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Seminar on Engineering Mathematics

2008 Engineering Mathematics Group


Editors: Azami Zaharim et al.

APPLICATION OF TAGUCHI METHOD IN OPTIMIZING


TURNING PARAMETERS OF TITANIUM ALLOY

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

Taguchi offers a simple and systematic approach to optimize a performance,


quality and cost. Taguchi optimization methodology is applied to optimize
cutting parameters in turning Ti-6Al-4V ELI with coated and uncoated cemented
carbide tools. The turning parameters evaluated are cutting speed, feed rate, depth
of cut and type of cutting tool, each at three levels. The results of analysis show
that the cutting speed and type of tool have a very significant effect on the tool
life, and the feedrate and type of tool have also a very significant effect on the
surface roughness.

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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process condition, which are minimally sensitive to the various causes of


variation, and which produce high-quality products with low development and
manufacturing costs (Park 1996). Taguchi’s parameter design offers a simple,
systematic approach and can reduce number experiment to optimize design for
performance, quality and cost. Signal to noise ratio and orthogonal array are two
major tools used in robust design. Signal to noise ratio, which measures quality
with emphasis on variation, and orthogonal arrays, which accommodates many
design factors simultaneously (Park 1996, Phadke 1998). Taguchi method offers
the quality of product is measured by quality characteristics such as: nominal is
the best, smaller is better and larger is better (Phadke 1998, Ranjit 2001).
Optimization with Taguchi method in end milling using conceptual S/N ratio
approach and Pareto ANOVA can be concluded that Taguchi’s robust design
method is suitable to analyze the metal cutting problem. Conceptual S/N ratio
and Pareto ANOVA approaches for data analysis draw similar conclusion. As
found by Jaharah (Ghani, et.al. 2004), in process end milling use of high cutting
Edited by: Azami Zaharim et al.

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).

DESIGN OF EXPERIMENT AND EXPERIMENTAL DETAILS

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).

TABLE 1 Factors and Levels Used in the Experiment

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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roughness of machined surface was measured using surface roughness tester


model Mpi Mahr Perthometer.

EXPERIMENTAL RESULTS AND ANALYSIS

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.

No. Designa Levels Maks -


Factors Ranks
Colum tion 0 1 2 Min
1 Cutting speed A 36.92 32.91 24.72 12.20 1
2 Feedrate B 36.97 30.84 27.74 10.23 4
5 Depth of cut C 35.50 33.79 25.26 10.24 3
9 Type of tool D 37.75 26.38 30.42 11.37 2

TABLE 3. ANOVA Analysis of S/N Ratio for Tool Life.

No. Desig D Contr.


Factors SS V F P
Col. nation F (%)
1 Cutting speed A 2 695.51 347.754 44.49 0.000 21.31
2 Feedrate B 2 477.36 236.682 30.53 0.001 14.63
3 Cutting speed x feedrate AxB 4 143.82 35.956 4.60 0.049 4.41
5 Depth of cut C 2 541.05 270.523 34.61 0.001 16.58
6 Cut. speed x depth of cut AxC 4 518.63 129.657 16.59 0.002 15.89
8 Feedrate x depth of cut BxC 4 242.47 60.618 7.75 0.015 7.43
9 Type of tool D 2 598.11 299.056 38.26 0.000 18.33
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Error 6 46.90 1.44


Total 26 3263.85 100

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.

can be controlled by a suitable cutting speed selected. Previous researchers


suggest similar results. They clamed that the tool life was affected significantly
by the cutting speed. Increase in cutting speed caused a greater increase in cutting
temperature at the cutting edge of the tools. The higher temperature generated
during machining caused the tools to lose their strength and plastic deformation
occurred (Che Haron 2001, Ezugwu 2005).
Figure 1(a) shows that A0 is the maximum value with 36.92 of S/N ratio, and
decrease dramatically to A1 (32.91), and then follow to A2 with 24.72. S/N ratio
for A1 decreased, it is possibly due to heat generated when machining of titanium
at high cutting speed. The main effects for the cutting speed, feedrate and depth
of cut have same trend lines.The Figure 1(b) shows the interaction between
cutting speed and feed rate (AxB), cutting speed and depth of cut (AxC) and feed
rate and depth of cut (BxC). The S/N ratio value of interaction between cutting
speed and depth of cut at (AxC)2 is a maximum and gives the best interaction
condition, then followed by (BxC)2. Interaction between cutting speed and feed
rate (AxB) is less significant effect on tool life value.

" # "!#
! !

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

No. Desig Level average Max. -


Variable Factors Rank
column nation 0 1 2 Min.
1 Cutting speed A -8.918 -7.221 -8.213 1.697 4
2 Feed rate B -3.022 -8.757 -12.574 9.553 1
5 Depth of cut C -7.063 -8.961 -8.329 1.897 3
9 Type of tool D -9.403 -3.252 -11.697 8.445 2

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Application of Taguchi Method in Optimizing Turning parameters of Titanium Alloy

TABLE 5. ANOVA analysis of S/N ratio for surface roughness

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.

$
'

'

% '

" # "!#
& ! & !

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

A. Bhattacharyya. 1984. Metal Cutting - Theory and practice, India.

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.

E.O. Ezugwu. 2005. Key Improvements in The Machining of Difficult-to-Cut


Aerospace Superalloys, International Journal of Machine Tools &
Manufacture, 1353-1367.

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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.

Phadke, M. S. 1998. Quality Engineering Using Design of Experiment, Quality


Control, Robust Design and Taguchi Method, California, Warsworth &
Books.

Ranjit, R. 1990. A Primer on The Taguchi Method, Society of Manufacturing


Engineers,. Michigan, Dearborn.

Ranjit, R. 2001. Design of experiment Using The Taguchi Approach, New York,
John Wiley & Sons Inc.
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