of thermal distortion [13]. Therefore an investigation for understanding the effect of cutting parameters, i.e. cutting speed, feed and depth of cut on the workpiece surface nish during high speed cutting at dry cutting conditions is needed. As the higher cutting speed is employed for higher material removal, or achieving better nish, the machine tool power consumption will increase. In the present work, an attempt has been made to evaluate the contribution of cutting parameters during high speed machining on the workpiece surface nish and corresponding machine power consumption using Taguchis Orthogonal Array Design and Analysis of Variance (ANOVA). The experiments were carried out taking AISI 1045 steel as the workpiece material and coated carbide tool for turning. The cutting speed was varied from a minimum of 58 m/min to a maximum of 240 m/min at four different levels and feed and depth of cut was also been varied to four levels. 1.2 Taguchi design Taguchi has developed a methodology for the application of factorial designed experiments that has taken the design of experiments from the exclusive world of the statistician and brought it more fully into the world of manufacturing. His contributions have also made the practitioners work simpler by advocating the use of fewer experimental designs, and providing a clearer understanding of the nature of variation and the economic consequences of quality engineering in the world of manufacturing. Taguchi introduces his approach, using experimental design for [14]: designing products/processes so as to be robust to environmental conditions; designing and developing products/processes so as to be robust to component variation; minimizing variation around a target value.

is the use of parameter design, which is an engineering method for product or process design that focuses on determining the parameter (factor) settings producing the best levels of a quality characteristic (performance measure) with minimum variation. Taguchi designs provide a powerful and efcient method for designing processes that operate consistently and optimally over a variety of conditions. To determine the best design requires the use of a strategically designed experiment which exposes the process to various levels of design parameters. The purpose of experimentation should be to reduce and control variation of a product or a process; subsequently, decisions must be made regarding which parameters affect the performance of a product/process. Since variation is a large part of the discussion relative to quality, analysis of variation (ANOVA) is the statistical method used to interpret experimental data and make necessary decisions [14]. ANOVA is a statistically based decision tool for detecting any differences in average performance of groups of items tested. ANOVA is a mathematical technique which breaks total variation down into accountable sources; total variation is decomposed into its appropriate components. There have been plenty of recent applications of Taguchi techniques to materials processing for process optimization [1519]. Statistical methods and Taguchis technique was used for investigating machinability [20], and optimizing power consumption [21]. In another study, it was observed that power consumption is one of the most important parameters for condition monitoring [22]. The study revealed that when cutting uid is used, cryogenic environment is the most signicant factor in minimizing power consumption followed by cutting speed and depth of cut [21]. The effects of feed rate and nose radius were found to be insignicant compared to other factors.

2 Experimental technique 2.1 Experimental setup The experimental investigation presented here was carried out on a Kirloskar lathe with 5 kW power rating. The workpiece used for investigation was AISI 1045 steel, with chemical composition of 0.5% carbon, 0.15% silicon, 0.6% manganese, 0.05% sulphur and 0.04% phosphorus. AISI 1045 steels are most commonly used for all forms of close tolerance shafting, e.g. hydraulic shaft, pump shaft, piston rods, sprockets and springs, cylinders, cams, crank shafts, keys, small arm parts, etc. A precisely prepared machined/ ground and polished shafting, seam free surface nish is rst induction hardened to a case depth of 1.272.28 mm (0.05000 to 0.09000 ) resulting in a minimum surface hardness

Taguchi techniques have been widely used in engineering design. The main thrust of the Taguchi techniques

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of approximately Rockwell C 50. This imparts the necessary properties to the bar as the extra hardness ensures superior wear resistance. The bars are hard chromed in the same manner as chrome plated shafting thus allowing the same advantageous corrosion and wear resistance, but with the induction hardening, the bars give superior service. This necessitates the requirement of a high nished product. In this experiment, in order to investigate the surface nish of the machined workpiece and machine tool power consumption, during cutting of the AISI 1045 steel, a multilayered coated (TiC and TiN) tungsten carbide tool was used. A view of the cutting zone arrangement is shown in Fig. 1. The surface roughness of the nished work surface was measured with the help of a surface roughness tester. The material, characteristics of tool and detail of experimental design set-up are listed in Table 1. 2.2 Experimental design A fully factorial experiment uses all the possible combinations of a number of factors at their respective test levels to arrive at an outcome. But more efcient test plans, as developed by statisticians, fractional factorial experiments (FFEs) use only a portion of the total combinations to estimate the main factor effects and some, not all, of the interactions. Certain treatment conditions are chosen to

Fig. 1 View of the cutting zone

Table 1 Experimental set-up and conditions Machine tool Work piece Cutting condition Cutting tool Tool material Tool geometry (NRS) Tool holder Surface roughness tester Kirloskar Lathe, 5 kW power rating AISI 1045 steel (L/D = 3) Dry SNMG 120408 (Sandvik make) Coated carbide (P-1025 series) -6, -6, 6, 6, 15, 75, 0.8 mm R174-3-2020-12 (Sandvik, TmaxP) SURFTEST 301 (Mitutoyo Make)

maintain the orthogonality among the various factors and interactions. According to Taguchi, depending upon number of levels in a factor, a 2 or a 3 level Orthogonal Array (OA) can be selected. In this situation a possible matrix is a 16 trial OA which is labeled as L16 matrix. One can observe that there are 15 columns in this array which may have a factor assigned to each column. The 16 trials provide 15 degrees of freedoms (dofs) for the entire experiment allocated to 15 columns of two levels, each column with one dof. Such an array allows all the error dofs to be traded for factor dofs and provide the particular test combinations that accommodate that approach. It can be seen that each column provide eight tests under level 1 and eight tests under level 2. This is the feature that provides orthogonality to the experiment. In this experimental design, the original OA was modied to test each factor at four levels. Since a four level factor would require three dofs, three mutually interactive columns were merged. The three merged columns provided for the necessary dofs in this experimental study. This is the real power of OA, i.e. the ability to evaluate several factors in a minimum of tests. This is called an efcient experiment since much information is obtained from few trials. The factors that were thought to inuence the response were: A, cutting speed; B, Feed rate; and C, depth of cut (doc). These factors were evaluated over four levels each to adequately cover the entire range available by the machine tool. Table 2 shows the factors and their corresponding level assignment. The assignment of factors to a saturated design FFE is not difcult; all columns are assigned a factor. However, the experiments which are not fully saturated (when all columns cannot be assigned factors) may be more complicated to design. Taguchi has provided two tools to aid in assignment of factors and interactions to arrays. These are (1) linear graphs and (2) triangular tables. Each OA has a particular set of linear graphs and triangular tables associated with it. The linear graphs indicate various columns to which factors may be assigned and the columns subsequently evaluate the interaction of these factors. The triangular tables contain all the possible interactions between factors (columns). There are various simple roughness amplitude parameters that are commonly specied to designate the surface nish. Out of those, three most common and signicant parameters were considered here in this experiment and measured to quantify the surface quality. These are average surface roughness (Ra), root-mean-square or r.m.s. roughness (Rq), and maximum peak-to-valley roughness (Rt or Rmax). A hole was drilled on the face of the workpiece to allow it to be supported at the tailstock (Fig. 1). A pre-cut with a

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1 mm depth of cut was performed on each work piece prior to actual turning using a different coated carbide tool. This was done in order to remove the rust layer or hardened top layer from the outside surface and to minimize any effect of inhomogeneity on the experimental results. After each test, once the cut for a specied time was over, the roughness (in a direction across the lay) of the nished worksurface was measured by placing the circular workpiece on a magnetic V-block over a granite surface plate. Each test, with a particular process condition, was carried out using a new cutting tool edge. Then after collecting all the data for all combinations, analysis of variance (ANOVA) was carried out, the contribution of each factor was calculated and the best parametric level along with condence intervals were established.

3 Results and discussion Experiment was conducted to assess the effect of cutting speed, feed rate and depth of cut on the surface nish and machine power consumption. Table 3 illustrates the experimental results of Ra, Rq and Rt and power consumption. 3.1 Analysis of variance (ANOVA) The experimental results were analyzed using analysis of variance (ANOVA) for identifying the signicant factors affecting the performance measures. The results of ANOVA for the surface roughness of Ra, Rq and Rt are shown in Tables 4, 5 and 6, respectively. The ANOVA result for the

Table 2 Assignment of the levels to the factors

Factors Cutting velocity (A) Feed rate (B) Depth of cut (C)

Unit m/min mm/rev mm

Level-1 58 0.045 1

Level-2 96 0.100 1.2

Level-3 151 0.125 1.5

Level-4 240 0.160 2

Table 3 Experimental results following L16 orthogonal array

L16 Orthogonal array Expt. no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Cutting speed (A) 58 58 58 58 96 96 96 96 151 151 151 151 240 240 240 240 Feed rate (B) 0.045 0.1 0.125 0.16 0.045 0.1 0.125 0.16 0.045 0.1 0.125 0.16 0.045 0.1 0.125 0.16 DOC (C) 1 1.2 1.5 2 1.2 1 2 1.5 1.5 2 1 1.2 2 1.5 1.2 1

Performance measurements or response Ra (lm) 3.96 4.23 3.9 4.84 2.79 2.82 3.13 3.27 2.31 2.66 2.56 3.97 2.15 1.57 1.3 1.49 Rq (lm) 4.83 4.91 4.93 6.34 3.4 3.5 2.11 3.86 2.99 3.12 3.18 4.69 2.64 1.83 1.68 1.87 Rt (lm) 19.3 21.2 23.6 29.03 15.77 16.43 20.01 17.57 18.7 16.17 14.2 18.8 12.1 11.47 10.15 9.13 Power (W) 519.2 457.8 492.04 512.6 490.5 525.6 578.6 558.8 627.2 675.7 580.8 527.6 692 689.07 647.46 780.5

Table 4 ANOVA result for workpiece surface roughness Ra (lm) [95% condence level, Fcritical Source Cutting speed, A (m/min) Feed, B (mm/rev) Depth of cut, C (mm) Error Total SS 13.6049 1.14097 0.67207 0.97329 16.3912 DOF 3 3 3 6 15 Variance 4.53496 0.38032 0.22402 0.16221 F

(5, 3, 6)]

F(critical) 4.76 4.76 4.76

C (%) 83.001 6.9609 4.1002 5.9379 100

27.957 2.3446 1.381

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Prod. Eng. Res. Devel. (2009) 3:3140 Table 5 ANOVA result for workpiece surface roughness Rq (lm) [95% condence level, Fcritical Source Cutting speed, A (m/min) Feed, B (mm/rev) Depth of cut, C (mm) Error Total SS 21.5436 3.1133 0.25985 2.4424 27.3591 DOF 3 3 3 6 15 Variance 7.18118 1.03777 0.08662 0.40707 F 17.641 2.5494 0.2128
(5, 3, 6)]

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F (critical) 4.76 4.76 4.76

C (%) 78.744 11.379 0.9498 8.9272 100

power consumption is shown in Table 7. This analysis was carried out for a signicance level of a = 0.05 (condence level of 95%). Tables 4, 5, 6 and 7 shows the realized signicance levels, associated with the F tests for each source of variation. The last columns of the tables show the percent contribution of signicant source to the total variation indicating the degree of inuence on the result. The principle of the F test is that the larger the F value for a particular parameter, the greater the effect on the performance characteristic due to the change in that process parameter. In Tables 4, 5 and 6, the ANOVA result shows that the F value for the factor cutting speed (factor A) is larger than that of the other two cutting parameters, i.e., the largest contribution to the workpiece surface nish parameters (Ra, Rq, and Rt) is due to the cutting speed. The portion of the total variation observed in the experiment attributed to each signicant factor is reected by the percent contribution in the last column of the tables. Cutting speed (the most signicant factor) contributed 83% for Ra, 78.7% in the case of Rq, and 79% for Rt. The percent contribution of the second most signicant factor feed rate (factor B) was found to be only 7% for roughness parameter Ra and 11% for Rq. But for Rt the second most signicant factor was found to be depth of cut with a contribution of 11.3%. The error contribution is 5.9%,

8.9% and 6.2% for Ra, Rq and Rt, respectively. As the percent contribution due to error is very small it signies that neither any important factor was omitted nor any high measurement error was involved [14]. Therefore, for the workpiece surface nish (in case of all the three parameters Ra, Rq and Rt) cutting speed was found to be the only signicant parameter with percent contribution of up to 83%, followed by feed rate which contributed a maximum of 11.4%. However, for Rt depth of cut contributes higher than feed with a contribution of 11.3%. Table 7 shows the ANOVA results for the power consumption by the machine motor. The results of the F test clearly indicate that the cutting speed is the most signicant factor compared to the other two factors, and that the depth of cut was found to be the second most signicant factor. The percent contribution gives a better understanding for the interpretation of the results, which shows that the contribution due to the cutting speed is 77.5% whereas the depth of cut contributes only 13.2%. The error contribution was 8.6%. 3.2 Main effect plot The main effect plot for the three different surface parameters Ra, Rq and Rt has been shown in Figs. 2, 3, 4
(5, 3, 6)]

Table 6 ANOVA result for workpiece surface roughness Rt (lm) [95% condence level, Fcritical Source Cutting speed, A (m/min) Feed, B (mm/rev) Depth of cut, C (mm) Error Total SS 316.64 13.492 45.3544 24.8903 400.377 DOF 3 3 3 6 15 Variance 105.547 4.49734 15.1181 4.14839
(5, 3, 6)]

F 25.443 1.0841 3.6443

F(critical) 4.76 4.76 4.76

C (%) 79.086 3.3698 11.328 6.2167 100

Table 7 ANOVA result for power consumption (W) [95% condence level, Fcritical Source Cutting speed, A (m/min) Feed, B (mm/rev) Depth of cut, C (mm) Error Total SS 97,068 858.572 16542.3 10829.5 125,298 DOF 3 3 3 6 15 Variance 32,356 286.191 5514.09 1804.92

F 17.927 0.1586 3.055

F (critical) 4.76 4.76 4.76

C (%) 77.469 0.6852 13.202 8.643 100

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and that for power consumption in Fig. 5. The plots show the variation of individual response with the three parameters, i.e. cutting speed, feed rate and depth of cut separately. In the plots, the x-axis shows the values of each parameter at four levels and y-axis the response values. Horizontal line in the plot shows the mean value of the responses. Figure 2 shows the main effect plot for workpiece surface roughness Ra for cutting speed, feed rate and depth of cut. The results show that with the increase in cutting speed there is a continuous decrease in surface roughness value. A cutting speed of 58 m/min produces the

highest roughness and 240 m/min cutting speed shows the lowest one, i.e. the best surface nish. In the gure the almost at line variation indicates that there is a very little or virtually no effect due to feed rate and depth of cut. Figure 3 shows the main effect plot for rms roughness parameter, Rq. Here also, the main effect plot shows the decrease in roughness with increased cutting speed. At 58 m/min the maximum rms roughness was observed whereas a cutting speed of 240 m/min shows the lowest roughness. Feed rate and doc again shows very little effect on the rms roughness, Rq which is shown by almost a at

Main Effect Plot for W/P Surface Roughness, Ra (micron)

6.0 4.5 3.0 1.5 0.0 58 6.0 4.5 3.0 1.5 0.0 1.0 1.2 1.5 2.0 96 151 240 0.045 0.100 0.125 0.160

Cutting Speed (m/min)

Feed Rate (mm/rev)

Mean

DOC (mm)

Fig. 2 Main effect plot for workpiece surface roughness Ra (lm)

Fig. 3 Main effect plot for workpiece surface roughness Rq (lm)

Main Effect Plot for W/P Surface Roughness, Rq (micron)

8 6 4 2

Cutting Speed (m/min)

Feed Rate (mm/rev)

Mean

0 58 8 6 4 2 0 1.0 1.2 1.5 2.0 96 151 240 0.045 0.100 0.125 0.160

DOC (mm)

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line. Figure 4 shows the main effect plot for peak-to-valley roughness, Rt. From Figures 2, 3 and 4, it is interesting to note that after a very high feed value, the surface roughness (Ra, Rq, Rt) starts to increase. This tendency appears at the highest feed value of 0.16 mm/rev. Figure 5 shows the main effect plot for power consumption by the machine. The plot shows the power consumption continuously increases with increase in cutting speed. The at line for the feed rate clearly shows the nil variation (0.6% contribution, refer Table 7) due to feed rate and a very small increase in power with depth of cut. Increase in depth of cut increases the power consumption
Cutting Speed (m/min)

but Fig. 5 shows that for depth of cut of 1.0 mm at 58 m/ min cutting speed there is a hike in power consumption. This clearly indicates the existence of built-up-edge which was formed at the lowest cutting speed when doc is also lower. As b-u-e diminishes at relatively higher cutting speed because of the less time available for the workpiece material to adhere or weld temporarily on the tool tip, the power consumption falls down and again increases as usual with increased depth of cut. All the main effect plots show that the major effect on the responses is due to cutting speed and very little effect due to feed rate and depth of cut. For all the Figs. 2, 3 and 4
Feed Rate (mm/rev)

Main Effect Plot for W/P Surface Roughness, Rt (micron)

30

20

10

Mean

0 58 30 96 151 240 0.045 0.100 0.125 0.160

DOC (mm)

20

10

1.0

1.2

1.5

2.0

Fig. 4 Main effect plot for workpiece surface roughness Rt (lm) Fig. 5 Main effect plot for machine power consumption (W)

Main Effect Plot for Power Consumption,(Watt)

800 600 400 200

Cutting Speed (m/min)

Feed Rate (mm/rev)

Mean

0 58 800 600 400 200 0 1.0 1.2 1.5 2.0 96 151 240 0.045 0.100 0.125 0.160

DOC (mm)

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the higher roughness value are produced at lower cutting speed (58 m/min) and an increase in cutting speed reduces the roughness parameters with a lowest value achieved at highest cutting speed of 240 m/min. 3.3 Optimal design Typically the experimenter would like to obtain some particular response from a product or a process; a higher average response is better (HB), a nominal value is best (NB), or a lower average response is better (LB). Depending on the characteristic, different treatment conditions will be chosen to obtain satisfactory results. The lower the better response is used for situations where the target value is zero. Surface roughness measured on a part is one such response parameter used in this case. The higher the better response is used when the largest value is desired, such as weld strength, fuel mileage or yield. The plots of the signicant factors shown in Figs. 2, 3 and 4 can be used to estimate the mean surface roughness with optimal design conditions. Since there are two signicant factors in this experiment, plots were used to establish their most useful levels to give a smaller roughness value. Factor A, (cutting velocity) when set at 240 m/ min (Level 4) and Factor B (feed rate) when set at 0.125 mm/rev (Level 3) gave the smallest roughness values. The procedure of estimating the mean value depends upon the additivity of the factorial effects. If one factorial effect can be added to another to accurately predict the result, then good additivity exists. Since no interaction exists between the two main factors the factors could be added to obtain a lower roughness value. When surface roughness Ra is considered, from Table 8, an estimated average when the two most signicant factors are at their better level is lA4 B3 A4 B3 T 1:416 The 95% condence interval for the surface roughness Ra is from Table 3; T 2:934 1:6275 2:7225 2:934

r F95%;1; dof error Verror CI neff N where neff 1 dof associated to that level 16 2:28571 F95%;1;6 5:99 and neff 133 Verror 0:16221 from Table 4 r 5:99 0:16221 Thus; CI 0:652 2:28571 Finally, the estimated average with the condence interval at 95% condence (when the two most signicant factors are at their better level) is 1:416 0:652 lA4 B3 0:764 1:416 0:652 lA4 B3 2:068

Similarly, when roughness parameter Rq is concerned, estimated average is at A4B3 level. Then, lA4 B3 A4 B3 T from Table 3; T 3:4925 2:005 2:975 3:4925 1:4875 The 95% condence interval for the surface roughness Rq is F95%;1;6 5:99 and neff 2:28571;

Verror 0:40707 from Table 5 Thus; CI 1:033 Finally, the estimated average with the condence interval at 95% condence (when two most signicant factors are at their better level) is 0:4545 lA4 B3 2:5205

Again, when roughness parameter Rt is concerned, estimated average is at A4C1 level. Then, lA4 C1 A4 C1 T from Table 3; T 17:102 10:7125 14:765 17:102 8:3755 The 95% condence interval for the surface roughness Rt is

Table 8 Mean values for each factor at each level for different roughness parameter Level Roughness Ra (lm) " A 1 2 3 4 4.2325 3.0025 2.875 1.6275 " B 2.8025 2.82 2.7225 3.3925 " C 2.7075 3.0725 2.7625 3.195 Roughness Rq (lm) " A 5.2525 3.2175 3.495 2.005 " B 3.465 3.34 2.975 4.19 " C 3.345 3.67 3.4025 3.5525 Roughness Rt (lm) " A 23.2825 17.445 16.9675 10.7125 " B 16.4675 16.3175 16.99 18.6325 " C 14.765 16.48 17.835 19.3275

Bold values indicate the levels of the signicant factors for which the best result obtained and the optimal design are calculated

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F95%;1;6 5:99 and neff 2:28571; Verror 4:14839 from Table 6 Thus; CI 3:297 Finally, the estimated average with the condence interval at 95% condence (when two most signicant factors are at their better level) is 5:08 lA4 C1 11:67: As of surface roughness parameters when the mean values for each factor at each level for the machine power consumption is calculated and tabulated, Table 9 resulted. Table 10 provides the comparative data of factors and levels which affect the various roughness responses as well as those which affect the power consumption. In this case, the different levels of two of the three signicant factors provide a lower roughness response as well as lower power consumption leading to a conict so a compromise has to be reached. As could be seen in the table, level 4 for factor A provides for the lowest roughness values but leads to highest power consumption. Same is true for factor C, where level 1 provides for lower roughness values and level 2 provides for lower power consumption. Factor B however, has no effect on power consumption and should always be set at level 3. In this situation, the levels of factors which reduce the roughness and power consumption are conicting, so a compromise has to be reached depending upon specic work requirements. It could also be seen that if Rt value is not of prime concern, the depth of cut should be set at level 2 as it reduces the power consumption at this process setting. The estimated point calculation for power consumption as a lower the best response has been calculated as under

lA1 C2 A1 C2 T from Table 3; T 584:7 495:41 530:84 584:7 441:55 F95%;1;6 5:99 and neff 2:28571; Verror 1804:92 from Table 7 Thus; CI 68:78 Finally, the estimated average with the condence interval at 95% condence (when the two most signicant factors are at their better level) is 372:77 lA1 C2 510:33.

4 Conclusion In this study, two of the three machining parameters (namely cutting velocity, feed rate and depth of cut) were positively correlated with surface roughness. The study showed that with increase in cutting velocity the roughness response value was decreased. Factorial designs are widely used in experiments involving several factors to identify the main and the interaction effects of different factors on the response pattern. In factorial design, the main effect averages the impact of the treatments of one factor across the treatment levels of other factors. The interaction effects are dened as the average effects of the simultaneous variation of different factors. The magnitude and the direction of these factors effects help to determine the relative importance of the factors. In this study, analysis of variance (ANOVA) was used to conrm these interpretations. From the plots of main factors (Figs. 2, 3, 4, 5) and F test of the factors and their interactions (Tables 4, 5, 6, 7), it was interpreted that main effects were prominent in determining the average roughness response and power consumption. Also the results indicated little or no interaction between the main factors on the dependent variable. Cutting speed was found to be the most signicant parameter for the work piece surface roughness (Ra, Rq and Rt) with a percent contribution of 83% in bringing down the average roughness values. The contribution of feed rate was observed to be 6.9% and 11.4% for roughness parameter Ra and Rq, respectively, and depth of cut was found to be a signicant factor for Rt with a contribution of 11.3%. The error contribution was observed to be 8.9%

Table 9 Mean values for each factor at each level for power consumption Level 1 2 3 4 " A 495.41 538.375 602.825 702.2575 " B 582.225 587.0425 574.725 594.875 " C 601.525 530.84 591.7775 614.725

Bold values indicate the levels of the signicant factors for which the best result obtained and the optimal design are calculated

Table 10 Factor affects and their optimum levels Factor Effects surface roughness Ra A: Cutting velocity, m/min B: Feed rate, mm/rev C: Depth of cut, mm Level 4 Level 3 Rq Level 4 Level 3 Level 1 Level 2 Rt Level 4 Level 1 Effects power consumption

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Prod. Eng. Res. Devel. (2009) 3:3140 6. Gillibrand D, Sarwar M, Pierce CT (1996) The economic benet of nish turning with coated carbide. J Surf Coat Technol 86 87(2):809813. doi:10.1016/S0257-8972(96)03059-9 7. Sundaram RM, Lambert BK (1979) Surface roughness variability of AISI 4140 steel in ne turning using carbide tools. Int J Prod Res 17:249258. doi:10.1080/00207547908919612 8. Tonshoff HK, Wobker HG, Brandt D (1995) Hard turning inuence on the workpiece properties. Trans NAMRI/SME 23:215220 9. Tonshoff HK, Wobker HG, Brandt D (1996) Tool wear and surface integrity in hard turning. J Prod Eng 3(1):1924 10. Abaro AM, Apinwall DK, Wise MLH (1995) Tool life and workpiece surface integrity evaluations when machining hardened AISI H13 and AISI E52100 Steels with conventional ceramic and PCBN tool materials. SME technical paper, pp 159 11. Noordin MY, Venkatesh VC, Chan CL, Abduallah A (2001) Performance evaluation of cemented carbide tools in turning AISI 1010 steel. J Mater Process Technol 116:1621. doi: 10.1016/S0924-0136(01)00838-X 12. Luk WK, Scrutton RF (1986) The origin of groove wear in the turning operation. Int J Prod Res 6:197206. doi:10.1080/ 00207546708929780 13. Trent EM, Wright Paul K Metal Cutting. Butterworth Heinemann, New York 14. Ross PJ. Taguchi techniques for quality engineering. McGrawHill, New York 15. Yang WH, Tarng YS (1998) Design optimization of cutting parameters for turning operations based on the Taguchi method. J Mater Process Technol 84:122129. doi:10.1016/S0924-0136 (98)00079-X 16. Nian CY, Yang WH, Tarng YS (1999) Optimization of turning operations with multiple performance characteristics. J Mater Process Technol 95:9096. doi:10.1016/S0924-0136(99)00271-X 17. Davim JP (2003) Design optimization of cutting parameters for turning metal matrix composites based on the orthogonal arrays. J Mater Process Technol 132:340344. doi:10.1016/S0924-0136 (02)00946-9 18. Nalbant M, Gokkaya H, Sur G (2007) Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning. J Mater Des 28(4):13791385 19. Ersan A, Necip C, Burak B (2007) Design optimization of cutting parameters when turning hardened AISI 4140 steel (63 HRC) with Al2O3 ? TiCN mixed ceramic tool. J Mater Des 28(5): 16181622 20. Davim J (2007) Paulo, Figueira Lus Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques. J Mater Des 28(4):11861191 21. Aman A, Hari S, Pradeep Kumar, Manmohan S. Optimizing power consumption for CNC turned parts using response surface methodology and Taguchis techniquea comparative analysis, J Material Process Technol, 2007, online 22. Faleh A (2005) Al-Sulaiman M, Baseer A, Sheikh Anwar K Use of electrical power for online monitoring of tool condition. J Mater Process Technol 20:364371

thereby suggesting that no important factor were missed and measurement error was also negligible. Other factors like tool geometry, tool materials, application and effect of coolant, etc. were kept as constant and not studied in this experimental work. The most optimal results for surface roughness were observed when the cutting speed was set at 240 m/min and feed rate of 0.125 mm/rev. However, for Rt, doc was another signicant factor to be set at 1 mm. Conicting results were obtained when measuring the power consumption with other levels of the same contributing factors reduced the power consumption. Cutting speed was once again observed to be most signicant factor to reduce the power consumption during these machining trials with a contribution is 77.4%, followed by the depth of cut (13.2%). The feed rate has no signicant affect on the power consumption and thus should be set at a level which is most appropriate and most economical. This study thus concluded that higher cutting speeds provide for higher surface nish, but will lead to higher power consumption. Thus a compromise must be arrived depending upon the accuracy requirements on the part to be machined and economic requirements. At lower depth of cut and at lower cutting speed, formation of built-up-edge is found and this lead to a higher machine power consumption.

References
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