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Gusri, A.I. 1, Che Hassan, C.H.1 , Jaharah, A.G.1, Yanuar,B.1, Yasir, A.1, Nagi,A.1
1. Department of Mechanical and Material, Universiti Kebangsaan Malaysia,
Kuala Lumpur mifavil@yahoo.com, chase@vlsi.eng.ukm.my
ABSTRACT
Keywords: Taguchi method, tool life, S/N ratio and surface roughness.
INTRODUCTION
The quality of design can be improved by improving the quality and productivity
in company-wide activities. Those activities concerned with quality include in
quality of product planning, product design and process design (Park 1996, Ranjit
2001). Robust design is an engineering methodology for obtaining product and
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speed (355 m/min), low feed rate (0.1mm per tooth) and low depth of cut (0.5
mm) are recommended to obtain better surface finish for the specific test range.
Application of Taguchi’s method for parametric design was carried out to
determine an ideal feed rate and desired force combination Although mild
interactions exist between a horizontal feed rate and desired force, the
experimental results showed the expected trends, namely that surface roughness
decreases with a slower feed rate and also with larger grinding force (Phadke
1998, Liu, et al. 2005).
The experiments were carried out with four factors at three levels each, as shown
in Table 1. The fractional factorial design used is a standard L27 (313) orthogonal
array (Park 1996). This orthogonal array is chosen due to its capability to check
the interactions among factors. The machining trials were carried out on the lathe
machine (Colchester T4, 6000 rpm) in dry condition. The three inserts were used
uncoated carbide tool K313 (WC-Co) and coated carbide tool KC 9225 (TiN-
Al2O3-TiCN-TiN) and KC 5010 (TiAlN).
Levels
Factors
0 1 2
A- Cutting speed (m/min) 55 75 95
B- Feed rate (mm/rev) 0.15 0.25 0.35
C- Depth of cut (mm) 0.10 0.15 0.20
D- Tool type K313 KC9225 KC5010
The maximum flank wear land (VB) was measured every one pass machining
using Mitutoyo Tool Maker Microscope with 20x magnification. The surface
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Tool Life
Average S/N ratio for every level of experiment is calculated based on the
recorded value as shown in Table 2. Different values of S/N ratio between
maximum and minimum are (main effect) also shown in Table 2. The cutting
speed and the type of tool are two factors that have highest different values are
12.20 and 11.37, respectively. Based on the Taguchi prediction that the bigger
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Application of Taguchi Method in Optimizing Turning parameters of Titanium Alloy
different value of S/N ratio will gives a more effect on tool life or more
significant. So that, it can be concluded that increase the cutting speed will
reduce the tool life significantly and also the change of tool geometry. The results
of data analysis of S/N ratio for tool life values, which are calculated by Taguchi
Method, are shown in Table 4. DF (degree of freedom), S (sum of square), V
(variance), F (variance ratio), P (significant factor) in percent and contribution
each level (Ranjit 1990).
TABLE 2 Average for S/N Ratio and Main Effect of Tool Life.
Table 3 shows that the cutting speed and the type of tool have more influence
on tool life value. Significant factor (P) values for both are 0.000 in percentage,
respectively. In statistical analysis of Taguchi method, the smallest P value gives
more significant effect on responded tool life parameters. In this case, α = 0.05 is
recommended by Taguchi analysis for engineering case. The significant values
for the cutting speed, the feedrate, the depth of cut and the type of tool are
significant. The contribution of the cutting speed and the type of tool are 21.31%
and 18.33% respectively, whereas the contribution of the feedrate and the depth
of cut are lower than the type of tool. The interaction parameters between cutting
speed and depth of cut (AxC) is significant, with significant value 0.002, and its
contribution is 15.89%. The most significant factor, which affects the tool life
measured in turning Ti-6Al-4V ELI, is the cutting speed therefore the tool life
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Edited by: Azami Zaharim et al.
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FIGURE 1. Main effects of factors machining in the S/N ratio of tool life (a) and
Interaction S/N ratio for tool life with smaller is better (b)
Surface Roughness
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The feed rate is the most significant factor that effected on the surface roughness
value, and followed by the type of tool, which have delta values are 9.553 and
8.445, respectively.
TABLE 4. Average for S/N ratio and main effect of surface roughness
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Application of Taguchi Method in Optimizing Turning parameters of Titanium Alloy
Design Cont.
No Varible Factors DF SS V F P
ation (%)
1 Cutting speed A 2 13.083 6.542 1.36 0.327 1.482
2 Feed rate B 2 416.179 208.089 43.13 0.000 47.146
3 Cutting speed x feed rate AxB 4 44.858 11.214 2.32 0.170 5.082
5 Depth of cut C 2 16.800 8.400 1.74 0.253 1.903
6 Cutting speed x depth of cut AxC 4 5.958 1.490 0.31 0.862 0.675
8 Feed rate x depth of cut BxC 4 13.697 3.424 0.71 0.614 1.552
10 Type of tool D 2 243.223 171.611 35.57 0.000 38.881
Error 6 28.949 4.825 3.279
Total 26 100
Table 5 shows that the feed rate and the type of are very significant factor on
the surface roughness value because of the significant factor (P value) for both
are 0.000. In statistical analysis of Taguchi method, selected P value is 0.05. In
addition to P value for cutting speed and depth of cut are insignificant. The
feedrate and type of tool give a contribution for the surface roughness are 47.146
% and 38.881%, respectively. From this result, it can be concluded that the
feedrate is more significant factor and give most contribution on the surface
roughness. Bhattacharyya found that the surface roughness is primarily
dependent on the feedrate and the nose radius of tool (Bhattacharyya 1984). The
nose radius related to type of tool, because of three types of tool were applied in
this experiment have different tool nose radius. The most significant factor
affecting surface roughness measured in turning Ti-6Al-4V is the feed rate
therefore the quality of surface roughness can be controlled by a suitable feed
rate value. Previous researchers suggest similar results. They claimed that the
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surface roughness well strongly depends on the feed rate followed by the cutting
speed. Jaharah (Ghani, et al. 2004) recommended that to obtain better surface
finish for specific test range in end milling was use of high cutting speed (355
m/min), low feed rate (0.1 mm/tooth) and low depth of cut (0.5 mm).
Effect of levels on surface roughness value is significant compare with cutting
speed and depth of cut factors as shown in Figure 2(a) that B0 is the maximum
value with –3.022 of S/N ratio, and decrease dramatically to B1 (-8.757), and
then follow to B2 (–12.574). The same trend can also be observed on type of
tool factor for each level. It is caused by different of nose radius of cutting edge
of tool. KC9225 tool (D1) has nose radius is 0.4 mm and it is bigger than 0.2 mm
from K313 (D0). The Figure 2 (b) shows the S/N ratio value at (AxB)1 is a best
interaction because of it gives the biggest delta value, and then followed by
interaction (AxC)0.
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Edited by: Azami Zaharim et al.
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FIGURE 2 Main Effects for Factors Machining Verse S/N Ratio of Surface
Roughness (a) and Interaction S/N Ratio for Surface Roughness with Smaller is
Better (b)
CONLUSION
1. Taguchi’s robust design method is suitable to optimize the tool life and
the surface roughness in turning Ti-6Al-4V ELI.
2. The significant factors in turning Ti-6Al-4V ELI on surface roughness
were feedrate and type of tool, with contribution 47.146% and 38.881%,
respectively and for tool life were cutting speed and type of tool with
contribution of 21.31% and 18.33%, respectively.
3. The optimal condition for tool life was resulted at 55 m/min of cutting
speed, 0.15 mm/rev of feed rate, 0.10 of depth of cut and uncoated coated
carbide with K313, and for surface roughness was resulted at 75 m/min
of cutting speed, 0.15 mm/rev of feed rate, 0.10 of depth of cut and CVD
coated carbide with KC9225.
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REFERENCES
C.H. Che Haron. 2001. Tool life and surface integrity in turning titanium alloy,
Journal of Materials Processing Technology, 231-237.
C.H. Liu, C. Andrian. 2005. Grinding Force Control in Automatic Surface Finish
System, Journal of Materials Processing Technology 170, 367 – 373.
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Application of Taguchi Method in Optimizing Turning parameters of Titanium Alloy
J.A. Ghani, I.A. Choudhury and H.H. Hassan. 2004. Application of Taguchi
method on the optimization of end milling parameters, Journal Material
Processing and Technology, 145, 84-92.
Park, S. H. 1996. Robust Design and Analysis for Quality Engineering, London,
Chapman & Hall.
Ranjit, R. 2001. Design of experiment Using The Taguchi Approach, New York,
John Wiley & Sons Inc.
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