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Minimization of Cutting Force by Optimizing the Cutting Parameters

Using Taguchi Method in Turning
To cite this article: M S H Bhuiyan 2019 IOP Conf. Ser.: Mater. Sci. Eng. 530 012006

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ICRAIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 530 (2019) 012006 doi:10.1088/1757-899X/530/1/012006

Minimization of Cutting Force by Optimizing the Cutting

Parameters Using Taguchi Method in Turning

M S H Bhuiyan*
School of Mechanical Engineering, University of Science Malaysia, 14300 Nibong
Tebal, Pulau Pinang, Malaysia

Corresponding author *: [email protected], [email protected]

Abstract. The changes in magnitude of cutting force demonstrate the different occurrences in
turning. The pattern of cutting force signal illustrates the cutting tool conditions and also
corresponds to the changes in the cutting parameters. Obtaining an optimal cutting condition
would significantly minimize the cutting force in turning, can reduce respective power
consumption and consequently, extent the life of cutting tool. Choosing the optimal cutting
parameters in turning would safeguard the cutting tool from catastrophe and could ensure a
better surface finish of workpiece. From the orthogonal array and S/N ratio, the cutting speed
of 120 m/min, feed rate of 0.32 mm/rev and depth of cut of 1 mm is found to be optimum
cutting parameters. The magnitude of cutting force is found to be minimal and the surface
finish is seen to be comparatively low at this cutting condition. The tool life at this cutting
condition is found to be the longest for that particular tool – workpiece combination.

Keywords: Cutting parameter optimization, Taguchi method, Cutting force, Flank wear,
Surface roughness.

1. Introduction
Turning is one of the mostly used machining techniques in manufacturing industry. In turning, the
tool-workpiece combination, and cutting parameters play the most significant role and define the
product quality, tool condition and the rate of power consumption in machining. Choosing the optimal
cutting speed, feed rate, and depth of cut for machining can reduce tool wear and improve the surface
finish of workpiece. Different methods are available to perform this optimization task. Li et al. [1]
have used Taguchi method, response surface method (RSM), and multi-objective particle swarm
optimization algorithm (MOPSO) to identify the optimal cutting parameters in CNC machining. They
have used the Taguchi method to design the experiment, and subsequently employed the signal-to-
noise (S/N) ratio to analyze the performance of parameters. In other studies, the cutting speed, feed
rate and depth of cut have been optimized with the help of Taguchi design of experiment (DOE),
signal to noise (S/N) ratio and analysis of variance (ANOVA) methods [2-3]. Fratila and Caizar [4]
have applied Taguchi method to select optimal process parameters for minimum surface roughness
and minimum cutting power required in semi-finished cutting. In another study, Camposeco-Negrete
[5] has optimized the cutting parameters using Taguchi method focusing on the surface roughness and
cutting power consumption in turning. Nalbant et al. [6] have used the Taguchi method to find the
optimal cutting parameters for surface roughness in turning. They have employed the orthogonal
array, the signal-to-noise ratio, and analysis of variance to study the performance characteristics in
turning. Similar method has been applied by and Ravi & Kulkarni [7] and Vijay Kumar et al. [8] in

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ICRAIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 530 (2019) 012006 doi:10.1088/1757-899X/530/1/012006

different two investigations to find out the optimal cutting condition in CNC turning. In this study, the
Taguchi method has been applied in optimization of the cutting parameters based on the cutting force.
Then the results obtained from the Taguchi analysis have been cross-verified with the workpiece
surface finish and flank wear data measured during turning.

2. Materials and Methods

A round bar (92 mm diameter and 760 mm long) of ASSAB-705, medium carbon steel (hardness
HB270-310) has been used as the workmaterial, which contained carbon (0.35%), chromium (1.40%),
iron (95.95%), manganese (0.70%), molybdenum (0.20%), and nickel (1.40%) by weight. A DSBNR
2525M 12 tool holder and TiN coated tungsten carbide, type: SNMG 12 04 08-PM tool insert
assembly has been employed to cut the material. The experiment was conducted in dry cutting mode
for this investigation. The cutting conditions and tool-workpiece combination have a significant effect
on tool wear and on the surface roughness. The tool flank wear has been measured by taking the tool
insert off from the tool holder after some 12 minutes of cut. A magnification of 40X has been used to
capture the image of flank wear by light source microscope, Model: I CAMSCOPE(G). From the
captured image, the average flank wear has been measured using a measuring software, ‘Measure IT’.
The surface finish of workpiece has been measured with a handy profile-meter type: ‘Mahr
Perthometer M1/M1 CNOMO 3755350’ at the end of 12 minutes of cut.
The turning operation is performed on a COLCHESTER VS MASTER3250 (165 mm × 1270
mm) Gap bed Center Lathe machine. A tri-axial force dynamometer Type: KISTLER 9257A have
been used to measure the cutting force during machining. The frequency range of the tri-axial force
dynamometer is 10 Hz – 400 kHz. A DEWE- 43 module and a charge amplifier Type: KISTLER 5019
have been employed as signal processing units to process the captured signal. The DEWE-43 module
has a low-pass filter of LP: 1000 kHz and the charge amplifier has a high-pass filter of HP: 180 kHz.
The signals captured using the force dynamometer have been processed inside these modules before
storing for analysis. The schematic diagram of the experiment setup is shown in Figure 1.

Figure 1. Setup for capturing the cutting force signals in turning.

3. Design of Experiments
The parameter design has been carried out under the design of experiment using the Taguchi method
to optimize the machining process. The cutting parameters used in the experiment are presented in
Table 1.

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ICRAIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 530 (2019) 012006 doi:10.1088/1757-899X/530/1/012006

Table 1. Cutting conditions.

Cutting speed (m/min) 120, 150, 170

Feed rate (mm/rev) 0.20, 0.32, 0.50
Depth of cut (mm) 0.5, 1, 2

The design of experiment has been performed with Minitab software. The cutting parameters
have been optimized focusing on minimal cutting force requirement in turning. It is expected that the
optimal cutting conditions obtained from the parameter design are insensitive to the variation of
environmental conditions and other noise factors.
The orthogonal array has been used to study the entire parameter space with a small number of
experiments only and thus to identify the optimal cutting condition. A loss function transformed into
S/N ratio has been defined to calculate the deviation between the experimental value and the desired
value. The ‘lower-the-better’ category of the performance characteristic for the analysis of the S/N
ratio has been used in the design of experiment. The S/N ratio for each level of process parameters is
computed based on the S/N analysis.
Finally, a confirmation experiment is conducted to verify the optimal process parameters
obtained from the parameter design. The results have been tested by the surface roughness and flank
wear measured during machining. In this paper, the cutting parameter design by the Taguchi method is
adopted to obtain optimal machining performance in turning.

4. Results and Discussions

The orthogonal arrays of the cutting parameters and the S/N ratios have been obtained from the
Taguchi analysis to find the optimal cutting parameters among the cutting conditions. From literature,
the larger S/N ratio corresponds to the better performance characteristic regardless of the category of
the performance characteristic. Therefore, the optimal level of the process parameters is the level with
the highest S/N ratio. It has been also reported that the optimal combination of the process parameters
can be predicted with the orthogonal array, and the S/N analyses [6].
A three-level, three factors fractional factorial design, L9 has been used to generate an
orthogonal array. Each row of the matrix represents one trial. The orthogonal array obtained from the
Taguchi method is shown in Table 2.

Table 2. Orthogonal array.

SN Cutting speed Feed rate Depth of cut Flank wear Surface roughness Cutting
(m/min) (mm/rev) (mm) (mm) (µm) force (N)
S1 120 0.20 0.5 0.1165 3.994 45.8
S2 120 0.32 1.0 0.1185 3.912 24.3
S3 120 0.50 2.0 0.1304 4.453 48.5
S4 150 0.20 1.0 0.1145 3.997 28.2
S5 150 0.32 2.0 0.1289 3.896 128.7
S6 150 0.50 0.5 0.1127 4.081 118.5
S7 170 0.20 2.0 0.1601 4.099 151.3
S8 170 0.32 0.5 0.1483 3.998 29.9
S9 170 0.50 1.0 0.1571 4.463 81.1

The tool life, surface roughness and cutting force graphs for these trials are represented in the Figure
2.

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ICRAIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 530 (2019) 012006 doi:10.1088/1757-899X/530/1/012006

0.4 12

Surface roughness, Ra (µm)

S1
0.3 S1 9
Flank wear, VB (mm)

S2
S2 S3
S3 S4
0.2 S4 6 S5
S5 S6
S6 S7
0.1 S7
3
S8
S8 S9
S9
0 0
0 20 40 60 80 0 20 40 60 80
Time, t (min) Time, t (min)

a) b)

160
Cutting Force, F (N)

120

80

40

0
S1 S2 S3 S4 S5 S6 S7 S8 S9

Run number, S
c)
Figure 2. a) Tool life graph, b) Surface rouhness profile, and c) Amplitude of RMS force signal.

Though we can have some idea about the possible optimal cutting conditions for the reduced cutting
force from the above graphs, however, it is rather difficult to choose a particular trial condition as the
optimal cutting condition. From the S/N ration analysis, the most optimal cutting parameters can be
identified.
The main effects and the S/N ratios for different combination of the cutting parameters have
been obtained to identify the optimal cutting condition. Figure 3 illustrates the changes of mean data
and S/N ratios at different cutting conditions.

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ICRAIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 530 (2019) 012006 doi:10.1088/1757-899X/530/1/012006

a) Mean data plot for cutting force b) S/N ratio plot for cuttingg force

c) Mean data plot for flank wear d) S/N ratio plot for flank wear

e) Mean data plot for surface roughness f) S/N ratio plot for surface roughness
Figure 3. The mean data and single-to-noise ratio graphs.

From the Taguchi analysis results, three different optimal cutting conditions have been obtained for
cutting force, flank wear, and surface finish optimization. For cutting force optimization, the optimal
cutting speed has been obtained 120 m/min, feed rate 0.32 mm/rev and depth of cut of 1 mm; whereas
for flank wear optimization, the cutting speed, feed rate and depth of cut have been changed to 150
m/min, 0.20 mm/rev and 0.5 mm respectively. An exceptional drop of tool wear and cutting force has
been observed at feed rate of 0.32 mm/rev, which can be attributed to the phenomena of chip breakage
taken place during metal-cutting [9]. For surface roughness optimization, the optimal cutting speed
and depth of cut have been found to be similar like that of flank wear optimization parameter except
the feed rate, which has been changed to 0.32 mm/rev. Therefore, it can be deduced that, when it is to
optimize the cutting force and surface roughness, one has to be more concerned about the depth of cut.
In case of optimizing the cutting force and flank wear, both the feed rate and the depth of cut are to be
given consideration significantly. For the flank wear and surface roughness optimization, the feed rate
has to be monitored with great importance.

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ICRAIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 530 (2019) 012006 doi:10.1088/1757-899X/530/1/012006

Figure 4 shows the tool wear and surface roughness graphs obtained from the experiment of these
three optimal cutting conditions.

a) flank wear b) surface roughness

Figure 4. a) Tool wear curve, b) Surface roughness graph.

From the tool wear and surface roughness graphs of Figure 4, it has been observed that the rate of
flank wear was minimal at the optimal cutting condition found for flank wear optimization, and the
rate of surface roughness was the least at the optimal cutting condition for surface roughness
optimization. Though, both the tool wear and surface roughness graphs obtained for cutting force
optimization have shown some similar trends to those for tool wear and surface roughness
optimization, the tool life was the longest for the optimal cutting condition gained for cutting force
optimization. Therefore, the optimal cutting condition found for cutting force optimization has been
chosen to carry out the experiment to investigate the cutting tool condition using force signal in
turning.

5. Conclusions
The optimal cutting parameters obtained from Taguchi analysis have been tested with experiment
before recording the force signal in tool condition monitoring during turning. The optimal cutting
condition of v = 120 m/min, f = 0.32 mm/rev, and doc = 1 mm found for cutting force optimization
was the optimum among all three optimal cutting conditions. The flank wear and surface roughness
graphs plotted from the experimental results have also supported the optimum cutting condition that
obtained for cutting force optimization.

Acknowledgments
The author would like to thank the University of Science Malaysia for providing the facility to carry
out this research.

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ICRAIEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 530 (2019) 012006 doi:10.1088/1757-899X/530/1/012006

[5] Camposeco-Negrete C 2013 Optimization of cutting parameters for minimizing energy

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