Optimization of Process Parameters in Turning Operation of Inconel 800 & Cu-Ni 70/30 Using Taguchi and Anova Method

OPTIMIZATION OF PROCESS PARAMETERS IN
TURNING OPERATION OF INCONEL 800 & Cu-Ni

70/30 USING TAGUCHI AND ANOVA METHOD
Submitted in partial fulfilment of the requirements of the degree of Bachelor of
Technology in Mechanical Engineering
Submitted By:
Rohtash kumar (133151)
Pankaj Chouhan (133242)
Dungavath Babunaik (133122)
Supervisor:
Dr. N Selvaraj
(Professor)
DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY
WARANGAL
2016-2017
Approval Sheet
This Project Work entitled “OPTIMIZATION OF PROCESS PARAMETER
IN TURNING PROCESS” by Rohtash, Pankaj and Babunaik is approved for
the degree of
Bachelor of Technology
In
Mechanical Engineering
Examiners
_________________________________
_________________________________
_________________________________
Supervisor (s)
__________________________________
__________________________________
___________________________________
Chairman
__________________________________________
Date: ___________________
Place: __________________
II
Declaration
I declare that this written submission represents my ideas in my own words and where others’
ideas or words have been included, I have adequately cited and referenced the original sources.
I also declare that I have adhered to all principles of academic honesty and integrity and have
not misrepresented or fabricated or falsified any idea/data/fact/source in my submission. I
understand that any violation of the above will be cause for disciplinary action by the institute
and can also evoke penal action from the sources which have thus not been properly cited or
from whom proper permission has not been taken when needed.
Rohtash kumar
(133151)
Pankaj Chouhan
(133242)
Dungavath Babunaik
(133122)
Date: ___________________
III
DEPARTMENT OF MECHANICAL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY WARANGAL
2016-2017
Certificate
This is to certify that the project work entitled “OPTIMIZATION OF PROCESS
PARAMETER IN TURNING PROCESS” is a bonafide record of work carried by:
Rohtash kumar 133151
Pankaj Chouhan 133242
Dungavath Babunaik 133122
Submitted to the faculty of “Mechanical Engineering Department”, in fulfilment of the

requirement for the award of the degree of Bachelor of Technology in “Mechanical
Engineering” at National Institute of Technology, Warangal during the academic year 2016-
2017.
Dr. Srinivasa Rao S Dr. N Selvraj,

Head of the Department (HOD), Professor,
Department of Mechanical Engineering Department of Mechanical Engineering
NIT Warangal. NIT Warangal.
IV
Acknowledgements
We consider it as a great privilege to express our deep gratitude to many respected and kind
personalities who helped, guided and inspired us in the each phase of our project till successful
completion.
We would like to express our deepest gratitude to our guide Dr. N Selvaraj, Professor,
Department of Mechanical Engineering, National Institute of Technology, Warangal, for his
constant guidance, supervision, suggestions and invaluable encouragement throughout this
project.
We are very grateful to College Workshop Staff specially Mr. Yellasmay and Shyam sir for
providing us tools and space for conducting our experiments.
We are thankful to Mr. Rohit, Mr. Prasad Reddy and Mr. Gopal Rao for their immense
assistance during designing and conducting the experiments.
We are also grateful to Cutting Edge Technology, Hyderabad who provided us tool inserts
and Mallinath Metals, Mumbai from where we purchased our Work-piece materials.
Last but not least we are very thankful to Project Evaluation Committee, for their strenuous
efforts to evaluate the projects and their great suggestions.
We wish to thank all the academic and non-academic staff members of the department for their
kind cooperation and support given throughout our project work. We are also thankful to all of
our friends who have helped and given valuable suggestions in all stages of the development of
the project.
Rohtash Kumar 133151

Pankaj Chouhan 133242
Dungavath Babunaik 133122
V
Abstract
Manufacturing is a never ending and ever growing process, it is used everywhere in our day to
day life components. Turning, milling, drilling etc. are major machining processes.
Surface quality of the machined part can be checked and judged by measuring the surface
roughness or surface finish of the part. Machinability is the ease with which a components can
be machined efficiently. In today era achieving high surface finish, high material removal rate
and lowest forces (e.g. cutting force) is major concern.
This project is an attempt to discuss these problems and to achieve the best combinations of
input parameters of turning process e.g. Speed, Feed, Depth of cut to achieve best surface finish
with reasonable material rate and lowest forces (e.g. Cutting force).
The project will include the selection of Workpiece as well as Tool material, design of process
parameters based on Taguchi method, experimental work and optimization of input parameters.
This project report is divided into various chapters. Introduction about manufacturing and
machining processes are discussed in first chapter. In is the classifications of the different
machining process is described. The overall idea of the project is also reflected.
In the first chapter introduction and overall idea about the project is discussed.
In the second chapter we have included the literature review which we have done throughout
the year; mainly in project part-B. It includes the work of other authors through which we have
gone.
In third chapter Problem formulation, objective and motivation for the project are elaborated.
Different terminology are explained in fourth chapter. The fifth chapter deals with experimental
procure for project. Sixth chapter deals with Optimization techniques for turning operation.
In 7th chapter the effects of control factors are discussed. The experimental details is elaborated
in eighth chapter using Taguchi method and ANOVA analysis. Calculation is also done in this
chapter.
The overall result and outcomes of the project work is discussed in ninth chapter. Tenth chapter
is dedicated to confirmation test of optimised process parameter of turning operation.
Finally in the last chapter, overall conclusion of project work is discussed along with the future
scope of the project.
VI
Table of Contents
Chapter-01 Introduction................................................................................. 1
1.1 Machining Operation...................................................................................................2
1.1.1 Conventional Machining Operation................................................................3
1.1.2 Non-conventional Machining Operation.........................................................4
1.2 Turning Operation.......................................................................................................5
1.3 Industrial applications of turning................................................................................9
1.3.1 Applications of turning operation...................................................................9
1.3.2 Challenges and difficulties............................................................................10
1.4 Modelling and Optimization.....................................................................................11
1.5 Engineering material.................................................................................................12
1.5.1 Work piece material......................................................................................12
1.5.2 Tool material.................................................................................................12
1.6 Stage in metal cutting................................................................................................12
1.6.1 Rough cut......................................................................................................13
1.6.2 Finish cut.......................................................................................................13
Chapter-02 Literature Survey.......................................................................14
2.1 Inconel 718................................................................................................................14
2.2 Inconel CU-Ni...........................................................................................................14
2.3 Tool material.............................................................................................................15
2.4 Tool wear..................................................................................................................16
2.5 Taguchi method .......................................................................................................16
2.6 GRA and ANOVA...................................................................................................17

VII
Chapter-03 Formulation of Problem..........................................................18
3.1 Motivation for project.............................................................................................18
3.2 Objective and Approach of Project.........................................................................19
Chapter-04 Terminology Used....................................................................20
4.1 Cutting speed..........................................................................................................20
4.2 Feed rate.................................................................................................................20
4.3 Spindle speed..........................................................................................................20
4.4 Axial depth of cut ..................................................................................................21
4.5 Radial depth of cut .................................................................................................21
Chapter-05 Experimental Procedure.........................................................22
5.1 Introduction ...........................................................................................................22
5.1.1 Properties and Application of Work piece material...................................22
5.1.2 Properties of tool material (Insert).............................................................24
5.1.3 Designation of Tool...................................................................................26
5.2 Experimental set-up...............................................................................................27
5.2.1 Specification of lathe.................................................................................28
5.2.2 Specifications of Tool holder....................................................................28
5.2.3 Specification of Dynamometer.................................................................29
5.2.4 Specification of Roughness tester.............................................................30
5.3 Assumptions..........................................................................................................32
VIII
Chapter-06 Optimization Methods...........................................................33
6.1 Taguchi method....................................................................................................33
6.1.1 Introduction.............................................................................................33
6.1.2 Approach to optimize the machining process..........................................34
6.2 ANOVA method..................................................................................................35
Chapter-07 Effects of Process parameter on Response parameter.......36
7.1 Surface Roughness...............................................................................................36
7.1.1 Effect of Cutting Speed on Surface Roughness.......................................37
7.1.2 Effect of Feed rate on Surface Roughness...............................................38
7.1.3 Effect of Depth of Cut on Surface Roughness.........................................39
7.2 Cutting Force........................................................................................................39
7.2.1 Effect of Cutting Speed on Cutting Force................................................40
7.2.2 Effect of Feed Rate on Cutting Force.......................................................41
7.2.3 Effect of Depth of Cut on Cutting Force..................................................42
7.3 Material Removal Rate (MRR)............................................................................43
7.3.1 Effect of Cutting Speed on MRR.............................................................43
7.3.2 Effect of Feed Rate on MRR....................................................................43
7.3.3 Effect of Depth of Cut on MRR...............................................................43
Chapter-08 Experiment Details................................................................44
8.1. Inconel 800..........................................................................................................44
8.1.1 Selection of process parameters and their level......................................44
8.1.2 Design of Experiment.............................................................................45
IX
8.1.3 Experimental Analysis of surface roughness..........................................46
8.1.4 Experimental Analysis of cutting force..................................................47
8.1.5 Experimental Analysis of Material Removal Rate.................................49
8.2. Cupro-Nickel 70/30............................................................................................50
8.2.1 Selection of process parameters and their level.....................................50
8.2.2 Design of Experiment............................................................................51
8.2.3 Experimental Analysis of surface roughness.........................................51
8.2.4 Experimental Analysis of cutting force.................................................53
8.2.5 Experimental Analysis of Material Removal Rate................................55
Chapter-09 Results and Discussion........................................................57
9.1 Inconel 800...................................................................................................57
9.1.1 Analysis of Surface roughness (Ra)......................................................57
9.1.2 Analysis of Main cutting force..............................................................58
9.1.3 Analysis of Feed force...........................................................................59
9.1.4 Analysis of Radial force........................................................................59
9.2 Cu-Ni 70/30...................................................................................................60
9.2.1 Analysis of Surface roughness (Ra) .....................................................60
9.2.2 Analysis of Main cutting force..............................................................61
9.2.3 Analysis of Feed force...........................................................................61
9.2.4 Analysis of Radial force........................................................................62
9.2.5 Analysis of Material Removal Rate.......................................................63
X
Chapter-10 Confirmation Test...............................................................64
10.1 Predicted confidence interval for confirmation experiments............................64
10.2 Conformation test..............................................................................................65
Chapter-11 Conclusion...........................................................................67
11.1 Future Scope.....................................................................................................68
References....................................................................................................................69
XI
List of Figures
Figure 1.1 Straight Turning......................................................................................................5
Figure 1.2 Taper Turning.........................................................................................................6
Figure 1.3 Profile Turning........................................................................................................6
Figure 1.4 Turning and external grooving................................................................................6
Figure 1.5 Facing......................................................................................................................7
Figure 1.6 Face grooving..........................................................................................................7
Figure 1.7 Cutting with form tool.............................................................................................7
Figure 1.8 Boring and internal grooving...................................................................................8
Figure 1.9 Drilling.....................................................................................................................8
Figure 1.10 Cutting off..............................................................................................................8
Figure 1.11 Threading...............................................................................................................9
Figure 1.12 Knurling.................................................................................................................9
Figure 5.1 (a) Schematic illustration of a right-hand cutting tool for turning..........................26
5.1 (b) Carbide inserts...................................................................................................26
Figure 5.2 Methods of mounting inserts on tool holders: (a) Clamping, (b) Wing lock pins.
(c)Examples of inserts mounted using thread less lock pins, which are secured with side
screws. ......................................................................................................................................26
Figure 5.3 Experimental set-up.................................................................................................27
Figure 5.4 Work piece on lathe machine..................................................................................28
Figure 5.5 Tool holder..............................................................................................................28
Figure 5.6 Typical Measuring Chain with DAQ-System Type 5697A1. ................................29
Figure 5.7 Measurement capability of Surface tester...............................................................31
Figure 5.7 Measurement of Surface roughness with Surface tester.........................................31
XII
Figure 7.1 Components of surface texture...............................................................................37
Figure 7.2 cutting force components in turning.......................................................................39
Figure 7.3 Cutting forces vs. cutting speed at doc = 0.5 mm and f = 0.2 mm/rev...................40
Figure 7.4 Cutting forces vs. feed rate at v = 69.24 m/ min and doc = 1 mm.........................41
Figure 7.5 Cutting forces vs. depth of cut at v = 69.24 m/ min and f = 0.2 mm/rev...............42
Figure 9.1 S/N Ratio values for Surface Roughness.............................................................57
Figure 9.2 S/N Ratio values for Main Cutting Force............................................................58
Figure 9.3 S/N Ratio values for Feed Force.........................................................................59
Figure 9.4 S/N Ratio values for Radial Force......................................................................60
Figure 9.5 S/N Ratio values for Surface Roughness............................................................60
Figure 9.6 S/N Ratio values for Main Cutting Force...........................................................61
Figure 9.7 S/N Ratio values for Feed Force.........................................................................61
Figure 9.8 S/N Ratio values for Radial Force......................................................................62
Figure 9.9 S/N Ratio values for MRR..................................................................................63
XIII
List of Tables
Table-8.1 Cutting parameters and

levels....................................................................................44
Table-8.2 Taguchi L9 (3 × 3) orthogonal array design layout.................................................45
Table-8.3 Experimental readings for the response parameter as the average surface
roughness..................................................................................................................................46
Table-8.4 Response Table for Means Ra..................................................................................46
Table-8.5 ANOVA analysis for means of average surface roughness.....................................46
Table-8.6 Experimental readings for the response parameter as the cutting force
components..............................................................................................................................47
Table-8.7 Response Table for Means Fz.................................................................................47
Table-8.8 Response Table for Means Fy.................................................................................48
Table-8.9 Response Table for Means Fx.................................................................................48
Table-8.10 ANOVA analysis for means of Fz.........................................................................48
Table-8.11 ANOVA analysis for means of Fy.........................................................................48
Table-8.12 ANOVA analysis for means of Fx.........................................................................49
Table-8.13 Experimental readings for the response parameter as the material removal rate...49
Table-8.14 Response Table for Means MRR...........................................................................50
Table-8.15 ANOVA analysis for means of MRR....................................................................50
Table-8.16 Cutting parameters and levels................................................................................51
Table-8.17 Taguchi L9 (3 × 3) orthogonal array design layout..............................................51
roughness (Ra).........................................................................................................................52
XIV
Table-8.19 Response Table for Means Ra..............................................................................52
Table-8.20 ANOVA analysis for means of average surface roughness..................................53
Table-8.21 Experimental readings for the response parameter as the cutting force
components..............................................................................................................................53
Table-8.22 Response Table for Means Fz...............................................................................54
Table-8.23 Response Table for Means Fy...............................................................................54
Table-8.24 Response Table for Means Fx...............................................................................54
Table-8.25 ANOVA analysis for means of Fz........................................................................54
Table-8.26 ANOVA analysis for means of Fy........................................................................55
Table-8.27 ANOVA analysis for means of Fx.........................................................................55
Table-8.28 Experimental readings for the response parameter as the material removal rate...56
Table-8.29 Response Table for Means MRR...........................................................................56
Table-8.30 ANOVA analysis for means of MRR....................................................................56
Table 10.1 Predicted interval for Inconel 800..........................................................................64
Table 10.2 Predicted interval for Cupro-Nickel 70/30.............................................................65
Table 10.3 Confirmation test value for Inconel 800................................................................65
Table 10.4 Confirmation test value for Cupro-Nickel 70/30...................................................66
XV
Abbreviation Notation and Nomenclature
DOC Depth of cut
DOF Degree of freedom
f Feed rate, mm/revolution
M.S Mean of squares
S.S Sum of squares
Cu Copper
Ni Nickel
ANOVA Analysis of Variance
Greek letters:
ρ Density, kg/m3
α Rake Angle, degrees
XVI
Chapter-01
Introduction
In recent years the demand for best quality product at lowest price/cost is a major topic
of discussions. The technology is reforming day by day according to the demand of customers.
Manufacturing is a never ending and ever growing process, it is used everywhere in our day to
day life components. Turning, milling, drilling etc. are major machining processes.
In machining process, the turning operation is most used process to machine parts. It is
the fundamental process is being used to turn and finish the parts. The aim of any manufacturer
is to produce the parts with best quality at affordable price according to market demand. The
quality of the part can be measured under different loading conditions and at the time of
applications. The turned part’s quality can be checked by touching it physically and can be
measured quantitatively by surface roughness measurement devices.
There are some major concerns in the process of machining the part like demand of
highly customised quality product according to market demand and requirements. So a
manufacturer always try to use optimization techniques in metal cutting processes to achieve
high quality in terms of good surface finish with high production rate i.e. more parts can be
produced in given time. At the same time tool’s performance is also monitored to reduce wear
and tear of cutting tool, so that the life of tool can be increased. Some unavoidable sources may
also affect the quality and performance of machined part e.g. environmental effects. Cutting
forces are used to determine and calculate the wear and tear of cutting tool. These should be
done at optimum material removal rate.
To reduce the cost of production and final price of product, it is very much necessary to
reduce the manufacturing cost which include fixed cost and variable cost. One way to reduce
variable cost is to increase the life of cutting tool, so that the uses frequency of cutting tool can
1
be increased and we require the less number of cutting tool to produce the same quantity of
output parts.
Machining is a term which include a wide number of operations like turning, milling,
grinding and drilling etc. Generally this term is used for describing the removal of material from
intended part. Machining or manufacturing is a system consisting of machine, tool and work
piece.
1.1 Machining Operations and types-

Machining is a process to machine a part. It is a broad term which is used to describe
the material removal from a work piece. It is a controlled process that converts raw materials
into useful final product of desired shape and size. Machining can be done on wood, metals,
alloys, ceramics, plastics as well as composite materials. The relative motion between tool and
work piece is essential to machine a part to produce a desired product.
Generally the hardness of cutting tool materials should be more than the part to be
machined in conventional machining operations. But in modern machining operations work
piece of high hardness material can be machined with cutting tool having less hardness, these
are called modern machining.
Machining operations are done under controlled material process and these type of
operation in present day is called subtractive manufacturing [10]. The process of controlled
material addition is called additive manufacturing. Here controlled part refers to use of machine
tools in addition of using only power tools and hand tools. Machining can be performed either
manually or automatically using Computer Numeric Control (CNC).The three major machining
processes are turning , milling and drilling. Apart from these other miscellaneous machining
processes are broaching, sawing, shaping, planning, boring and tapping etc. These all are
conventional machining processes. Non-conventional or modern machining processes include
Abrasive jet machining, Abrasive water jet machining, Electrical discharge machining, electron
beam machining, ultrasonic machining and photochemical machining etc.
The followings are the types [10] and characteristics [11] of machining operations:
2
1.1.1 Conventional Machining Operation:
a) Turning-
In turning lathes are the principal machine tools. Turning is performed on lathe machine.
In this operation workpiece is continuously rotated and tool is brought near to work piece and
longitudinal (parallel to axis of work piece) or orthogonal (perpendicular to axis of workpiece)
motion is given to tool according to the required shape of final product. In turning single point
cutting tool is used to generate the required shape of final product. Rotating workpiece provides
the primary motion and feed motion is given by sliding the cutting tool slowly in parallel
direction to the rotating workpiece. Depth of cut is given in perpendicular direction of rotating
workpiece axis. The following are the Characteristics of Turning:
 Turning and facing operations can be performed on all types of materials.
 It requires skilled labor and operator to operate machine and tools.
 Generally the rate of production is low but medium to high rates can be achieved with
special types of lathes e.g. Turret lathes and automatic lathe machines which requires
less skilled labor.
 The commercial tolerances range for fine turning is 0.05 to 0.13 mm, and it is around
0.13mm for rough turning. It varies from 0.025 to 0.05 mm for skiving.
b) Milling-
In this operation milling machines are used as primary machine tool. In this cutting tool
which rotates continuously to bring cutting edges to bear against workpiece. Feed motion is
provided in the direction of perpendicular to the tool’s axis of rotation, rotating milling cutter
provides speed motion.
There are two types of milling operations:

i. Peripheral milling
ii. Face milling
There are four types of milling machines:
i. Plain milling machines,
ii. Hand milling machines,
iii. Universal milling machines, and
iv. Omniversal milling machines, they have arrangement of applying either
horizontal cutters or vertical cutters installed on axis.
3
Characteristics of Milling:
 In milling both table and cutting tools can be made moveable.

 Some milling machine can perform operations as rebating, cutting, routing , die-
sinking and other complex tool-paths
 Milling machines can perform versatile operations.
 The maintenance cost is low, due to their long and glitch-free life, the return on
investment is high.
c) Drilling-
Drilling operation is primarily performed on drilling machine (drill press) but it can also
performed on lathes and milling machine (mills). It produces round hole. It is performed by
multi-point rotating cutting tool. Motion is given to tool in a direction parallel to its axis of
rotation, it goes into workpiece and produces required shape which is generally round shape.
d) Boring-
In this operation a tool having single bent pointed tip is fed into a roughly made hole in
spinning workpiece. This is done to slightly enlarge the previously drilled hole to improve the
surface quality and accuracy. This is done to achieve fine finishing at the final stage of product
manufacturing.
Characteristics of Boring:
 By boring operation Internal surfaces or profiles can be made,

 To avoid chatter the boring bar should have high stiffness.
 The commercial tolerances for boring is ± 0.025 mm.
e) Reaming – In this operation the size of previously drilled hole is changed according to the
requirement.
1.1.2 Non-conventional Machining operations-

In non-conventional machining operation there is no constraint of having tool more
hardness than workpiece. Sometimes there is no contact direct contact between cutting tool
and workpiece. These are the main non-conventional machining operations:
a) Electrical discharge machining,
4
b) Electro-chemical erosion machining,
c) Laser-cutting machining,
d) Water jet cutting machining ,
e) Abrasive water jet machining,
f) Abrasive jet machining.
1.2 Turning Operation and its types-

Turning is the most used and common machining operation. It is done on the lathe
machine. The workpiece continuously rotate in the lathe chuck and rotation to chuck is given
by motor directly or with complex mechanisms of gears and pulleys. The cutting tool is
continuously fed into radial direction and along in axial direction to give radial depth of cut and
axial depth of cut respectively. Generally the lathe are of two forms (i). Traditional lathe, is it
also termed as manual lathe since operator has to continuously operate all the operations. (ii)
The automated lathe, it is also termed as computer numerical controlled (CNC) lathe machine.
In this some operations can be done automatically. Turning operation involves a large number
of operations. The following are the major operations performed under the turning:
1.2.1 Straight turning:

Straight turning is performed to reduce the cross-section continuously. In this the
material is removed in layer by layer, staring from low depth of cut to high depth of cut.
Figure 1.1 Straight Turning
5
1.2.2 Taper turning: The taper is made on workpiece by gradual removal of material in
machining operations.
Figure 1.2 Taper Turning
1.2.3 Profiling: A special profile is made on the workpiece with the profiling tool.
Figure 1.3 Profile Turning
1.2.4 Turning and external grooving: A groove is made on the workiece with the help
of single point cutting tool. In this operation first straight turning is done and then groove
is made.
Figure 1.4 Turning and external Grooving
6
1.2.5 Facing: Facing is generally done at the beginning and at the end of the complete
operation. In this operation the cutting tool moves advances in perpendicular direction of
the workpiece and moves across the end of the work piece.
Figure 1.5 Facing
1.2.6 Face grooving: In this operation the groove is made on the cross-section of the
workpiece. It is done in the parallel direction of the axis of the workpiece.
Figure 1.6 Face grooving
1.2.7 Cutting with a form tool: A from tool is used to make the identical shape on the
workpiece in machining operation. Work piece is continuously rotated and from tool is fed
into rotating workpiece.
Figure 1.7 Cutting with form tool
7
1.2.8 Boring and internal grooving: Turning can be done on outer or inner side of
workpiece. Boring is the operation which is performed when the turning is done internal.
Workpiece is rotated on lathe chuck and tool or bit is held on tail-stock and fed into the
rotating workpiece to make desired hole or groove.
Figure 1.8 Boring and internal grooving
1.2.9 Drilling: Drilling is done on lathe machine to produce hole in the workpiece and a
drilling bit which is held on tail-stock, is advanced into rotating workpiece.
Figure 1.9 Drilling
1.2.10 Cutting off: The tool is fed into the perpendicular direction of the rotating
workpiece. This is done to divide the workpiece into two parts.
Figure 1.10 Cutting off
8
1.2.11 Threading: For producing threads on the workpiece, first the straight turning and
facing are done. The tool is held on tool post and gear arrangement is done according to the
pitch of the thread. The continuous feed is given to tool to form threads.
Figure 1.11 Threading
1.2.12 Knurling: To make more handling grip of the product, knurling is performed on the
workpiece. This is done with the help of special knurling tool. There is no material removal
in this process, only the tool structure is embossed on the wokpiece.
Figure 1.12 Knurling
1.3 Industrial applications of Turning and its limitations-

1.3.1 Applications of turning operations:
The following are the major applications of turning operations.
a) Turning operation is done to remove the unwanted material from the workpiece to
get the desired shape of the final product.
b) Turning is used in making axisymmetric parts in machining.
c) The major application involve making round bar and producing threads on it.
d) Chamfering is done on lathe machine to make round corner of product.
e) Parting is done to divide the object in more than one part.
f) Threading is done to produce external or internal thread on the round bar specimen.
g) Boring is performed to resize and make wider cross-section of hole which has been
already done.
9
h) Drilling is used to make a hole in the object on lathe machine. Object is held on
chuck and rotation is given to it. A stationary tool is advanced in to rotating part to
produce hole.
i) Knurling is a cross-hatched texture in workpiece. It is done on bar so that the grip
can be increased. It is performed on lathe machine.
j) Turning is very much useful operation to produce precise surface. Turning operation
is performed on the parts produced from castings of various types. It is also
performed on forged, extruded and the parts which are welded or brazed.
1.3.2 Challenges and difficulties:
According to Evan Jones Thorne et al [13] these are major challenges faced while
turning-
a) Heat management- In turning operation high temperature are generated and these
lead to high heat generation. This heat can affect badly tool and workpiece and
degrades the surface quality. So there should be a proper way or channel to remove
the heat generated in machining. The best way is to use cooling fluids.
b) Setup Selection- It is very important to set and optimize tool and toolholder. It is
very critical to select and set tools and inserts. For proper setup jigs and fixtures are
used, sometimes tail tailstock is used for support. Tail stock is used for long and
difficult turning objects.
c) Surface finish- The quality of the final product is the main criterion for selection of
product. The surface quality is checked by surface finish. By the proper selection of
tool or tool insert according to workpiece hardness, the better surface finish can be
achieved.
d) Chatter- It may happen due to incorrect selection of cutting speeds and feed rates. If
the machine and tool (or tool holder) are not rigid, than vibration are created during
the machining operation. It is recommended to stop chatter before it starts. For
reducing or completely removing chatter, high feed rates and a larger tool-nose
radius are selected. Worn-out or dull edges tool creates chatter.
e) Chip Control, Evacuation- Machining results in chip formation. There are many
types of chips. It is recommended to remove chips continuously from machining
zone, but they are generated continuously and may create problems in surface finish.
To control and remove long chips, the chip breakers are used. But due to uses of this
the heat may be generated.
10
Apart from these:
f) Tool failure is the major problem in the turning at high speed or at any abnormal
conditions. Tool may failure in three mode as (i) Temperature failure (ii) Fracture
failure and (iii) Gradual failure.
So it is very important to remove or minimize the challenges to machien desired and

required final product at affordable cost.
1.4 Modelling and Optimization:

Starting from the selection of input variables, observing and optimization of it there are
some tools and techniques which are used.
1.4.1 Selection of input variables:
The input variables likes cutting speed, feed rate and depth of cut are selected based on
the physical and mechanical properties of workpiece as well as tool materials. We have taken
three level for input variables- small, medium and large. If we apply the factorial form then we
have to conduct 3×3×3= 27 experiments. It is a large numbers of experiments which have to be
conducted. It will consume a lot of time as well as resources, this will increase the cost of
production or manufacturing and this will lead to increase in the price of final product. So to
reduce the number of experiments and to achieve the same results we use Taguchi method. In
this we use Taguchi L9 orthogonal array to arrange the level of experiment input variables. This
reduces the number of experiment from 27 to only 9, so there is great reduction in the cost of
manufacturing and a lot of time can be saved.
1.4.2 Software used for observation of response:
During the conduction of experiment, the measurement of force is done with the Kistler
Dynaware software. The surface finish is measured with the Surtronic S128 Roughness tester.
1.4.3 Optimization methods-
For the optimization of input parameters the Taguchi and ANOVA methods are used.
11
1.5 Engineering material:
1.5.1 Work piece material:
In turning operation ferrous as well as nonferrous materials can be machined. Apart

from this other materials like plastics and other organic materials can be turned to get final
product. Generally metals like carbon steel, Aluminium, brass, copper and zinc are machined
in turning operation. Metals have high machinability than non-metal.
These are the source materials on which experiments are carried out. These can vary
from flat to round in shape. But in case of lathe machine the workpiece material is generally
round in shape. It is installed in between centres of lathe and properly fitted on lathe chuck. The
rotation to it is given by providing rotation to chuck (3-jaw in our workshop) by directly motor
or through some complex arrangements of gears and pulley.
1.5.2 Tool material:
Cutting tool is used for machining of the workpiece. Tool is placed on the tool post of
the lathe machine. Tool material is selected based on the physical and mechanical properties of
workpiece like hardness, tensile strength and temperature variations behaviour. Generally the
hardness of the tool material is greater than the workpiece material in conventional machining
operations.
The tool material should have these properties [12]:
a) It should have high toughness to resist fracture failure.

b) It should have capability to withstand at high temperature i.e. it should have good hot
hardness to resist temperature failure.
c) It should have wear resistance and capacity to prolong the life of the tool during gradual
wear happens.
1.6 Stages in metal cutting:

Generally metal cutting operation is not performed in one go, it is done in series of
operations. Based on purpose (outcome) and cutting conditions machining operations are
divided into two categories:
12
1.6.1 Roughing cuts:
When we need to remove large amount of material from the starting workpart as rapidly
as possible, i.e. with a large Material Removal Rate (MRR), than roughing cuts are used. In
roughing cut it produces a shape close to the desired form. Subsequent finishing operation are
performed on part to achieve final desired surface finish.
When we required to complete the part and achieve the final dimension, tolerances, and
surface finish, finishing cuts are used.
In manufacturing process generally first one or more roughing cuts are usually
performed on the work and then it is followed by one or two finishing cuts.
Roughing cut operations are performed at high feeds and depths, but actual values of
process parameters depend on the workpiece materials.
Finishing operations are performed at low feeds and depths. The value of cutting speeds
are more in finishing then roughing.
1.6.2 Finishing cuts
In machining temperature of machining zone is increased and a high amount of heat is

generated. So it is very much necessary to control the temperature of tool and workpiece to
enhance the machinability and to increase the life of cutting tool. For doing this job cutting fluid
is often applied to the machining operation to cool and lubricate the cutting tool.
Selection of cutting fluid is done very wisely and according to the chemical and physical
properties of cutting tool and work piece material, so that their microstructure don’t change.
In modern days other forms of metal cutting are becoming more and more popular.
These area called modern machining operations. Example of these modern machining
operations are water jet cutting, abrasive water jet cutting, electrical discharge machining etc.
No or very less amount of heat is generated in water jet machining so it is also called cold
cutting, which eliminates the damage caused by a heat affected zone. But in laser and plasma
cutting operation, high amount of temperatures are generated and may damage the workpiece
and its surface integrity.
13
Chapter-02
Literature Survey
2.1 Literature Survey of Inconel 718

Inconel is a family of austenitic nickel-chromium based super alloys and the author is
investigated on Inconel 718 alloy. Inconel has unique properties such as high-temperature and
mechanical strength. It even maintains oxidation and corrosion resistance at high temperatures.
It is widely used in space vehicles, pollution control equipment, chemical processing, medical
applications, steam turbine power plants, marine applications, automotive sector etc. But, it
falls under a category of “Difficult-to-cut materials” because of its individual characteristics
such as affinity to react with tool material, lower thermal conductivity, hardness, work
hardening, availability of abrasive carbide particles in the form of fine grain etc. makes it harder
to machine [1];[2];[3].
2.2 Literature Survey of Inconel CU-Ni

Copper – nickel (Cu – Ni) based alloys such as cupro-nickel 70/30 is used in several
application due to its unique properties. It is accepted in marine application due to possessing
the high corrosive resistance in sea water.
14
It also consists properties such as good tensile strength, good thermal conductivity and
macro fouling resistance Cupro-nickel 70/30 mostly uses in heat exchangers and condenser
because of its good thermal conductivity and expansion. In the past during coinage, copper –
nickel alloys are highly used with silver to produce silver coin. Copper – nickel alloys are
difficult to cut because of large nickel contain in alloy. Nickel has a silver - white appearance
and it increases the ductility and malleability along with magnetism in alloy material. In
superalloys, nickel is responsible for having extremely corrosive resistance properties and it
also gives the ability to superalloys to retain their properties even at high temperatures and
makes them difficult to cut[1];[2].
2.3 Literature Survey of tool material

The different tool materials are available such as cermets, ceramic tool materials (such as Si3N4
ceramics, Al2O3/TiC mixed ceramics, and the latest SiC whisker-reinforced Al2O3 ceramics),
cast cobalt alloys tools, Diamond tip tool, high speed steel (HSS), cubic boron nitride (CBN)
cutting tools etc. to perform machining operation such as turning, drilling, milling etc.The
multi-layer (TiAlN/TiCN/TiN) coated carbide tools, produced by the PVD (Physical Vapor
Deposition) or CVD (Chemical Vapor Deposition) technique gives better performance than
high-speed steel (HSS), cast cobalt alloys and cemented tungsten carbides tools when
machining nickel-based alloys [1]; [2]; [3];[4];[5]. But the cost put a limit on these tool
materials to use in the different engineering applications.
PVD (Physical Vapor Deposition) and CVD (Chemical Vapor Deposition) are the techniques
used in forming very thin layers (thickness in micrometer) of different material onto a surface
to improve its properties such as excellent abrasion resistance, wear resistance, corrosion
resistant, high temperature and good impact strength.
The PVD (physical vapor deposition) is a technique that is performed by sputtering (ejecting
material from a "target" to "substrate") and evaporation of a pure material. The pure material is
gasified from the target and bombarded on the substrate material. After the condensation
process, the layer is formed onto the substrate material. This technique is carried out without
taking place any chemical reactions during the whole process. The PVD technique is mostly
used on medical instruments, firearms, aerospace and cutting tools.
15
The CVD (chemical vapor deposition) is a technique that involves the chemical reactions of
impure source material as it uses volatile precursor as a carrier. The mixture of pure source
material and the volatile precursor is deposited onto the substrate. Then the mixture sticks to
the substrate and the precursor leaves the layer by the process of decomposition. This whole
process is carried out into the chamber that has the substrate. CVD has a great importance in
the process of atomic layer deposition.
The summary is that CVD or PVD both create a very thin layer of the source material. But the
difference is in the approach of deposition of the source material onto the substrate. PVD uses
a pure source material followed by physical processes while CVD uses a mixed source material
followed by chemical processes.
2.4 Literature Survey of Tool wear

Superalloy, Inconel 718 is investigated to find out the tool wear in ceramic inserts by selecting
different cutting speeds while keeping feed and depth of cut constant. Ceramics have optical
properties, mechanical properties such as indentation hardness, shear strength and plasticity,
electrical properties such as semiconductor, positive thermal coefficient, superconductivity,
ferroelectricity and supersets. The study shows that the round type ceramic KYON2000
RNGN120700 (having -7 rake angle) and the square type ceramic KYON4300 SNGN120712
(having +5 rake angle) are ascendant by notch wear, flank wear and flank wear, crater wear,
respectively. The square type ceramics insert shows less flank wear at low cutting speeds but
the round type ceramics insert having less flank wear with the high cutting speeds.
2.5 Literature Survey of Taguchi method

The machining process such as turning process involves variable cutting parameters. These
parameters are mainly cutting speed, depth of cut and feed rate and type of machining
environment (dry or wet). The influence of input parameters on the surface roughness, cutting
temperature, cutting forces and tool wears are quantified through the experimentation and
compared with predicted valves of response parameters which are obtained using Taguchi
method. The magnitude of feed force and cutting force are linear in the cutting speed range of
45-55 m/min with medium feed rate. The tool life decreased by 55 seconds when the cutting
speed increased from 45 m/min to 55 m/min by keeping feed 0.05 mm/rev and depth of cut 0.5
mm as constant trough out the process.
16
Generally, abrasion and microchipping type of wear were to be found during the turning of
Inconel 718 under dry cutting condition. The author concluded that the tungsten carbide inserts
(k20) with the medium cutting speed and medium feed rate range while keeping the low depth
of cut, is required to obtain minimum cutting force and super finish along with overcoming the
problems in the machining of Inconel 718 [1].
2.6 Literature Survey on GRA and ANOVA

Tzeng et al. [6] investigated the optimal machining parameters in CNC turning using grey
relational approach (GRA) technique, on SKD 11 using carbide insert coated with multilayer
titanium nitride (TiN). SKD 11 is a high carbon high chromium alloy steel with high hardness
used in the main template such as the steel plate for pad printing, the production of dies, jigs
and fixtures, precision gauge etc. This material has peculiar properties such as good wear
resistance, less deformation and good quenching. The four machining parameters were taken,
the cutting speed (m/min), the feed rate (mm/rev), the depth of cut (mm) and the cutting fluids
mixture ratio (%), to optimize the response parameter such as roundness, average and maximum
roughness. Minimum surface roughness is desired, so “smaller is better” S/N ratio was selected.
The most prominent factor that affects roughness average is the depth of cut. The roundness
and roughness maximum is mostly influenced by cutting speed. To find out the most prominent
factor ANOVA analysis is used and it identified that the most influences factor more than other
factors is the depth of cut and the percentage contribution of the feed to the turning process is
the minimum. It was concluded that machining at the low depth of cut minimizes the roughness
average, roundness and the roughness maximum simultaneously.
17
Chapter-03
Formulation of Problem
After doing enough literature survey and review, we came to the point to formulate the
Problem Statement for our project.
3.1 Motivation for project :
The following are the main reasons or rationale for the present project work:
a) Turning is the mostly used machining process in manufacturing division.

b) The technology is improving day by day so it is essential to produce customized product at
affordable price according to market demand and requirements.
c) The prediction of turning output variables (Material removal rate, surface finish and cutting
forces) is essential for the optimization of machining (cutting) conditions parameters (feed
rate, cutting speed and depth of cut). By knowing these, the production rate, quality of
product and cutting tool life can be optimised and improved.
d) If we design the experiment input variables using factorial method for 3 input variable and
having 3 level each, we have to conduct 27 experiments.
e) Taguchi method is an efficient tool to design the experiment input variables in efficient way
with lowest expenditure.
After going through the above observations, we find that it is necessary to:
a) Design the experiment with its variable by Taguchi method and achieve results with
Taguchi and ANOVA methods.
18
b) Develop a methodology to estimate Surface finish, Materials removal rate and Cutting
forces for entire range of input parameters.
c) Study the effect of input parameters (feed rate, cutting speed and depth of cut) on output
variable (material removal rate, surface finish and cutting forces) to get optimised response.
3.2 Objective and Approach of Project:

The overall aim of the proposed project work is to design and develop the experimental
work for alloy materials using Taguchi and ANOVA method and to perform experimental work
on CNC or lathe machine. We are using Dynaware software developed by Kistler to find out
the forces and Handy Surf for measuring the surface roughness. The specific objective of our
project work are-
a) To achieve the best combination of Feed, Speed, Depth of Cut for CU-Ni 70/30 and Inconel
800 using Taguchi L9 orthogonal array design.
b) Optimization of Input parameter for achieving good surface finish, lowest cutting forces
and maximum material removal rate.
c) To reduce the manufacturing cost of part, and making affordable price of final product.
d) To establish a procedure for predicting the outputs for given input variables.
e) To demonstrate the use of Dynaware Software for measuring the forces (eg. Cutting force,
radial force etc.)
To achieve the goal (Objective) of our project work, the research for project work is conducted
thorough the following different approaches:
Phase 1: Design the experiment for CU-Ni 70/30 and Inconel 800 using Taguchi L9
orthogonal array design.
Phase 2: Conduction of Experimental work.
Phase 3: Recording the output variables.
Phase 4: Calculation and Analysis of obtained output variables.
Phase 5: Validation of Project work by performing Confirmation test
19
Chapter-04
Terminology Used
In turning operation experiment cutting speed, feed rate and depth of cut are taken as
input parameter and surface finish (roughness) are taken as responses (outputs). The material
removal rate is calculated theoretically. The main terms used are as following [14, 15]:
4.1 Cutting speed:

It is also known as surface speed. It is the distance that is advanced in one revolution of
the spindle by the cutting tool or workpiece. Cutting speed directly varies according to the
diameter of the workpiece. Higher the diameter, higher will be the cutting speed. So it varies as
the diameter (cross-section) reduces. It can be kept constant in CNC machine which use CSS
(constant surface speed). It is given in meter per minute or meter per seconds.
4.2 Feed rate:

The speed of the cutting tool's movement relative to the workpiece as the tool makes a
cut. The feed rate is measured in inches per minute (IPM) and is the product of the cutting feed
(IPR) and the spindle speed (RPM). The generally and most used unit is mm per revolutions
(mm/rev.)
4.3 Spindle speed:

The speed or velocity of the spindle is directly given in terms of Revolutions per Minute
(RPM). RPM represents the number of turns completed in one minute around a fixed axis.
20
4.4 Axial depth of cut:
It the depth of cutting tool moving along the central axis of workpart during the cut, it
is similar as to done in facing operation. A low feed rate is required is required to make large
axial depth of cut, otherwise it creates high load and results in increase in temperature and this
lead to reduction of tool life. The axial depth of cut is given gradually to the tool as it moves
forward for each pass.
4.5 Radial depth of cut:

It is the depth of the tool in radial direction as cutting tool moves forward for machining.
It is given perpendicular to the axis of the workpiece. Here also low feed rate are given to
maintain and control the temperature rise of tool and workpiece and to enhance the life of
cutting tool.
21
Chapter-05
Experimental Procedure
5.1 Introduction
The turning experiment is carried out on lathe machine. The lathe machine used is
conventional manual lathe. The experimental set-up is a system consisting of machine, tool,
work piece and measuring instruments. The tool used is insert. The workpiece materials are Cu-
Ni 70/30 and Inconel 800.
5.1.1 Properties and Application of Work piece material

In project part-A the experiments were conducted on EN-8 steel. Two workpiece
materials are chosen for project part-B. These are:
(i) Cu-Ni 70/30 : The following are the properties of the Cu-Ni 70/30 material:
Chemical Composition:
The following are the major elements of the compositions.
S.N. Element Content (%)

1 Copper, Cu 70.0
2 Nickel, Ni 30.0
22
Physical Properties: Density = 8.94 g/cm3
Melting point= 2140 °F
Mechanical Properties:
Tensile strength (ultimate) = 372-517 Mpa
Tensile strength (Yield) = 88.0 to 483 MPa (depends on temperature)
Elongation at break= 45.0 %
Machinability=20%
Poison ration= 0.34
Shear modulus= 57.0 GPa
Elastic modulus= 150 GPa
Characteristics:
It is alloy and great resistance to corrosion and erosion.
It is strong and ductile.
Excellent resistance to attack by fresh water.
It has more strength than 90/10 material.
Applications:
It is used where high temperature and pressure with large velocities is major problem.
It has applications in marine services.
Used in tidewater power plant, oil refineries and desalinization plants.
Used in manufacturing of condenser, heat exchangers, water piping and tanks.
23
(ii) Inconel 800: The following are the properties of the Inconel material:
Chemical properties:
Physical properties:
Density = 7.94 g/cm3
Mechanical properties:
Tensile strength = 600 MPa
Yield strength = 275 MPa
Elongation at break = 45%
Characteristics:
Inconel 800 is a Fe-Ni-Cr alloy, it has sufficient resistance to oxidation.
It has special application in high-temperature equipment in industries.
It has excellent resistance to chloride stress-corrosion cracking.
It can maintain its structure at high temperatures.
It has good strength and high resistance to oxidation.
Applications:
The major application is the production of heat exchangers and process piping.
Manufacturing of carburizing fixtures and jigs.
In high heat bearable components like furnace components.
Electric range heating-element sheathing
Extruded tubing for ethylene and steam methane reforming furnaces
Ammonia effluent coolers are produced with this alloy.
In production of tubes which are used in nuclear steam generator.
5.1.2 Properties of tool material (Insert)

The tool materials selection is crucial stage in experiments executions. The workpiece
material in project part-A was EN-8 steel so HSS tool was used for experiment execution. In
project part-B, we have chosen alloys as workpiece material, which are i). Cu-Ni 70/30 and ii).
Inconel 800.
24
The hardness of these materials is very high due to presence of nickel in them so a tool
having more hardness them is selected. So the carbide inserts are chosen for tool inserts so that
the compatibility between workpiece and tool insert can be maintained.
Tool material specifications: “CNMP120408 CNMP432 WS25PT”. It is made by

WIDIA and it is having negative insert. CNMP120408 is ISO designation of tool and
CNMP432 is ANSI designation. Which tells tool insert has:
Insert 1C= 12.7 mm
Insert width= 0.738 mm
Corner radius= 0.123 mm
Diameter of through hole= 5.15 mm
WS25PT represents manufacturer’s grade. It has PVD-TiAlN (physical vapour

deposition of titanium aluminium nitrate) coating, which makes it tough, ultrafine grain
substrate.
Purpose of coating:
a) It provide corrosion resistance to insert and protect from rust.

b) Coating enhances appearances of insert.
c) Due to coating the surface can be used for more than one operations.
d) Coating strengthens the tool material for better performances.
25
Figure 5.1 (a) Schematic illustration of a right-hand cutting tool for turning.
5.1 (b) Carbide inserts (Source 2)
Figure 5.2 Methods of mounting inserts on tool holders: (a) Clamping, (b) Wing
lock pins. (c)Examples of inserts mounted using thread less lock pins, which are
secured with side screws. (Source 2)
5.1.3 Designation of Tool-

Generally the hardness of tool material should be more than workpiece material that is
to be machined. There should be relative motion and physically contact between tool and
workpiece in conventional machining processes. But in modern days it is applicable only to
conventional machining processes. In non-conventional machining process the workpiece
hardness can be more than the cutting tool and it is not necessary that there should be contact
between cutting tool and waorkpiece.
A cutting tool has one or more sharp cutting edges to cut the material and it is called
single point and multi-point cutting edge tool respectively. There are two surfaces which
connect the cutting edge, these are- The rake face and the flank.
26
The rake face is oriented at a certain angle and it is termed as ‘rake angle (α )’, it directs
the flow of newly formed chip in machining [10]. It is measured relative to the plane
perpendicular to the work surface, the value of rake angle can be negative or positive.
The clearance is provided between the cutting tool and newly formed work surface by flank of
the tool. Flank protects surface from abrasion. Relief angle is measured in between the work
surface and flank surface.
Cutting tool can be divided into two type based on edge(s) of tool:
a) Single point tool-
A single point tool has one cutting edge and is used for machining in the processes of
turning, boring and planing. During machining operation the point of the cutting tool penetrates
into the original work surface of the workpart. The point of toll is rounded to a certain radius
and this is termed as the nose radius. This is done to reduce the fracture of cutting tool.
b) Multiple-cutting-edge tool
Multiple-cutting-edge tools have more than one cutting edge. Motion is given to them
relative to the workpart by rotating. Multiple cutting edge tools are used in drilling and milling.
Many elements of tool geometry may be similar in spite of having different shapes of these
tools.
5.2 Experimental set-up-

The experimental set-up is a system consisting of machine, tool, work piece and
measuring instruments.
Figure 5.3 Experimental set-up
27
5.2.1 Specification of lathe-
The lathe which we used for our experimental work is manual operated, variable
speed precision lathe.
Its specifications are as:

(i) Designation: TEQIP/WS/EQ/22 /06-07
(ii) It is precision lathe machine with Hydro- copying attachment.
(iii)It has three jaw chuck.
(iv) Swing Cover Bed: 350 mm
(v) Distance Between Centres: 750 mm
(vi) Swing Over Carriage: 200 mm
(vii) Spindle Variable Speeds: 45-1800 R.P.M, it has following value-
45,70,90,108,140,165,215,255,330,335,510,585,770,900,1170,1800 R.P.M.
(viii) We can give feed rate in range of 0.055 to 7.0 mm/rev
Figure 5.4 Work piece on lathe machine
5.2.2 Specifications of Tool holder
We used the tool holder for insert with following specifications:

PCLNR 2020 K12 WIDAX
The cross-section of tool holder is 20mm × 20 mm
Figure 5.5 Tool holder
28
5.2.3 Specification of Dynaware
The value of force was measured with Kistler Dynoware software[7]. This is user
friendly software and have main use in force measurement. It has following characteristics:
i. It has simple operation.

ii. It has useful signal evaluation. It easily calculates functions.
iii. It can record up to twenty-eight measuring channels in one go.
iv. It visualizes the measured curve in real time and show the results.
v. Stationary as well as rotary system are supported by the Kistler DynoWare.
Connection Description:
The dynamometer is placed on carriage and tool post and tool holder are placed on it.
We used Dynamometer type 9129AA in our experiment. The dynamometer is connected with
Charge Amplifier with connecting cables. The connecting cables is high resistant and is of type
1677A5. The type of Charge Amplifier is 5070A. The Charge Amplifier is connect to main
power source and at the same time it is also connected with DAQ-System with connecting
cables having type of 1700A111A2 and Type 1200A27. The final connection is made from
DAQ-System to laptop. The pre-requirement for this is that the laptop should have installed the
DynaWare software in it.
Operation Description:
After the proper connection of all the equipments, the experiment is started and
simultaneously reading are taken on laptop with software. We get graphs for each reading there
and we have to take average value from that for calculation. The same is repeated throughout
the experiment.
Figure 5.6 Typical Measuring Chain with DAQ-System Type 5697A1 (Source: Kistler)
29
5.2.4 Specification of Roughness tester
For measurement of surface finish, we used Surtronic S128 Roughness tester [8]. It is
made by Taylor Hobson. It is robust in construction and it is portable surface finish tester.
General Description and Characteristics:
It has USB connectivity so it can be added to laptop or PC for analysing the observed
data. It can be mounted flat or curved surfaces perfectly.
It is tough, fast in response and reliable- It gives results in few seconds after pressing
the measurement button. It also shows profile graph.
It has impact resistant rubberised body. It has touch screen and protected by Mylar. It
has battery of capacity 3000mAh heavy duty Li-Poly. Around up to 2000 measurements can be
taken from a single charge. Overall it is long last design.
The device can made ready in less than 1 seconds by proper uses of InstantOn
technology. It can last long as more than 5000 hours in standby mode. It is handheld roughness
tester and provides 7 parameters per screen (page) in measurement settings.
It can be adjusted up to 50mm up or down in vertical direction and it can reach up to 7

cm into bores. It gives the graph of the profile being measured with digital value of various
roughness.
By the application of this:
(i) Throughput is improved.

(ii) Part scrappage can be reduced.
(iii)Tool wear can be monitored.
(iv) Traceability can be insured by the application of this device.
Applications:
(i) Any surface can be measured with this device without the need for any stands or fixtures
or without any costly riser blocks. This device has anti-slip V-feet characteristics so any
flat or curved surfaces can be measured by the system. The stylus can even measure the
surface from upside down also.
(ii) Measurements in shop floor,
(iii)Industrial applications,
(iv) Used in inspection room.
(v) Process control- Machining operations like turning, grinding, milling and honing.
(vi) Automotive- Used in measurement of surface of gears, con rods and crankshafts.
30
(vii) Heavy industry- It has wide applications in shipbuilding, pipelines division as well as
sheet steel sectors.
(viii) Aerospace- Components like turbine blades and shafts, components of wings can be
measured easily with this device.
(ix) Other applications includes bonding, print rollers etc.
(x) It is used in automobile, aerospace and bearing manufacturing industries.
Standards and traceability:

The reference standards are supplied to the system and this can be used for both to
calibrate the instrument as well as to check for stylus wear. This is done to make sure that most
accurate results are achieved in measurements.
Figure 5.7 Measurement capability of Surface tester
Figure 5.7 Measurement of Surface roughness with Surface tester
31
5.3 Assumptions:
In our project and experimental work these are the main assumptions which are made:
a) We are considering Feed, cutting speed and depth of cut as our input parameters and
surface finish (roughness) and cutting forces are response or output.
b) Machine and tools are rigid.
c) Tool vibration is neglected.
d) The effect of temperature is neglected.
e) Wear and tear of tool is neglected.
f) We are calculating material removal rate as theoretically.
g) The work piece material is free from solid particles like dust, oxide films and rust.
h) The depth of cut is small, so the cutting speed in finishing and actual turning is assumed
constant.
i) Abnormal cutting like Irregular and interrupted are neglected.
32
Chapter-06
Optimization Methods
6.1 Taguchi method

6.1.1 Introduction:
Taguchi method is a statistical approach. Taguchi and Konishi developed this method
to improve the quality of goods manufactured. But over the decades, the Taguchi method is
used in other field also, such as Production Engineering, Medical field. This method is
developed to study the variation of process parameters on response parameters by conducting
minimum number of experiment. It requires the careful selection of input parameters. So that,
the noise factor effects can be nullified. Taguchi Method helps to identify best control factors
to obtain the optimum results of the process. Orthogonal Arrays (OA) are used to conduct a set
of experiments. Taguchi method involves analysis of the data and it provides the influencing
order of process parameters by considering a set of experimental data which is achieved by
designing the orthogonal array on the basis of fixed control factors and their levels. It also helps
to predict the quality of components produced.
In the further chapters, the application of Taguchi’s Method is demonstrated to improve

the surface finish characteristics and cutting force characteristics of machined component,
which is machined on a lathe machine.. Surface finish affects the life and the quality of any
product. So, it is desirable to obtain higher grades of surface finish at minimum cost by
minimizing the surface roughness.
33
6.1.2 Approach to optimize the machining process
There are several methods which are used to optimize the manufacturing process such
as Build-Test Fix, One factor at a time, full factorial design method etc.
1. Design of Experiment (DOE)
The design of experiment (DOE) involves all process parameters in their specified range
and designs a set of experiment. The Design of Experiments is considered as one of the broad
approach in product developments. It is a statistical approach which provides a predictive
knowledge of a complex, multi-variable process with few trials. Following are the major
approaches to DOE.
1.1. Full Factorial Design
A full factorial experiment consists more than one factor with their levels. The
experimental design involves all possible combinations generated by the levels across all the
factors. The full factorial design allows studying the effect of each process/input parameter on
the response parameter, as well as the effects of interactions of process parameter on the
response parameters. If there are k factors each at 2 levels; a full factorial design must runs 2K.
Thus for 3 factors at 3 levels it would take 27 trial runs.
1.2. Taguchi Method
The Full Factorial Design requires a large number of experiments to be carried out as
stated above. As the factor number increase, the full factorial design has more number of trail
runs. So, it become bulky and complex. To avoid such problem Taguchi presented the use of
orthogonal array to study the whole parameter space with lesser number of experiments to be
conducted. Taguchi thus, recommends the use of the loss function to measure the performance
characteristics that are deviating from the desired target value. The value of this loss function
is further transformed into signal-to-noise (S/N) ratio. Usually, there are three categories of the
performance characteristics to analyse the S/N ratio. They are: nominal-the-best, larger-the-
better, and smaller-the-better.
The use of Taguchi’s parameter design involves the following steps:
a. Identify the main function and its side effects.
b. Identify the noise factors, testing condition and quality characteristics.
c. Identify the objective function to be optimized.

34
d. Identify the control factors and their levels.
e. Select a suitable Orthogonal Array and construct the Matrix.
f. Conduct the Matrix experiment.
g. Examine the data; predict the optimum control factor levels and its performance.
h. Conduct the verification experiment.
Two types of factors are involved in machining process such as control factors and noise factors.
The control factors are cutting speed, depth of cut, feed rate, nose radius and coolant etc. and
the noise factors corresponding to control factors are machine condition, temperature, vibration,
operator skill etc.
The most important in Taguchi method is to identify the objective function such as
smaller-is-better for surface roughness and larger-is-better for MRR (material removal rate). If
the objective is smaller-the-better than the S/N Ratio for this functions is
Where: n = Sample Size, and y = Observed Surface Roughness during that run
The factors and their levels are selected from the knowledge of literature survey. After selecting
factors and their levels an experimental setup is made by using an appropriate orthogonal array.
The summary is that Taguchi method gives the same optimal result as full factorial analysis.
But it perform less number of experiment that provide benefits economically and save the time.
6.2 ANOVA method:

ANOVA is developed by Ronald fisher. ANOVA is a computational technique. It
enables to estimate the percentage contributions of each of the process parameter. ANOVA is
that the total sums of the squares (total variation) is equal to the sum of the SS (sums of the
squares of the deviations) of all the condition.
The assumptions for the ANOVA analysis is that:
1. They are normally distributed and errors are independent

2. Expected values of the errors are zero
3. The variances of all errors are equal to each other
35
Chapter-07
Effects of Process parameter on responses
7.1 Surface Roughness:-

The surface finish or surface texture is defined in term of waviness, lay and surface
roughness. The surface texture denotes the nature of surface or the quality of the product. It is
inversely proportional to surface roughness i.e. as surface finish increases the surface roughness
decreases that’s result in having a good quality product.
Surface roughness is quantified in the normal vector direction of the surface. It is the
deviation of the real surface normal vector to the ideal surface normal vector. For the smooth
surface variation in the normal vector direction is small but for the rough surface deviation are
large. So, surface roughness which is also called roughness, denote the state of machined
surface whether it is smooth or rough. The surface roughness is measured in micrometres (µm).
36
Figure 7.1 Components of surface texture
Waviness is a component of surface finish. It is somehow similar to the surface

roughness except it quantify the irregularities with the large spacing than the surface roughness.
The sample length for measurement of waviness is larger than roughness. Waviness can be seen
through naked eyes.
Lay is define as the direction of the finish surface pattern. Lay patterns can have vertical,
horizontal, radial, circular, isotropic, cross-hatched direction.
The empirical formula for the average surface roughness (Ra) measurement is given as:
𝑓2
𝑅𝑎 =
31.2 × 𝑟𝑛
Where:
𝑟𝑛 = Tool tip radius in mm;
f = Feed in mm/tooth;
Ra= average surface roughness in µm.
7.1.1 Effect of Cutting Speed on Surface Roughness:
The cutting speed is the rate at which the metal is removed by tool. It is denoted by the
symbol V and given in meters per minute. In general, the surface roughness varies with cutting
speeds as the cutting speed increases the surface roughness decreases. But in actual that is
happened for a certain range of cutting speed and for the different materials the range is also
having different values.
37
In the starting of cutting speeds, the irregularities on the machined surface increase i.e.
the surface finish decrease that is happened due to the accumulation of heat at the tool tip. Due
to the excessive heat, the cutting edge of the tool goes into plastic state and become blunt due
to the deformation that leads to rough cutting of specimen and leaves chatter and scratch marks.
Further, as we increase the cutting speed the tool cutting edge staying time become shorter at
one position that allows accumulating less heat at the tool contact area with work-piece. That
leads to having good surface finish with fewer irregularities on the surface. As the cutting
surface increases furthermore, the heat accumulates very less at the contact between workpiece
and tool edge that leads the problems for the work-piece to not able to go under plastic
deformation during cutting operation. The material becomes harder and it is difficult to cut with
the tool that leads to increasing in surface roughness. So the summary is, the cutting speed
neither keep less nor keep it high.
7.1.2 Effect of Feed rate on Surface Roughness
The feed is the distance travel by the tool on the work-piece per revolution of spindle.
It is denoted by the symbol f and given in millimetres per revolution. Generally, the surface
roughness varies proportionally with the square of feed as the feed increases the surface finish
decreases i.e. the surface roughness increases. But in actual it depends upon the type of cutting
tool material, workpiece material properties, setup rigidity, thermal conductivity of tool and
workpiece material, whether it is dry or wet cutting and other parameters. If all other parameters
keep in their well-known range and constant throughout the process then it is possible to
evaluate the effect of feed on surface finish. For the soft material, as the feed increase the surface
roughness also increase but for the hard material whose thermal conductivity is less, as the feed
increase the surface roughness decrease till a certain increment. As the feed increase further
beyond a limit the irregularities start to increase on the surface of workpiece i.e. the surface
roughness increase and the product lose its quality or surface finish. So the summary is the
optimum feed that gives minimum surface roughness cannot be fixed for a material because it
depends on the machining condition and varies with it.
38
7.1.3 Effect of Depth of Cut on Surface Roughness:
The depth of cut is expressed as the thickness of metal removed in one cut of the tool.
It is denoted by the symbol doc and given in millimetres. The depth of cut has significant effect
on surface roughness. As the depth of cut increases the surface roughness also increases. It
happens due to the more load on tool cutting edge that leads to the grain distortion of tool
material during the plastic state of the material. The tool deformation occurs due to the heat that
is generated onto the tool flank surface mainly due to the friction between flank surface and
chip witch are following over the flank surface during a cut. As the work-piece and tool material
properties and machining condition changes, there is a possibility that the surface finish may
be better at higher depth of cut.
7.2 Cutting Force:

In the turning process, the cutting force act on the area of contact between the material
and tool. This cutting force can be represented as three components (tangential cutting force,
feed force, radial force) which are perpendicular to each other. These forces are responsible for
chatter on the workpiece surface, vibrations during the cutting operation and decrement in setup
rigidity. Generally, the cutting force is measured in newton’s (N). These three forces are:
Figure 7.2 cutting force components in turning
1. The tangential cutting force or main cutting force acts perpendicular to the spindle axis at the
periphery of the workpiece. The direction of this force is downward on the tool cutting edge.
The tangential cutting force is mainly responsible for chip-off from the workpiece among all
three forces. It depends on the tool and workpiece material.
39
2. The feed or axial force acts parallel to the spindle axis along the workpiece and opposite to the
feed direction. The axial force causes a problem in the interaction between tool cutting edge
and the workpiece. This force acts on the tool in such a way that it pushes the tool cutting edge
away from the workpiece surface in the longitudinal direction. Due to insufficient rigidity the
axial force influence the cutting action and material removal rate.
3. The radial or passive or thrust force acts perpendicular to the spindle axis and in the radial
direction. The radial force responsible for pushing the tool away in the radial direction from the
workpiece. Although, the thrust force is significantly small in comparison to other forces but
still it affects the cutting operation.
The empirical formula for the calculation of the cutting force is given as:
𝐹𝑖 = 𝐶𝐹𝑖 × 𝑓 × 𝑑𝑜𝑐
Where:
𝐶𝐹𝑖 = Specific cutting energy coefficient (N/mm2 );
F = Feed rate (mm/rev);
doc = Depth of cut (mm);
i = index which represent the cutting force components [feed force (f), radial force(r or p),
tangential cutting force(c)].
The machining parameters in turning process such as cutting speed, feed, depth of cut etc.
affect the cutting forces. The discussion on this affects are as following [9]:
7.2.1 Effect of Cutting Speed on Cutting Force:
Figure 7.3 Cutting forces vs. cutting speed at doc = 0.5 mm and f = 0.2 mm/rev
40
Generally, as the cutting speed increase by keeping the feed and the depth of cut
constant, the cutting force components such as tangential cutting force, axial force, thrust force
decreases. The decrement in the cutting force component does not remain uniform as the cutting
speed increases. The decrease in cutting force components can be explained by the temperature
effects on the workpiece. The increment in the cutting speed raises the temperature in the cutting
zone. Due to high temperature, the workpiece material undergoes in the plastic state and become
easy to cut. That leads to the decrement in the cutting force because the effort to machine the
workpiece is decreased as the material become soft. It is found that the decrease in the cutting
force occur sharply until a cutting speed achieves, beyond that the decrease in the cutting force
components become slower. The feed force is more sensitive to the variation of the cutting
speed in comparison to other two cutting force component.
7.2.2 Effect of Feed Rate on Cutting Force:
Figure 7.4 Cutting forces vs. feed rate at v = 69.24 m/ min and doc = 1 mm
The feed affects the cutting force components in such a way that by increasing the feed,
the cutting force can be increased. It can be explained by the fact that as the feed rate increase,
the sheared chip area also increases and due to this phenomenon the separation of material from
41
the workpiece requires greater forces than before. The tangential cutting force and the feed or
axial force increases rapidly with the feed rate. But for the passive or thrust force, the increment
rate is being slower in comparison to other two cutting force components. So, it is appropriate
to say that the thrust force is less sensitive to the variation of the feed rate compared to the
tangential and feed force. In this case, the main cutting force dominates the other two forces.
7.2.3 Effect of Depth of Cut on Cutting Force:
Figure 7.5 Cutting forces vs. depth of cut at v = 69.24 m/ min and f = 0.2 mm/rev.
The depth of cut affect the cutting force components in such a way that by increasing
the depth of cut, the cutting force can be increased. It can be explained by the sheared chip area.
Because corresponding to the larger area the higher force is required to cut the material. It is
found that the tangential force is more sensitive to the variation of the depth of cut because it
increases sharply with the increased depth of cut. The feed force is less sensitive than the
tangential force. The radial or thrust force remain almost constant with the increase in depth of
cut. So, it is appropriate to claim that the tangential force is the main cutting force because it
has a much larger impact on cutting operation compared to other cutting force components. So,
during the calculation, the feed and radial force can be neglected.
42
The summary is that the cutting force components (tangential cutting force, radial force
and feed force) are increasing with the increment in the feed rate and depth of cut, but they are
decreasing as the cutting force increases. The variation of feed rate is the most prominent factor
for affecting the cutting forces.
7.3 Material Removal Rate (MRR):

A raw material piece is cut into a desired shape and size by controlling material removal
process. The material removal rate is the rate at which the material is removed from the
workpiece. The material removal rate is the output parameter which is affected by feed, cutting
speed and depth of cut. The MRR is measured in mm3 /min.
The empirical formula for the calculation of the cutting force is given as:
𝑉𝑜𝑙𝑢𝑚𝑒 𝑅𝑒𝑚𝑜𝑣𝑒𝑑
MRR = 𝑇𝑖𝑚𝑒
𝑀𝑅𝑅 = 𝑉𝑐 × 𝑓 × 𝑑𝑜𝑐
Where:
𝑉𝑐 = cutting velocity (mm/min);
f = width of cut (mm);
doc = depth of cut (mm).
7.3.1 Effect of Cutting Speed on MRR
The material removal rate is proportional to the cutting speed. The material removal
rate linearly increase with the increasing cutting speed.
7.3.2 Effect of Feed Rate on MRR
The material removal rate is proportional to the feed rate. As the feed rate increase, the
linear increment occur with the material removal rate i.e. the material removal rate also
increase.
7.3.3 Effect of Depth of Cut on MRR
The material removal rate is proportional to the depth of cut. The material removal rate
linearly increase with the increasing depth of cut.
43
Chapter-08
Experiment Details
8.1. Experiment Details for Inconel 800:

8.1.1 Selection of process parameters and their level
The experiment is carried out on Inconel 800 using Taguchi's design of experiment
method. Taguchi method involves selection of control factors and their levels and response
parameters. Three control factors are selected: cutting speed (V), feed (f), depth of cut (doc)
with 3 levels for each factor. The response parameters are selected for the experimentation is
surface roughness (Ra), cutting forces (tangential cutting force (Fz), feed force (Fy), radial force
(Fx)) and material removal rate (MRR). The Table -1 contains the list of machining input
parameters and their level for turning process:
S.N Cutting Notation Unit Levels of factors

O Parameter
1 2 3
1 Cutting speed V Rpm 560 640 720
2 Feed f mm/rev 0.085 0.094 0.103
3 Depth of cut doc Mm 0.2 0.3 0.4
Table-8.1 Cutting parameters and levels
44
8.1.2 Design of Experiment:
If the full factorial design is used, it would have 27 experiments. So, the Taguchi design
of experiment is used to decrease the experiments so that the unnecessary wastage of material
can be decreased. So, the standard L9 (3 × 3) orthogonal array design by Taguchi design of
experiment is chosen. It only require 9 experiments to optimize the response parameters, a
fraction of the full factorial design.
S.N. Cutting speed (V) Feed(f) Depth of cut (doc)

1 560 0.085 0.2
2 560 0.094 0.3
3 560 0.103 0.4
4 640 0.085 0.3
5 640 0.094 0.4
6 640 0.103 0.2
7 720 0.085 0.4
8 720 0.094 0.2
9 720 0.103 0.3
Table-8.2 Taguchi L9 (3 × 3) orthogonal array design layout
8.1.3 Experimental Analysis of surface roughness for Inconel 800:

The quality of a machined surface depend upon the roughness of the surface. So, for a
better surface finish the roughness should be minimized. In the Taguchi design of experiment
the concept of S/N ratio is used to optimize the surface roughness (Ra). So, the S/N ratio for
surface roughness is considered as the "smaller-is-better" and calculated by using following
equation.
S/N ratio = -10 Log10 [{sum (𝑦 2 )}/ n]..................................... (i)
Where, n is the number of observations and y is the observed data.
The S/N ratios is computed for the surface roughness using Eq. 1 for each of the 9 runs and the
values are recorded in below Table for Inconel 800:
45
Exp Cutting Feed Depth of Ra1 Ra2 Mean Ra SNRA1
. Speed f cut (µm) ( µm ) ( µm )
No. V (mm/rev) doc
(rpm) (mm)
1 560 0.085 0.2 1.5 2.2 1.85 -5.4962
2 560 0.094 0.3 3.1 3.9 3.50 -10.9377
3 560 0.103 0.4 1.9 2.1 2.00 -6.0314
4 640 0.085 0.3 2.0 2.1 2.05 -6.2377
5 640 0.094 0.4 1.6 2.5 2.05 -6.4395
6 640 0.103 0.2 1.0 1.1 1.05 -0.4336
7 720 0.085 0.4 1.5 2.8 2.15 -7.0286
8 720 0.094 0.2 1.3 1.5 1.40 -2.9447
9 720 0.103 0.3 1.2 2.3 1.75 -5.2699
Table-8.3 Experimental readings for the response parameter as the average surface roughness
Level V f doc
1 2.450 2.017 1.433
2 1.717 2.317 2.433
3 1.767 1.600 2.067
Delta 0.733 0.717 1.000
Rank 2 3 1
Table-8.4 Response Table for Means Ra
The Taguchi design of experiment help to select the best pair of input parameters value
among the several possibilities and that provide the optimum valve of response parameter. It
also conclude in which order the input cutting parameters are affecting the response parameter
i.e. the rank of cutting parameter (Table-4). But the Taguchi design of experiment is unable to
provide the information about the exact contribution of each cutting parameter. That is done by
the analysis of variance (ANOVA).
So, to quantify the contribution (C, in percentage) of cutting parameters (V, f, doc) on the
average surface roughness (Ra), analysis of variance (ANOVA) is performed and recorded in
Table-5.
Source DOF S.S M.S F value C%

Speed (V) 2 1.0072 0.5036 3.35 27.81
Feed (f) 2 0.7772 0.3886 2.59 21.47
Depth of cut (doc) 2 1.5356 0.7678 5.11 42.41
Error 2 0.3006 0.1503 8.3
Table-8.5 ANOVA analysis for means of average surface roughness
Where: DOF (degree of freedom), S.S (sum of squares), M.S (mean of squares).
46
8.1.4 Experimental Analysis of cutting force for Inconel 800:
This cutting force in turning process is represented as three components (tangential
cutting force (Fz), feed force (Fy), radial force (Fx)) which are perpendicular to each other.
These forces are responsible for chatter on the work-piece surface, vibrations during the cutting
operation and decrement in setup rigidity. As the cutting force increase to cut the material the
more power is required. So, for a less power consumption and for the soft cutting, the cutting
force should be minimized. In the Taguchi design of experiment the concept of S/N ratio is used
to optimize the cutting force components. So, the S/N ratio for cutting force components is
considered as the "smaller-is-better" and calculated by using following equation.
S/N ratio = -10 Log10 [{sum (𝑦 2 )}/ n]................................................. (ii)
The S/N ratios is computed for the cutting force components using Eq. 1 for each of the 9 runs
and the values are recorded in below Table for Inconel 800:
Exp. Cutting Feed f Depth of Mean Mean Mean

No. Speed (mm/ rev) cut tangential feed force radial
V doc cutting force Fy force Fx
(rpm) (mm) Fz (N) (N)
(N)
1 560 0.085 0.2 112.5 97.81 38.88
2 560 0.094 0.3 146.9 126.30 57.03
3 560 0.103 0.4 183.4 150.20 74.02
4 640 0.085 0.3 119.7 101.40 51.83
5 640 0.094 0.4 149.4 136.60 80.31
6 640 0.103 0.2 102.5 96.52 35.14
7 720 0.085 0.4 153.8 131.70 85.70
8 720 0.094 0.2 103.0 101.10 38.22
9 720 0.103 0.3 134.2 117.30 56.58
Table-8.6 Experimental readings for the response parameter as the cutting force components
Level V f doc
1 147.6 128.7 106.0
2 123.9 133.1 133.6
3 130.3 140.0 162.2
Delta 23.7 11.4 56.2
Rank 2 3 1
Table-8.7 Response Table for Means Fz
47
Level V f doc
1 124.77 110.30 98.48
2 111.51 121.33 115.00
3 116.70 121.34 139.50
Delta 13.26 11.04 41.02
Rank 2 3 1
Table-8.8 Response Table for Means Fy
Level V f doc
1 56.64 58.80 37.41
2 55.76 58.52 55.15
3 60.17 55.25 80.01
Delta 4.41 3.56 42.60
Rank 2 3 1
Table-8.9 Response Table for Means Fx
The Taguchi design of experiment help to select the best pair of input parameter among the
several possibilities and that pair provide the optimum valve of response parameter. It also
conclude in which order the cutting parameters are affecting the response parameter i.e. the
rank of cutting parameter (Table-7, 8, 9). But the Taguchi design of experiment is unable to
cutting force components (tangential cutting force (Fz), feed force (Fy), radial force (Fx)),
analysis of variance (ANOVA) is performed and recorded in Table-10,11,12.

Speed (V) 2 903.23 451.61 51.18 15.42
Feed (f) 2 196.93 98.46 11.16 3.36
Depth of cut (doc) 2 4738.16 2369.08 268.50 80.91
Error 2 17.65 8.82 0.3
Table-8.10 ANOVA analysis for means of Fz

Speed (V) 2 268.01 134.01 197.90 8.73
Feed (f) 2 243.47 121.73 179.78 7.93
Depth of cut (doc) 2 2556.18 1278.09 18887.4732.61 83.29
Error 2 1.35 0.68 0.04
Table-8.11 ANOVA analysis for means of Fy
48
Speed (V) 2 32.61 16.31 0.88 1.14
Feed (f) 2 23.44 11.72 0.64 0.83
Depth of cut (doc) 2 2747.13 1373.57 74.53 96.72
Error 2 36.86 18.43 1.31
Table-8.12 ANOVA analysis for means of Fx
8.1.5 Experimental Analysis of Material Removal Rate (MRR) for Inconel

800:
The material removal rate is the response parameter which is affected by feed, cutting
speed and depth of cut. The material removal rate affect the timing of obtaining desire piece
through the machining process. So, in order to increase the production rate, the MRR should be
maximized. In the Taguchi design of experiment the concept of S/N ratio is used to optimize
the MRR. So, the S/N ratio for MRR is considered as the "larger-is-better" and calculated by
using following equation.
S/N ratio = -10 Log10 [{sum (1/𝑦 2 )}/ n]....................... (iii)
The S/N ratios is computed for the material removal rate using Eq. 1 for each of the 9 runs and
the values are recorded in below Table for Inconel 800:
Exp. Cutting Speed Feed f (mm/rev) Depth of MRR SNRA1

𝟑
No. V cut (𝐦𝐦 /𝐦𝐢𝐧)
(rpm) doc
(mm)
1 560 0.085 0.2 595.0 55.4903
2 560 0.094 0.3 987.0 59.8863
3 560 0.103 0.4 1442.0 63.1793
4 640 0.085 0.3 1020.0 60.1720
5 640 0.094 0.4 1504.0 63.5450
6 640 0.103 0.2 824.0 58.3185
7 720 0.085 0.4 1530.0 63.6938
8 720 0.094 0.2 846.0 58.5474
9 720 0.103 0.3 1390.5 62.8634
Table-8.13 Experimental readings for the response parameter as the material removal rate
49
Level V f doc
1 1008.0 1048.3 755.0
2 1116.0 1112.3 1132.5
3 1255.5 1218.8 1492.0
Delta 247.5 170.5 737.0
Rank 2 3 1
Table-8.14 Response Table for Means MRR
The Taguchi design of experiment help to select the best pair of input parameters value among
the several possibilities and that provide the optimum valve of response parameter. It also
conclude in which order the input cutting parameters are affecting the response parameter i.e.
the rank of cutting parameter (Table-14). But the Taguchi design of experiment is unable to
So, to quantify the contribution (C, in percentage) of cutting parameters (V, f, doc) in the
material removal rate, analysis of variance (ANOVA) is performed and recorded in Table-15.

Speed (V) 2 92380 46190 14.82 9.64
Feed (f) 2 44508 22254 7.14 4.64
Depth of cut (doc) 2 814915 407458 130.77 85.06
Error 2 6232 3116 0.65
Table-8.15 ANOVA analysis for means of MRR
8.2. Experiment Details for Cupro-Nickel 70/30:

8.2.1 Selection of process parameters and their level
The experiment is carried out on Cupro-Nickel 70/30 using Taguchi's design of

experiment method. Taguchi method involves selection of control factors and their levels and
response parameters. Three control factors are selected: cutting speed (V), feed (f), depth of cut
(doc) with 3 levels for each factor. The response parameters are selected for the experimentation
is surface roughness (Ra), cutting forces (tangential cutting force (Fz), feed force (Fy), radial
force (Fx)) and material removal rate (MRR). The Table -16 contains the list of machining input
parameters and their level for turning process:
50
S.N Cutting Notation Unit Levels of factors
O Parameter
1 2 3
1 Cutting speed V rpm 560 640 720
2 Feed F mm/rev 0.085 0.094 0.103
3 Depth of cut Doc mm 0.2 0.3 0.4
Table-8.16 Cutting parameters and levels
8.2.2 Design of Experiment:
If the full factorial design is used, it would have 27 experiments. So, the Taguchi design
of experiment is used to decrease the experiments so that the unnecessary wastage of material
can be decreased. So, the standard L9 (3 × 3) orthogonal array design by Taguchi design of
experiment is chosen. It only require 9 experiments to optimize the response parameters, a
fraction of the full factorial design.
S.N. Cutting speed (V) Feed(f) Depth of cut (doc)

1 560 0.085 0.2
2 560 0.094 0.3
3 560 0.103 0.4
4 640 0.085 0.3
5 640 0.094 0.4
6 640 0.103 0.2
7 720 0.085 0.4
8 720 0.094 0.2
9 720 0.103 0.3
Table-8.17 Taguchi L9 (3 × 3) orthogonal array design layout
8.2.3 Experimental Analysis of surface roughness for Cupro-Nickel 70/30:
The quality of a machined surface depend upon the roughness of the surface. So, for a
better surface finish the roughness should be minimized. In the Taguchi design of experiment
the concept of S/N ratio is used to optimize the surface roughness (Ra). So, the S/N ratio for
surface roughness is considered as the "smaller-is-better" and calculated by using following
equation.
S/N ratio = -10 Log10 [{sum (𝑦 2 )}/ n].............................. (iv)
51
The S/N ratios is computed for the surface roughness using Eq. 1 for each of the 9 runs and the
values are recorded in below Table for Cupro-Nickel 70/30:
Exp Cutting Feed f Depth Surface Surface Mean SNRA1

. Speed (mm/rev) of cut roughness roughness Surface
No. V doc Ra1 (µm) Ra2 ( µm roughness
(rpm) (mm) ) Ra ( µm )
1 560 0.085 0.2 1.2 1.7 1.45 -3.35458
2 560 0.094 0.3 1.4 1.6 1.50 -3.54108
3 560 0.103 0.4 1.1 1.5 1.30 -2.38046
4 640 0.085 0.3 1.8 2.2 2.00 -6.06381
5 640 0.094 0.4 2.0 1.1 1.55 -4.15808
6 640 0.103 0.2 1.0 1.1 1.05 -0.43362
7 720 0.085 0.4 1.3 2.2 1.75 -5.13883
8 720 0.094 0.2 1.1 1.2 1.15 -1.22216
9 720 0.103 0.3 2.0 1.5 1.75 -4.94850
roughness (Ra)
Level V f doc
1 1.417 1.733 1.217
2 1.533 1.400 1.750
3 1.550 1.367 1.533
Delta 0.133 0.367 0.533
Rank 3 2 1
Table-8.19 Response Table for Means Ra
average surface roughness, analysis of variance (ANOVA) is performed and recorded in Table-
20.
52
Speed (V) 2 0.03167 0.01583 0.90 4.25
Feed (f) 2 0.24667 0.12333 7.05 33.11
Depth of cut (doc) 2 0.43167 0.21583 12.33 57.94
Error 2 0.03500 0.01750 4.70
Table-8.20 ANOVA analysis for means of average surface roughness
8.2.4 Experimental Analysis of cutting force for Cupro-Nickel 70/30:

This cutting force in turning process is represented as three components (tangential
cutting force (Fz), feed force (Fy), radial force (Fx)) which are perpendicular to each other.
These forces are responsible for chatter on the work-piece surface, vibrations during the cutting
operation and decrement in setup rigidity. As the cutting force increase to cut the material the
more power is required. So, for a less power consumption and for the soft cutting, the cutting
force should be minimized. In the Taguchi design of experiment the concept of S/N ratio is used
to optimize the cutting force components. So, the S/N ratio for cutting force components is
considered as the "smaller-is-better" and calculated by using following equation.
S/N ratio = -10 Log10 [{sum (𝑦 2 )}/ n]................................................ (v)
The S/N ratios is computed for the cutting force components using Eq. 1 for each of the 9 runs
and the values are recorded in below Table for Cupro-Nickel 70/30:
Exp. Cutting Feed f Depth of Mean Mean Mean

No. Speed (mm/ rev) cut tangential feed force radial
V doc cutting force Fy force Fx
(rpm) (mm) Fz (N) (N)
(N)
1 560 0.085 0.2 95.22 111.90 26.52
2 560 0.094 0.3 127.50 59.75 43.45
3 560 0.103 0.4 181.90 65.27 68.84
4 640 0.085 0.3 96.08 50.28 31.64
5 640 0.094 0.4 116.20 56.12 44.37
6 640 0.103 0.2 80.64 50.28 18.26
7 720 0.085 0.4 80.43 69.83 23.38
8 720 0.094 0.2 88.79 111.90 22.96
9 720 0.103 0.3 100.03 59.75 31.11
Table-8.21 Experimental readings for the response parameter as the cutting force components
53
Level V f Doc
1 134.87 90.58 88.22
2 97.64 110.83 107.87
3 89.75 120.86 126.18
Delta 45.12 30.28 37.96
Rank 1 3 2
Table-8.22 Response Table for Means Fz
Level V f doc
1 87057 60.46 55.36
2 58.43 66.94 71.62
3 58.74 77.34 77.76
Delta 29.13 16.87 22.40
Rank 1 3 2
Table-8.23 Response Table for Means Fy
Level V f doc
1 46.27 27.18 22.58
2 31.42 36.93 35.40
3 25.82 39.40 45.53
Delta 20.45 12.22 22.95
Rank 2 3 1
Table-8.24 Response Table for Means Fx
The Taguchi design of experiment help to select the best pair of input parameter among
the several possibilities and that pair provide the optimum valve of response parameter. It also
conclude in which order the cutting parameters are affecting the response parameter i.e. the
rank of cutting parameter (Table-22, 23, 24). But the Taguchi design of experiment is unable to
cutting force components (tangential cutting force (Fz), feed force (Fy), radial force (Fx)),
analysis of variance (ANOVA) is performed and recorded in Table-25,26,27.

Speed (V) 2 3485 1742.3 3.23 42.75
Feed (f) 2 1428 713.8 1.32 17.51
Depth of cut (doc) 2 2162 1081.2 2.01 26.53
Error 2 1078 538.08 13.20
Table-8.25 ANOVA analysis for means of Fz
54
Speed (V) 2 1679.6 839.82 10.43 54.54
Feed (f) 2 434.7 217.36 2.70 14.12
Depth of cut (doc) 2 804.0 402.02 4.99 26.11
Error 2 161.0 80.51 5.23
Table-8.26 ANOVA analysis for means of Fy

Speed (V) 2 670.2 335.1 2.72 34.18
Feed (f) 2 250.5 125.3 1.02 12.78
Depth of cut (doc) 2 793.7 396.8 3.22 40.48
Error 2 246.3 123.1 12.56
Table-8.27 ANOVA analysis for means of Fx
8.2.5 Experimental Analysis of Material Removal Rate (MRR) for Cupro-

Nickel 70/30:
The material removal rate is the response parameter which is affected by feed, cutting
speed and depth of cut. The material removal rate affect the timing of obtaining desire piece
through the machining process. So, in order to increase the production rate, the MRR should be
maximized. In the Taguchi design of experiment the concept of S/N ratio is used to optimize
the MRR. So, the S/N ratio for MRR is considered as the "larger-is-better" and calculated by
using following equation.
S/N ratio = -10 Log10 [{sum (1/𝑦 2 )}/ n]
The S/N ratios is computed for the material removal rate using Eq. 1 for each of the 9 runs and
the values are recorded in below Table for Cupro-Nickel 70/30:
55
Exp. Cutting Speed Feed f (mm/rev) Depth of MRR SNRA1
𝟑
No. V cut (𝐦𝐦 /𝐦𝐢𝐧)
(rpm) doc
(mm)
1 560 0.085 0.2 595.0 55.4903
2 560 0.094 0.3 987.0 59.8863
3 560 0.103 0.4 1442.0 63.1793
4 640 0.085 0.3 1020.0 60.1720
5 640 0.094 0.4 1504.0 63.5450
6 640 0.103 0.2 824.0 58.3185
7 720 0.085 0.4 1530.0 63.6938
8 720 0.094 0.2 846.0 58.5474
9 720 0.103 0.3 1390.5 62.8634
Table-8.28 Experimental readings for the response parameter as the material removal rate
Level V f Doc
1 1008.0 1048.3 755.0
2 1116.0 1112.3 1132.5
3 1255.5 1218.8 1492.0
Delta 247.5 170.5 737.0
Rank 2 3 1
Table-8.29 Response Table for Means MRR
So, to quantify the contribution (C, in percentage) of cutting parameters (V, f, doc) in the
material removal rate, analysis of variance (ANOVA) is performed and recorded in Table-30.

Speed (V) 2 92380 46190 14.82 9.64
Feed (f) 2 44508 22254 7.14 4.64
Depth of cut (doc) 2 814915 407458 130.77 85.06
Error 2 6232 3116 0.65
Table-30 ANOVA analysis for means of MRR
56
Chapter-09
Results and Discussion
9.1 Inconel 800:

9.1.1 Analysis of Surface roughness (Ra):
Figure 9.1 S/N Ratio values for Surface Roughness

Figure 9.1 shows the optimal value of process parameters for the surface roughness of
Inconel 800. The optimal control factor values are 640 rpm as the cutting speed, 0.103 mm/rev
as the feed rate and 0.2 mm for the depth of cut, obtained at which the surface roughness is
having the minimum value.
57
The depth of cut is the most prominent factor that affect the roughness, followed by
cutting speed and feed rate. The contribution of depth of cut, speed and feed to the surface
roughness is 42.41%, 27.81%, 21.47%, respectively.
9.1.2 Analysis of Main cutting force :
Figure 9.2 shows the optimal value of process parameters for the main cutting force of
Inconel 800. The optimal control factor values are 640 rpm as the cutting speed, 0.085 mm/rev
as the feed rate and 0.2 mm for the depth of cut, obtained at which the main cutting force is
having the least value. The depth of cut is the most prominent factor that affect the main cutting
Figure 9.2 S/N Ratio values for Main Cutting Force
Force followed by cutting speed and feed rate. The contribution of depth of cut, speed and feed
to the main cutting force is 80.91%, 15.42%, 3.36%, respectively. The feed rate has least
contribution, so it concludes that the higher feed rate is acceptable for the turning of Inconel
800.
58
9.1.3 Analysis of Feed force:
Figure 9.3 S/N Ratio values for Feed Force
Figure 9.3 shows the optimal value of process parameters for the feed force of Inconel
800. The optimal control factor values are 640 rpm as the cutting speed, 0.085 mm/rev as the
feed rate and 0.2 mm for the depth of cut, obtained at which the feed force is having the
minimum value. The depth of cut is the most prominent factor that affect the feed force,
followed by cutting speed and feed rate. The contribution of depth of cut, speed and feed to the
feed force is 83.29%, 8.73%, 7.39%, respectively. The feed rate and the cutting speed have least
contribution, so it is appropriate to use higher feed and speed.
9.1.4 Analysis of Radial force:
Figure 9.4 shows the optimal value of process parameters for the radial force of Inconel
800. The optimal control factor values are 640 rpm as the cutting speed, 0.103 mm/rev as the
feed rate and 0.2 mm for the depth of cut, obtained at which the radial force is having the
minimum value. The depth of cut is the most prominent factor that affect the radial/thrust force,
thrust force is 96.72%, 1.14%, 0.83%, respectively. The feed rate and the cutting speed have
insignificant effect on radial force.
59
Figure 9.4 S/N Ratio values for Radial Force
9.2 Cu-Ni 70/30:

9.2.1 Analysis of Surface roughness (Ra):
Figure 9.5 S/N Ratio values for Surface Roughness
Figure 9.5 shows the optimal value of process parameters for the surface roughness of
Cu-Ni 70/30. The optimal control factor values are 560 rpm as the cutting speed, 0.103 mm/rev
as the feed rate and 0.2 mm for the depth of cut, obtained at which the surface roughness is
having the least value. The depth of cut is the most prominent factor that affect the surface
roughness, followed by feed rate and cutting speed. The contribution of depth of cut, feed and
speed to the surface roughness is 57.94%, 33.11%, 4.25%, respectively. The cutting speed have
least contribution, so it is acceptable to use higher cutting speed for turing of Cu-Ni 70/30.
60
9.2.2 Analysis of Main cutting force:
Figure 9.6 shows the optimal value of process parameters for the main cutting force of
Cu-Ni 70/30. The optimal control factor values are 720 rpm as the cutting speed, 0.085 mm/rev
as the feed rate and 0.2 mm for the depth of cut, obtained at which the main cutting force is
having the minimum value. The cutting speed is the most prominent factor that affect the main
cutting force, followed by depth of cut and feed rate. The contribution of the cutting speed,
depth of cut and feed to the main cutting force is 42.75%, 17.51%, 26.53%, respectively
Figure 9.6 S/N Ratio values for Main Cutting Force
9.2.3 Analysis of Feed force:
Figure 9.7 S/N Ratio values for Feed Force
61
Figure 9.7 shows the optimal value of process parameters for the feed force of Cu-Ni
70/30. The optimal control factor values are 720 rpm as the cutting speed, 0.085 mm/rev as the
feed rate and 0.2 mm for the depth of cut, obtained at which the feed force is having the
minimum value. The cutting speed is the most prominent factor that affect the feed force,
followed by depth of cut and feed rate. The contribution of cutting speed, depth of cut and feed
to the feed force is 54.54%, 26.11%, 14.12%, respectively.
9.2.4 Analysis of Radial force:
Figure 9.8 S/N Ratio values for Radial Force
Figure 9.8 shows the optimal value of process parameters for the radial force of Cu-Ni
70/30. The optimal control factor values are 720 rpm as the cutting speed, 0.085 mm/rev as the
feed rate and 0.2 mm for the depth of cut, obtained at which the radial force is having the
minimum value. The depth of cut is the most prominent factor that affect the radial force,
radial force is 40.48%, 34.18%, 12.78%, respectively.
62
9.2.5 Analysis of Material Removal Rate:
Figure 9.9 shows the optimal value of process parameters for the material removal rate
of Cu-Ni 70/30 and Inconel 800. The optimal control factor values are 720 rpm as the cutting
speed, 0.103 mm/rev as the feed rate and 0.4 mm for the depth of cut, obtained at which the
material removal rate is having the large value. The depth of cut is the most prominent factor
that affect the material removal rate, followed by cutting speed and feed rate. The contribution
of depth of cut, speed and feed to the radial force is 85.06%, 9.64%, 4.64%, respectively.
Figure 9.9 S/N Ratio values for MRR
63
Chapter-10
Confirmation Test
10.1 Predicted confidence interval for confirmation experiments:

Predicted interval at 95% confidence level helps to judge whether the optimum valve of
process parameters is acceptable or not. This conclusion can also be predicted through ANOVA
analysis. The predicted interval must be confirmed by conducting experiment on optimum
process parameters which is obtained through Taguchi method.
10.1.1 Inconel 800:

S. N. Response Parameter Predicted Interval
1 Surface Roughness 0.6754 < µRa (µm) < 3.17
2 Main Cutting Force 75.09 < Fz (N) < 106.38
3 Feed Force 80.625 < Fy (N) < 89.313
4 Radial Force 10.75 < Fx (N) < 55.99
5 Material Removal Rate (MRR) 1419.17 MRR (mm3 /min) < 2007.43
Table 10.1 Predicted interval for Inconel 800
64
10.1.2 Cupro-Nickel 70/30 :

1 Surface Roughness 0.3039 < µRa (µm) < 1.698
2 Main Cutting Force 68.6 < Fz (N) < 176.02
3 Feed Force 9.523 < Fy (N) < 85.035
4 Radial Force 51.8825 < Fx (N) < 65.04
5 Material Removal Rate (MRR) 1419.17 < MRR (mm3 /min) < 2007.43
10.2 Table 10.2 Predicted interval for Cupro-Nickel 70/30
10.3 Conformation test:

The confirmation experiment is conducted at the optimal setting of turning process
parameters. The conformation test explains the condition of optimum process parameters
whether they are acceptable as the optimum parameters or not.
10.1.3 Inconel 800:
S. N. Response Parameter Result of conformation test

1 Surface Roughness 1.0 µm
2 Main Cutting Force 95.65 N
3 Feed Force 86.73 N
4 Radial Force 37.2 N
5 Material Removal Rate (MRR) 1813 mm3 /min
Table 10.3 Confirmation test value for Inconel 800
65
10.2.1. Cupro-Nickel 70/30 :

1 Surface Roughness 0.85 µm
2 Main Cutting Force 70.12 N
3 Feed Force 43.80 N
4 Radial Force 17.31 N
5 Material Removal Rate (MRR) 1854 mm3 /min
Table 10.4 Confirmation test value for Cupro-Nickel 70/30
The mean surface roughness (Ra), MRR and the cutting force components are found within the
limit of the predicted optimal response parameter values for both materials except radial force
acting on cutting tool during Cupro-Nickel 70/30 turning. So, the conformation test conforms
that 560 rpm (cutting speed), 0.103 mm/rev (feed rate), 0.2 mm (depth of cut) is the optimum
value for the surface roughness of Cupro-Nickel and for the Inconel 640 rpm, 0.103 mm/rev,
0.2mm is the optimum process parameters.
66
Chapter-11
Conclusion
After the analysis of experiment detail it is observed that the tool and machine selection for
alloys is very crucial stage. From the study and above done calculations, we come up with some
important investigations which can be summarised as follows:
 Taguchi design of experiment based L9 (33) orthogonal array gives the systematic simple
and efficient approach to study the performance of control parameters.
 The order of importance in the sequence and optimal value of controllable factors to the
minimum surface roughness for Inconel 800, is (cutting speed) 640 rpm,(feed rate) 0.103
mm/rev, (depth of cut) 0.2 mm and for Cu-Ni 70/30, is 560 rpm, 0.103 mm/rev, 0.2 mm.
 The optimal combination of controllable factors for minimum cutting forces for Inconel is
640 rpm, 0.085 mm/rev, 0.2 mm for main cutting force and feed force but for the radial
force feed rate is 0.103 mm/rev, for Inconel 800.
67
 The optimal process parameters in the order of importance, for the minimum cutting forces
is 720 rpm, 0.085 mm/rev, 0.2 mm for main cutting force and radial force but for the feed
force the cutting speed is 640 rpm, for Cu-Ni 70/30.
 The cutting speed (720 rpm), feed rate (0.103 mm/rev), depth of cut (0.4 mm) are the
controllable factors for the maximum material removal rate.
 Through ANOVA analysis it is observed that the depth of cut is the most influencing control
parameter for the Surface roughness (42.41 %) and for the cutting force components (80.91
% for main cutting force, 83.29 % for feed force, 96.72 % for radial force) in Inconel 800
machining.
 For Cu-Ni 70/30, depth of cut (57.94 %) is the most influencing control factor for the surface
roughness while the cutting speed (42.75 % for main cutting force and 54.54 % for feed
force) is the most influencing control parameter for the cutting force components.
 The depth of cut is the most influencing parameter for maximum material removal rate with
the contribution of 85.06% for both materials.
16.1 Future Scope:

The same experiments can be carried out with the cooling fluids.
The effects of different cooling fluids can be examined in wet turning.
Tool wear can be observed and calculated for machining of these alloys.
The experiments can be carried out with diamond tool insert at high speed.
68
References
[1] Thakur.D, Ramamoorthy.B, and Vijayaraghavan.L, “Study on the machinability

characteristics of super alloy Inconel 718 during high speed turning”, Materials and
Design, Vol.30, 2009, pp.1718-1725.
[2] R. Arunachalam, M.A. Mannan,Machinability of nickel-based high temperature alloys,
Mach Sci Technol, 4 (1) (2000), pp. 127–168
[3] D. Dudzinski, A. Devillez, A. Moufki, D. Larrouquère, V. Zerrouki, J. Vigneau,A
review of developments towards dry and high speed machining of Inconel 718 alloy,Int J
Mach Tools Manufact, 44 (2004), pp. 439–456
[4] E.O. Ezugwu, Z.M. Wang, A.R. Machado,The machinability of nickel-based alloys: a
review,J Mater Process Technol, 86 (1999), pp. 1–16
[5] M. Field, J.F. Khales,Review of surface integrity of machined components, Ann CIRP,
20 (2) (1971), pp. 153–163
[6] C.J. Tzeng, Y.H. Lin, Y.K. Yang, and M.C. Jeng. Optimization of turning operations
with multiple performance characteristics using the Taguchi method and grey relational
analysis. Journal of Materials Processing Technology, 209(6):2753–2759, 2009.
[7] DynaWare Software [Online] 10-04-2017
(http://www.helmar.com.pl/helmar/plik/kistler_oprogramowanie-dynoware_nn4428.pdf)
[8] Surface Finish Tester [Online] 11-04-2017,
http://idef.hr/aploads/files/Surtronic_S100_Lowres_EN1.pdf
[9] http://anale-ing.uem.ro/2013/203.pdf
[10] Mchining [Online] 11-04-2017, https://en.wikipedia.org/wiki/Machining
[11] Terminology [Online] 12-04-2017,
https://www3.nd.edu/~manufact/MPEM_pdf_files/Ch08.pdf
69
[12] Machining Operation [Online] 12-04-2017, https://www.ctemag.com/news-
videos/articles/overcoming-five-common-challenges-when-turning.
[13] P.J. Ross, “Taguchi Technique for Quality Engineering”, McGraw-Hill, New York,
1988.
[14] R.K. Roy, “A Primer on Taguchi Method”, Van Nostrad Reinhold, New York, 1990.
70

Optimization of Process Parameters in Turning Operation of Inconel 800 & Cu-Ni 70/30 Using Taguchi and Anova Method

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OPTIMIZATION OF PROCESS PARAMETERS IN

TURNING OPERATION OF INCONEL 800 & Cu-Ni

DEPARTMENT OF MECHANICAL ENGINEERING

Submitted to the faculty of “Mechanical Engineering Department”, in fulfilment of the

Dr. Srinivasa Rao S Dr. N Selvraj,

Rohtash Kumar 133151

1.1 Machining Operation...................................................................................................2

1.1.1 Conventional Machining Operation................................................................3

1.1.2 Non-conventional Machining Operation.........................................................4

1.2 Turning Operation.......................................................................................................5

1.3 Industrial applications of turning................................................................................9

1.3.1 Applications of turning operation...................................................................9

1.3.2 Challenges and difficulties............................................................................10

1.4 Modelling and Optimization.....................................................................................11

1.5 Engineering material.................................................................................................12

1.5.1 Work piece material......................................................................................12

1.5.2 Tool material.................................................................................................12

1.6 Stage in metal cutting................................................................................................12

1.6.1 Rough cut......................................................................................................13

1.6.2 Finish cut.......................................................................................................13

Chapter-02 Literature Survey.......................................................................14

2.1 Inconel 718................................................................................................................14

2.2 Inconel CU-Ni...........................................................................................................14

2.3 Tool material.............................................................................................................15

2.4 Tool wear..................................................................................................................16

2.5 Taguchi method .......................................................................................................16

2.6 GRA and ANOVA...................................................................................................17

3.1 Motivation for project.............................................................................................18

3.2 Objective and Approach of Project.........................................................................19

Chapter-04 Terminology Used....................................................................20

4.1 Cutting speed..........................................................................................................20

4.2 Feed rate.................................................................................................................20

4.3 Spindle speed..........................................................................................................20

4.4 Axial depth of cut ..................................................................................................21

4.5 Radial depth of cut .................................................................................................21

Chapter-05 Experimental Procedure.........................................................22

5.1 Introduction ...........................................................................................................22

5.1.1 Properties and Application of Work piece material...................................22

5.1.2 Properties of tool material (Insert).............................................................24

5.1.3 Designation of Tool...................................................................................26

5.2 Experimental set-up...............................................................................................27

5.2.1 Specification of lathe.................................................................................28

5.2.2 Specifications of Tool holder....................................................................28

5.2.3 Specification of Dynamometer.................................................................29

5.2.4 Specification of Roughness tester.............................................................30

6.1 Taguchi method....................................................................................................33

6.1.2 Approach to optimize the machining process..........................................34

6.2 ANOVA method..................................................................................................35

Chapter-07 Effects of Process parameter on Response parameter.......36

7.1 Surface Roughness...............................................................................................36

7.1.1 Effect of Cutting Speed on Surface Roughness.......................................37

7.1.2 Effect of Feed rate on Surface Roughness...............................................38

7.1.3 Effect of Depth of Cut on Surface Roughness.........................................39

7.2 Cutting Force........................................................................................................39

7.2.1 Effect of Cutting Speed on Cutting Force................................................40

7.2.2 Effect of Feed Rate on Cutting Force.......................................................41

7.2.3 Effect of Depth of Cut on Cutting Force..................................................42

7.3 Material Removal Rate (MRR)............................................................................43

7.3.1 Effect of Cutting Speed on MRR.............................................................43