Surface Roughness

Limits and levels of control parameters

Limits
Control Low Medium High
Parameters (1) (2) (3)
Spindle speed (v)
220 380 540
(rpm)
Feed rate (f) 0.4 0.6
0.5
(mm/rev)
Depth of cut (d)
0.1 0.2 0.3
(mm)

Factorial combination
Sl. No.
V f D
1 1 1 1
2 1 1 2
3 1 1 3
4 1 2 1
5 1 2 2
6 1 2 3
7 1 3 1
8 1 3 2
9 1 3 3
10 2 1 1
11 2 1 2
12 2 1 3
13 2 2 1
14 2 2 2
15 2 2 3
16 2 3 1
17 2 3 2
18 2 3 3
19 3 1 1
 20 3 1 2
21 3 1 3
22 3 2 1
23 3 2 2
24 3 2 3
25 3 3 1
26 3 3 2
27 3 3 3

Experimental data

Turning parameter
Actual value
Combination Spindle Surface
EXP. Feed rate Depth of cut Roughness
NO. of process speed(rpm
(mm/rev.) (mm) (µm)
parameters )

1 1 1 1 220 0.4 0.1 8.8

2 1 1 2 220 0.4 0.2 8.83
3 1 1 3 220 0.4 0.3 8.85
4 1 2 1 220 0.5 0.1 9.03
5 1 2 2 220 0.5 0.2 9
6 1 2 3 220 0.5 0.3 9.09
7 1 3 1 220 0.6 0.1 10.4
8 1 3 2 220 0.6 0.2 10.2
9 1 3 3 220 0.6 0.3 10.9
10 2 1 1 380 0.4 0.1 12.52
11 2 1 2 380 0.4 0.2 12.8
12 2 1 3 380 0.4 0.3 12.94
13 2 2 1 380 0.5 0.1 10.28
14 2 2 2 380 0.5 0.2 9,88
15 2 2 3 380 0.5 0.3 9.36
16 2 3 1 380 0.6 0.1 12.74
17 2 3 2 380 0.6 0.2 11.52
18 2 3 3 380 0.6 0.3 11.3
19 3 1 1 540 0.4 0.1 7.5
20 3 1 2 540 0.4 0.2 7.24
21 3 1 3 540 0.4 0.3 7.6
22 3 2 1 540 0.5 0.1 6.16
23 3 2 2 540 0.5 0.2 6.23
24 3 2 3 540 0.5 0.3 7.1
25 3 3 1 540 0.6 0.1 6.75
26 3 3 2 540 0.6 0.2 6.46
27 3 3 3 540 0.6 0.3 6.9
 Example
5.4 S/N ratio calculation
Taguchi uses the loss function to measure the performance characteristic deviating
from the desired value. The value of loss function is then further transformed to S/N
ratio. Usually, there are three categories of the performance characteristic in the
analysis of the S/N ratio, that is, the lower-the-better, the higher-the-better, and the
nominal-the-better. The S/N ratio for each level of process parameters is computed
based on the S/N analysis and the smaller S/N ratio corresponds to the better
performance characteristic for minimum tool wear calculation. Therefore, the optimal
level of the process parameter is the level with the lowest S/N ratio. S/N ratio
calculation is done to find influence of the control parameters.

For Calculating S/N Ratio for Smaller-the-Better for Tool Wear, the Equation is
[ Yi] = - 10 log 10[ ( Xi2 )/ n ] Where Yi = S/N Ratio for Respective Result
Xi = Total Surface Roughness for each experiment I
= =1 to 27
n = no. of results for each experiment

For experiment no.1

Y1= - 10 log 10[ X12 / n ] = - 10 log 10 [ 8.82/ 1 ] = -18.889

For experiment no.2

Y2 = - 10 log 10 [ X22 / n ] = - 10 log 10 [ 8.832/ 1 ] = -18.91

For experiment no.3

Y3 = - 10 log 10 [ X32 / n ] = - 10 log 10 [ 8.852/ 1 ] = -18.93

For experiment no.4

Y4 = - 10 log 10 [ X42 / n ] = - 10 log 10 [ 9.032/ 1 ] = -19.11

For experiment no.5

Y5 = - 10 log 10 [ X52 / n ] = - 10 log 10 [ 92/ 1 ] = -19.08

For experiment no.6

Y6 = - 10 log 10 [ X62 / n ] = - 10 log 10 [ 9.09/ 1 ] = -19.17

For experiment no.7

Y7 = - 10 log 10 [ X72 / n ] = - 10 log 10 [ 10.42/ 1 ] = -20.34
For experiment no.8
Y8 = - 10 log 10 [ X82 / n ] = - 10 log 10 [ 10.22/ 1 ] = -20.17

For experiment no.9

Y9 = - 10 log 10 [ X92 / n ] = - 10 log 10 [ 10.92/ 1 ] = -20.74

For experiment no.10

Y10 = - 10 log 10[ X102 / n ] = - 10 log 10 [ 12.522/ 1 ] = -21.95

For experiment no.11

Y11 = - 10 log 10[ X112 / n ] = - 10 log 10 [ 12.8 2/ 1 ] = -22.14

For experiment no.12

Y12 = - 10 log 10[ X122 / n ] = - 10 log 10 [ 12.942/ 1 ] = -22.23

For experiment no.13

Y13 = - 10 log 10[ X132 / n ] = - 10 log 10 [ 10.282/ 1 ] = -20.23

For experiment no.14

Y14 = - 10 log 10[ X142 / n ] = - 10 log 10 [ 9.882/ 1 ] = -19.89

For experiment no.15

Y15 = - 10 log 10 [ X152 / n ] = - 10 log 10 [ 9.362/ 1 ] = -19.42

For experiment no.16

Y16 = - 10 log 10 [ X162 / n ] = - 10 log 10 [ 12.742/ 1 ] = -22.10

For experiment no.17

Y17 = - 10 log 10 [ X172 / n ] = - 10 log 10 [ 11.522/ 1 ] = -21.22

For experiment no.18

Y18 = - 10 log 10 [ X182 / n ] = - 10 log 10 [ 11.32/ 1 ] = -21.06

For experiment no.19

Y19 = - 10 log 10 [ X192 / n ] = - 10 log 10 [ 7.52/ 1 ] = -17.50

For experiment no.20

Y20 = - 10 log 10 [ X202 / n ] = - 10 log 10 [ 7.242/ 1 ] = --17.19
For experiment no.21
Y21 = - 10 log 10 [ X212 / n ] = - 10 log 10 [ 7.62/ 1 ] = -17.61

For experiment no.22

Y22 = - 10 log 10 [ X222 / n ] = - 10 log 10 [ 6.162/ 1 ] = -15.79

For experiment no.23

Y23 = - 10 log 10 [ X1232 / n ] = - 10 log 10 [ 6.232/ 1 ] = -15.88

For experiment no.24

Y24 = - 10 log 10 [ X242 / n ] = - 10 log 10 [ 7.12/ 1 ] = -17.02

For experiment no.25

Y25 = - 10 log 10 [ X252 / n ] = - 10 log 10 [ 6.752/ 1 ] = -16.58

For experiment no.26

Y26 = - 10 log 10 [ X262 / n ] = - 10 log 10 [ 6.462/ 1 ] = -16.20

For experiment no.27

Y27 = - 10 log 10 [ X272 / n ] = - 10 log 10 [ 6.92/ 1 ] = -16.77
 Table 5: S/N Ratio for Smaller the Better

Spindle Feed Depth of Response

Exp S/N Ratio
Speed (v) Rate ( f ) Cut (d) (SURFACE
. for Smaller
ROUGHNESS
No. RPM mm/rev mm is Better
) mm
1. 220 0.4 0.1 8.8 - 18.889
2. 220 0.4 0.2 8.83 - 18.91
3. 220 0.4 0.3 8.85 - 18.93
4. 220 0.5 0.1 9.03 - 19.11
5. 220 0.5 0.2 9 -19.08
6. 220 0.5 0.3 9.09 -19.17
7. 220 0.6 0.1 10.4 -20.34
8. 220 0.6 0.2 10.2 -20.17
9. 220 0.6 0.3 10.9 -20.74
10. 380 0.4 0.1 12.52 -21.95
11. 380 0.4 0.2 12.8 -22.14
12. 380 0.4 0.3 12.94 -22.23
13. 380 0.5 0.1 10.28 -20.23
14. 380 0.5 0.2 9.88 -19.89
15. 380 0.5 0.3 9.36 -19.42
16. 380 0.6 0.1 12.74 -22.10
17. 380 0.6 0.2 11.52 -21.22
18. 380 0.6 0.3 11.3 -21.06
19. 540 0.4 0.1 7.5 -17.50
20. 540 0.4 0.2 7.24 -17.19
21. 540 0.4 0.3 7.6 -17.61
22. 540 0.5 0.1 6.16 -15.79
23. 540 0.5 0.2 6.23 -15.88
24. 540 0.5 0.3 7.1 -17.02
25. 540 0.6 0.1 6.75 -16.58
 26. 540 0.6 0.2 6.46 -16.20
27. 540 0.6 0.3 6.9 -16.77

5.5 Overall mean of S/N ratio

The Calculation of overall mean is done by the following process:

K11 = Mean of low level values of spindle speed

K11= ( Y1+ Y2 + Y3 + Y4 + Y5 + Y6 + Y7 + Y8 + Y9) / 9 = (- 18.889 – 18.91 – 18.93 – 19.11
– 19.08 – 19.17 – 20.34 – 20.17 – 20.74 )/9 = - 19.48

K21 = Mean of medium level values of spindle speed

K21 = ( Y10+ Y11 + Y12 + Y13 + Y14 + Y15 + Y16 + Y17 + Y18 ) / 9 = (-21.95 – 22.14 N- 22.23
– 20.23 – 19.89 – 19.42 – 22.10 – 21.22 – 21.06)/9 = - 21.13

K31 = Mean of high level values of spindle speed

K31= ( Y19+ Y20 + Y21 + Y22 + Y23 + Y24 + Y25 + Y26 + Y27 ) / 9 = (- 17.50 – 17.19 – 17.61 –
15.79 – 15.88 – 17.02 – 16.58 – 16.20 – 16.77)/9 = - 16.72

K12 = Mean of low level values of feed rate

K12 = ( Y1+ Y2 + Y3 + Y10 + Y11 + Y12 + Y19 + Y20 + Y21) / 9 = (- 18.88 – 18.91 – 18.93 –
21.95 – 22.14 – 22.23 – 17.50 – 17.19 – 17.61)/9 = - 19.48

K22 = Mean of medium level values of feed rate

K22= ( Y4+ Y5 + Y6 + Y13 + Y14 + Y15 + Y22 + Y23 + Y24) / 9 = (- 19.11 – 19.08 – 19.17 –
20.23 – 19.89 – 19.42 – 15.79 – 15.88 – 17.02)/9 = - 18.39

K32 = Mean of high level values of feed rate

K32= ( Y7+ Y8 + Y9 + Y16 + Y17 + Y18 + Y25 + Y26 + Y27 ) / 9 = (- 20.34 – 20.17 – 20.74 –
22.10 – 21.22 – 21.06 – 16.58 – 16.20 – 16.77)/9 = - 19.46

K13 = Mean of low level values of depth of cut

K13= ( Y1+ Y4 + Y7 + Y10 + Y13 + Y16 + Y19 + Y22 + Y25) / 9 = (- 18.88 – 19.11 – 20.34 –
21.95 – 20.23 – 22.70 – 17.50 – 15.79 – 16.58)/9 = - 19.16

K23 = Mean of medium level values of depth of cut

K23 = ( Y2+ Y5 + Y8 + Y11 + Y14 + Y17 + Y20 + Y23 + Y26 ) / 9 = (- 18.91 – 19.08 – 20.17 –
22.14 – 19.89 – 21.22 – 17.19 – 15.88 – 16.20) / 9 = - 18.96
 K33 = Mean of high level values of depth of cut
K33 = ( Y3+ Y6 + Y9 + Y12 + Y15 + Y18 + Y21 + Y24 + Y27) / 9 = (- 18.93 – 19.17 – 20.74 –
22.23 – 19.42 – 21.06 – 17.61 – 17.02 – 16.77) / 9 = - 19.21

Table 6: Overall Mean of S/N Ratio

Average SN Ratio by Factor Level Overall
Level Spindle Feed Depth of Mean of S/N
Speed (v) Rate (f) cut (d) Ratio (Y0)
Low - 19.48 - 19.48 - 19.16
Medium - 21.13 - 18.39 - 18.96
High - 16.72 - 19.46 - 19.21
- 19.11
Delta =
4.41 1.09 0.25
Larger - Smaller
Rank 1 2 3

The values obtained in the above table 6 are represented graphically in figure 5.2.1,
figure 5.2.2 and figure 5.2.3
 Variation of Mean of S/N Ratio with Spindle Speed (rpm)

23.5

23.0
Mean of S/N Ratio

22.5

22.0

21.5

21.0

200 300 400 500 600 700 800 900 1000

Spindle Speed (rpm)

Figure 5.2.1: variation of mean of S/N ratio with spindle speed

 Variation of Mean of S/N Ratio with Depth Of Cut (mm)
25

24
Mean of S/N Ratio

23

22

21

20

0.6 0.7 0.8 0.9 1.0

Depth Of Cut (mm)

Fig5.2.2: variation of mean of S/N ratio with depth of cut

Variation of Mean of S/N Ratio with Feed Rate (mm/rev)

24
Mean of S/N Ratio

23

22

21

20
0.1 0.2 0.3 0.4 0.5 0.6 0.7
Feed Rate (mm/rev)
 Fig 5.2.3: variation of mean of S/N ratio with feed rate

From the calculations and the graphs it is found Depth of cut is the most influencing
parameter followed by feed rate and Spindle Speed.