Trends in Mechanical Engineering & Technology

ISSN: 2231-1793(online), ISSN: 2347-9965(print)

Volume 5, Issue 1
www.stmjournals.com

A Review on Machining of EN Series Steel

using Different Tools
Raman Brar1*, Manjeet Bohat1, V.P.S. Kalsi2, Sunil Dhingra1
1

Mechanical Engineering Department, U.I.E.T/Kurukshetra University, Kurukshetra

2
Head-Metrology Division, CSIR-CSIO, Chandigarh, India

Abstract
An elaborate study of review papers is conducted for the behavioral study of EN series steel,
while it is machined with optimum process parameters either conventional or nonconventional
machining processes. It is to benefit the Indian industry for manufacturing parts with better
quality and higher productivity. It is revealed from the literature that majority of medium
industry use nonconventional machines for generating intricate profiles. Present scenario of
industries look forward by quality product and high productivity. The study reveals different
machining processes like EDM, WEDM, TURNING, and MILLING. It will be beneficial for
medium-scale industries to sustain in the market by manufacturing better quality products
without losing time. Study of these papers revealed that very less work has been carried on
EN5 material using CNC milling machine.
Keywords: Surface roughness (SR), material removal rate (MRR), parameters optimization,
EN, Taguchi

*Author for Correspondence E-mail: ramanbrar272@gmail.com

INTRODUCTION
EN steel series is basically medium carbon
steel which is used in manufacturing of
springs, guides, studs, axles etc. It is also used
in automotive, aerospace, tool & die making
industries due to its properties. It has many
gradesEN2, EN5, EN8 EN9, EN16, EN19,
EN24, EN31, EN33 and EN41 etc. In this
review paper, an elaborate study of different
machining process parameters on different EN
series materials has been done. After study of
20 research papers it was concluded that
optimization of machining parameters like
speed, feed, depth of cut, pulse on, pulse off,
peak current and servo voltage etc. are useful
for the industries. These parameters help the
industries for better quality product and also in
achieving production goal. Research work of
the industries is reduced by this type of
experiments. It is also useful for academic
purpose in its optimization utilization in
structural design. Machine used in these
process were EDM, WEDM, TURNING,
MILLING, DRILLING and BORNING etc.
Following results were obtained from different
machines after the study of review papers. In
the EDM machining, there were machining

parameters like pulse on, pulse off, current and

bed speed. In this process, optimized values of
process parameters were evaluated by
conducting experiment. Design of experiment
was done by Minitab software. Result can be
evaluated by many methodologies like
Taguchi technique, ANOVA technique, RSM
etc. Results showed that peak current and
pulse on time increases with increase in MRR
and decreases by jet pressure. In the milling
process, different process parameters were
considered such as speed, feed, depth of cut,
tool types and coolant etc. Response
parameters taken were MRR and surface
roughness (SR). These were evaluated by
different methodologies after the evaluation of
results. Results showed that MRR and SR
increases with increase in cutting speed and
feed. After a certain limit, SR decreases with
increase in cutting speed and feed. In case of
WEDM, process parameters considered were
wire tensions, pulse width, wire electrodes,
pulse off time, pulse on time, and current etc.
Response parameters considered were SR and
material removal rate (MRR). Generally
results shows that SR and MRR are affected
when pulse on time is the most significant
factor.

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Review study of EN steel

LITERATURE REVIEW
More than 20 research papers were reviewed
and many machining parameters has been
revealed. Some of them are listed below:
Amit et al. [1] investigated the effect of
machining parameters on EN-5 steel using
EDM drilling. Experiment was designed with
the help of Taguchi method. The significant
factors affecting the machining performance
were peak current, pulse on time and jet
pressure. Response parameters taken were
MRR. It was observed that MRR increases
with increase in peak current and pulse on
time and decreases by jet pressure. As peak
current increases MRR also increases and
MRR is decreased by increase in jet pressure.
Ashok Raj et al. [2] revealed the optimization
of process parameters of EN8 using Taguchi
methodology. In this investigation, he
observed the machining performance with
various cutting speed, feed and depth of cut
using side and face milling. Orthogonal array
was identified by Taguchi technique. After the
experimental investigation, result showed that
cutting speed was statistically significant
factor influencing SR.
Moshat et al. [3] investigated the optimization
of CNC end milling process parameters using
PCA-based Taguchi method. In this
investigation, main purpose was to provide
good surface finish and high MRR of
aluminum. Three process parameters such as
spindle speed, feed rate and depth of cut were
taken. Response features used were SR and
MRR. By using Taguchi methodology, a
relationship between control factor and
responses was established by means of
nonlinear regression analysis resulting in a
valid mathematical model.
Vikas et al. [4] investigated the effect of
machine process parameters on MRR for
EN19 & EN41 materials using die sinking
EDM machine. Control factors considered
were pulse on time, pulse off time, discharge
current and voltage; while MRR was
considered as response variable. By using
Taguchi method, it has been considered that
discharge current has more effect on MRR as
compared to others variables.

Brar et al.

Annamalai et al. [5] experimentally achieved

the maximum MRR and minimum electrode
tool wear of EDM machine on EN24 material
using response surface modelling. Machining
parameters taken were peak current, pulse on
time and pulse off time. Investigation showed
that when peak current and pulse on time
increases, MRR, EWR and SR increases. Pulse
off time has no effect on it.
Dhole et al. [6] revealed the optimization of
milling machine process parameters using
Taguchi design approach. In this study, input
parameters taken were cutting speed, feed rate,
depth of cut and tool materials and the
response variable was cutting force. L18
orthogonal array was taken on EN33 materials.
It was observed that cutting force has major
influence on cutting speed and feed rate. When
cutting speed increases cutting force
decreases. But when feed and depth of cut
increases, cutting force also increases.
Maiyar et al. [7] reported the machining of
Inconel 718 super alloy by using End Milling
process. Taguchi-based grey relational
analysis method was used. Cutting velocity,
feed and depth of cut was used as control level
and SR and MRR was used as response. This
study showed that cutting velocity has more
influence on SR and MRR.
Kapoor and Singh [8] studied the results of the
effect of cryogenic treated brass wire electrode
on the surface of an EN31 steel machined by
WEDM. Full factorial experimental design
strategy was used in the experimentation.
Three process parameters, namely type of wire
electrode (untreated and cryogenic treated
brass wire electrodes), pulse width, and wire
tension has been considered. The process
performance was measured in terms of SR.
type of wire, pulse width and wire tension
significantly affecting the SR. In WEDM,
ANOVA results indicated that all the process
parameters have significant effect on SR.
Shivade et al. [9] investigated the optimization
of SR and tool tip temperature on EN8
material using turning process. In this process,
L9 orthogonal array was designed using
Taguchi technique. Speed and feed rate was
taken as machining parameters and an

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Trends in Mechanical Engineering & Technology

Volume 5, Issue 1
ISSN: 2231-1793(online), ISSN: 2347-9965(print)

optimized combination of input variable was

found by using ANOVA technique.
Noorani et al. [10] reported the improving SR
using CNC milling machine with aluminum
alloy 6061 samples due to process parameter
variation. Spindle speed, depth of cut, feed and
tool size were taken as control factors.
Classical method of design of experiment was
chosen for research. After the experimental
analysis, two factors were found highly
responsible for SR, i.e., feed rate and tool size.
Most SR was found when feed rate was high
with high depth of cut and low spindle speed.

SR. The tool used for face milling operation

was carbide inserted face milling cutter. From
the investigation, it was found that at 2500
rpm spindle speed, 200 mm/min feed and 0.2
mm depth of cut gave optimum level of input
parameter.
Pang et al. [15] researched on optimizing
machining parameter on CNC milling with
(HNT/AL/EP) composite. An orthogonal array
was designed using Taguchi method. In this
research, Taguchi gave the best optimal result
of lower SR.

Chaudary and Rampal [11] investigated the

effect of process parameters of WEDM on
EN5 materials using RSM technique. In this
process, control factors wers taken as pulse on,
pulse off, peak current, servo voltage; and
MRR was taken as response variable. For
designing the experiment, central control
design methodology was used. Experimental
result showed that Ton was the most
significant factor affecting MRR.

Rashid and Lani [16] applied artificial

intelligence method to predict SR for CNC
milling. Because conventional trial and error
method was time consuming. In this
experiment, the input variables were speed,
feed and depth of cut. Mathematical model
was developed by RSM technique and ANN
technique. Orthogonal array was taken as L27.
Analysis of variance shows that feed rate has
high influence on SR rather than others
parameters.

Brahmnhatt et al. [12] studied the optimization

parameters on EN9 steel for turning process
using Taguchi method. In this experiment,
spindle speed, feed and depth of cut were
taken as input variables. SR and MRR were
taken as output variables. By using ANOVA
technique, the parameters affecting response
variables was analyzed and a combination of
optimized values was evaluated.

Zhang et al. [17] optimized surface quality in a

CNC face milling operation. Experiment was
designed by L9 orthogonal array with the help
of Taguchi design and ANOVA technique was
used to identify significant factors affecting
SR. Aluminum blocks as a work piece of 19.1
X 38.1 X 76.2 mm was used. Results showed
that feed rate and spindle speed has high effect
on SR than depth of cut.

Rawangwong et al. [13] devised an approach

of face milling machining parameter on AA
7075 semi-solid using carbide tool. In this
research, spindle speed, feed and depth of cut
was taken as control level. Result revealed that
the factors affecting SR were feed rate and
cutting speed, while depth of cut unaffected
the SR. High speed and low feed gave low
roughness. Speed and feed rate were the most
responsible to tool wear.

Singh and Kumar [18] investigated the

optimization of bending strength in EN24
steel. Taguchi method was used for designing
the experiment. Machining parameters were
analyzed under varying currents (24.8 A, 29.2
A, 38.5 A), weld time (5 sec, 10 sec, 15 sec).
Results showed that time was an important
factor than current for bending strength. When
time tends to increase, the bending strength
also increases for maximum. Bending strength
current should be at maximum level.

Saini and Choudhary [14] researched on

machining parameter optimization of SS202
steel by using Taguchi method. In this
investigation, input machining parameters
were considered such as cutting speed, feed
and depth of cut. Response factor was taken as

Reddy et al. [19] studied the optimization of

process parameters of CNC end milling on
pre-hardened steel (P20) using RSM and
genetic algorithm. To achieve surface finish
this experiment should be conducted with

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Review study of EN steel

orthogonal array L50. Machining parameters

considered were nose radius, cutting speed,
feed and depth of cut. RSM interact with GA
to find out the machining parameters values.
Result showed that SR reduced by 44.22%.

CONCLUSIONS
From the above literature review, it can be
concluded that more work is required on EN
series materials using EDM and WEDM.
Optimized values of these machining
parameters have been evaluated for better
quality product and high productivity. Use of
many
methodologies
like
Taguchi
methodology, ANOVA methodology etc. for
optimization of process parameters give
improved result in the industry. Study of
papers revealed that very less work has been
initiated in conventional machining. Research
work should be encouraged for optimizing the
process parameters for machining EN5 steel.

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Cite this Article

Brar R, Bohat M, Kalsi VPS, Dhingra S.
A Review on Machining of EN Series
Steel Using Different Tools. Trends in
Mechanical
Engineering
and
Technology. 2015; 5(1): 3135p.

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