Application of Taguchi Method for Optimization of Parameters in Turning Operation

2016 ◽  
Vol 16 (3) ◽  
pp. 183-187 ◽  
Author(s):  
B. Singaravel ◽  
T. Selvaraj
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Cutting Tool ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Optimum Level ◽  
Turning Process ◽  
Tool Vibration ◽  
Machining Characteristics

AbstractCutting tool vibration analysis is the effective way to understand the machining characteristics of any material. In the present work, the effect of process parameters on cutting tool vibration is estimated using Taguchi method in turning of EN25 steel. Taguchi method uses Signal-to-Noise ratio (S/N) and Analysis of Variance (ANOVA) to determine the optimum level of process parameters and significant parameters. The results showed that cutting speed of 215 m/min, feed rate of 0.07 mm/rev and depth of cut of 0.5 mm are the optimum combination of process parameters. Cutting speed and depth of cut are the influencing parameters on cutting tool vibration. The results are experimentally verified and the results based on turning process response can be effectively improved.

Analysis of tool vibration and surface roughness during turning process of tempered steel samples using Taguchi method

2021 ◽  
pp. 095440892110019
Author(s):  
Menderes Kam ◽  
Mustafa Demirtaş
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Turning Process ◽  
Machining Time ◽  
Tool Vibration ◽  
Control Factors ◽  
Tempered Steel

This study analyzed the tool vibration (Vib) and surface roughness (Ra) during turning of AISI 4340 (34CrNiMo6) tempered steel samples using Taguchi Method. In this context, Taguchi design L18 (21 × 32) was used to analyze the experimental results. The vibration amplitude values from cutting tools were recorded for different machining parameters, control factors; two different sample hardness (46 and 53 HRc), three different cutting speeds (180, 220, 260 m.min−1), and feed rates (0.08, 0.14, 0.20 mm.rev−1) were selected. The machining parameters giving optimum Vib and Ra values were determined. Regression analysis is applied to predict values of Vib and Ra. Analysis of variance was used to determine the effects of machining parameters on the Vib and Ra values. The most important machining parameters were found to be the feed rate, sample hardness, and cutting speed for Vib and Ra, respectively. The lowest Vib and Ra values were obtained in 46 HRc sample as 0.0022 gRMS and 0.255 µm, respectively. The surface quality can be improved by reducing the sources of vibration by using appropriate machining parameters. As a result, there is a significant relationship between Ra and Vib. The lower Ra values were found during turning process of tempered steel samples according to the literature studies. It is suggested that the process can be preferred as an alternative process to grinding process due to lower cost and machining time. In application of the turning of experiment samples by ceramic cutting tool, a substantial technological and economical benefit has been observed.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

scholarly journals Effects of Process Parameters On Tool Vibration And Force Transmissibility In High-Speed Micro-Milling Machine

2021 ◽  
Author(s):  
Chitransh Singh ◽  
Arnab Das ◽  
Vivek Bajpai ◽  
Madan Lal Chandravanshi
Keyword(s):  
Process Parameters ◽  
High Speed ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Commercially Pure Titanium ◽  
Axial Thrust ◽  
Tool Vibration ◽  
Radial Thrust

Abstract High-speed micro-milling is an emerging technology used to produce micro and miniaturized products with smooth surface finish and high dimensional precision. However, tool vibration is a major problem in micro-milling as it directly affects the product accuracy, surface quality and tool life. Inappropriate selection of process parameters increases radial and axial thrust as well as force transmitted to structure during micro-machining which results in rapid tool vibration. This work focuses on the experimental investigation of process parameters (cutting speed and depth of cut) in order to reduce tool vibration due to axial and radial thrust in high-speed micro-milling. The tool used in this experiment is a 2-flute end mill cutter (1 mm cutter diameter) and workpiece is a commercially pure titanium (CpTi) plate. The operation was performed at different depth of cut and varying cutting speeds keeping the chip load constant. Vibration signals were acquired and processed to obtain the vibration thrust of the tool and the force transmitted to the structure. The results indicated that as the depth of cut and cutting speed increases, both axial as well as radial thrust decreases leading to lower vibration amplitude of the cutting tool and reduction in force transmitted to the machine structure.

Optimizing Feed Force in Turning Process Using Taguchi’s Parameter Design Approach

2014 ◽  
Vol 592-594 ◽  
pp. 668-672
Author(s):  
Praveen Kumar ◽  
Hari Singh
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Design Approach ◽  
Parameter Design ◽  
Depth Of Cut ◽  
Turning Process ◽  
Feed Force ◽  
Optimal Value ◽  
Optimal Setting

The objective of the paper is to obtain an optimal setting of turning process parameters (cutting speed, depth of cut and feed rate) resulting in an optimal value of the feed force when machining En19 steel with tungsten carbide cutting tool inserts. The effects of the selected turning process parameters on feed force and the subsequent optimal settings of the parameters have been accomplished using Taguchi’s parameter design approach. It was indicated by the results that the selected turning process parameters significantly affect the selected machining characteristic. The percent contributions of parameters as quantified in the S/N ANOVA envisage that the relative power of cutting speed (72.09 %) in controlling variation and mean feed force is significantly higher than that of the depth of cut (22.30 %) and feed rate (05.31 %). The predicted optimum feed force is 98.067 N. The results have been validated by the confirmation experiments.

Analysis of the Effect of Process Parameters for Circularity and Cylindricity Errors in Turning Process

2016 ◽  
Vol 852 ◽  
pp. 255-259 ◽  
Author(s):  
B. Singaravel ◽  
Chimmalagi Marulaswami ◽  
Thangiah Selvaraj
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Quality Criteria ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Work Piece ◽  
Turning Process ◽  
Machining Performance ◽  
Machining Operations

Turning is one of the fundamental machining operations and its process parameters leads to better machining performance. The economic benefit of turning operation is providing components with appropriate dimensional accuracy. In this work, the effects of process parameters on dimensional accuracy (circularity and cylindricity) parameters are analyzed in turning of EN25 steel. The process parameters considered are cutting speed, feed rate and depth of cut in order to minimize circularity and cylindricity. The result revealed that the minimum dimensional accuracy error values such as circularity and cylindricity are obtained in the combination of higher value of cutting speed and lower value of feed rate and depth of cut. This analysis is used to meet the machined work piece within the tolerance limit and improve the quality criteria.

Effect of Offset Distance on Cutting Forces and Heat Generation in Multi-Tool Turning Process

2014 ◽  
Vol 592-594 ◽  
pp. 211-215 ◽  
Author(s):  
R. Kalidasan ◽  
M. Yatin ◽  
D.K. Sarma ◽  
S. Senthilvelan
Keyword(s):  
Cutting Tool ◽  
Gray Cast Iron ◽  
Single Point ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Turning Process ◽  
Additional Tool ◽  
Offset Distance

Productivity enhancement assumes a paramount importance in today’s competitive industrial world. The aim of this work is to improve productivity in a conventional lathe with two single point cutting tools machining a workpiece simultaneously. An additional tool holding fixture is fabricated and integrated so that distance between the two cutting tools can be varied and has a provision to provide individual depth of cut. Experiments were performed on gray cast iron workpiece at different offset distances between the cutting tools, at a particular cutting speed, feed rate and depth of cut. In the multi-tool turning process, lagging rear cutting tool experiences lesser cutting force than leading front cutting tool. This behaviour is due to the machining of front cutting tool preheat as well as reduction of effective cutting speed while machining with rear cutting tool. With increase in offset distance, moment acting on the work piece contributes to increase in resistance against machining and hence front tool experiences higher force than rear cutting tool.

scholarly journals Taguchi Analysis on Cutting Forces and Temperature in Turning Titanium Ti-6Al-4V

2012 ◽  
pp. 59-63
Author(s):  
Satyanarayana Kosaraju ◽  
Venu Gopal Anne ◽  
Bangaru Babu Popuri
Keyword(s):  
Taguchi Method ◽  
Cutting Force ◽  
Process Parameters ◽  
Chemical Reactivity ◽  
Cutting Speed ◽  
Individual Performance ◽  
Process Parameter ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Titanium Grade

Titanium alloy machining is hindered basically due to its high chemical reactivity and low thermal conductivity. The present work is focused on investigating the effect of process parameters on machinability performance characteristics and there by optimization of the turning of Titanium (Grade 5) based on Taguchi method. The cutting speed, feed and depth of cut were used as the process parameters where as the cutting force and temperature ware selected as performance characteristics. The L9 orthogonal array based on design of experiments was used to conduct experiments. The degree of influence of each process parameter on individual performance characteristic was analyzed from the experimental results obtained using Taguchi Method. The cutting speed was identified as the most influential process parameter on cutting force and temperature.

Comparison of Process Parameters on Mild Steel and SS304 Through Statistical Analysis of Optimization Technique

2020 ◽  
Vol 12 (7) ◽  
pp. 888-893
Author(s):  
Vinit Kumar ◽  
Mazhar Hussain ◽  
Rajnish Singh ◽  
Shashank Kumar
Keyword(s):  
Stainless Steel ◽  
Mild Steel ◽  
Process Parameters ◽  
Feed Rate ◽  
Cutting Tool ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Stainless Steel 304

The present study concentrated on the variation of process parameters on metal removal rate (MRR) used in turning of widely used material (stainless steel 304 and Mild steel). Turning is essential and robust process of material removal in the form of chips. The Turning process involved lots of process parameters as tool geometry, feed rate, rotational speed of job and rigidity of machine tools etc. In the present work study was done on the following cutting parameters as cutting speed (85,150 and 250 rpm), feed rate (0.13, 0.28 and 0.15, 0.09 mm/sec), depth of cut (0.4, 0.7 and 1 mm). The three label orthogonal array for process parameters were selected for metal removal rate analysis. The carbide tipped cutting tool was selected as cutting tool of positive rake angle. The analysis of process parameters was done through Minitab 17 software. The orthogonal array was selected 3*3; by the use of signal to noise (S/N) ratio is to minimise the variation due to uncontrolled parameters with the help of Taguchi method. Total nine experiments were performing on stainless steel and other set of nine experiments were perform on the mild steel. The experimental results reveals that moderate cutting speed 150 rpm, 0.09 mm/sec feed rate and 1 mm depth of cut yield good results for stainless steel 304 grade and mild steel.

Vibratory Analysis of Turning Process

2011 ◽  
Vol 70 ◽  
pp. 333-338
Author(s):  
Roger Serra
Keyword(s):  
Cutting Tool ◽  
Structural Parameters ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Turning Process ◽  
Complex Dynamic ◽  
Vibratory Analysis ◽  
Finite Element Calculations ◽  
Tool Vibrations ◽  
Lathe Tool

The aim of the paper is to analyse the vibrations during a turning manufacturing process in terms of the Machine-Tool-Part unit having particularly complex dynamic characteristics. The vibratory phenomenon is influenced by many parameters like workpiece, tool overhang, cutting speed, depth of cut and feed rate. This phenomenon is not completely known yet, so the aim was to highlight its origins using two complementary approaches: numerical and experimental. Finite element calculations were carried out, in order to identify parameters which characterize vibrations in machining like structural parameters (lathe, tool holder, cutting tool, workpiece, tailstock, tool overhang ...). A design for an experiment of process parameters (depth of cut, feed and cutting speed) was used and one series of turning tests was performed. Results have shown a significant effect between these parameters on the resulting surface roughness, consumed power, cutting time and tool vibrations and a best comprehension of the process.

Influence of Cutting Speed and Offset Distance over Cutting Tool Vibration in Multi-Tool Turning Process

2014 ◽  
Vol 984-985 ◽  
pp. 100-105 ◽  
Author(s):  
R. Kalidasan ◽  
V. Ramanuj ◽  
D.K. Sarma ◽  
S. Senthilvelan
Keyword(s):  
Cutting Tool ◽  
Cutting Speed ◽  
Tangential Direction ◽  
Rear Side ◽  
Work Piece ◽  
Machining Parameters ◽  
Turning Process ◽  
Vibration Signals ◽  
Tool Vibration ◽  
Power Spectral

Multi-tool turning process employs more than one cutting tool for machining the work piece simultaneously. In the conventional turning process, effect of machining parameters over cutting forces, vibration, work piece surface finish and dimensional tolerances have been discussed in detail, however no attempt has been made in the multi-tool turning process. Cutting tool vibration is very important as it reveals the condition of cutting tool as well as work piece quality. In this study, a second cutting tool is introduced at the rear side of the lathe with some distance from conventional front cutting tool to machine the work piece simultaneously. Accelerometers are used to measure the vibration signals in the tangential direction of cutting. Obtained time domain vibration signals are converted to frequency domain signals by Fast Fourier Transform to reveal its power spectral density. In this work cutting speed and distance between front and rear cutting tool are varied to understand the cutting tool vibration. With increase in cutting speed and increase in distance between front and rear cutting tool, vibration reduces.

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