OPTIMIZATION OF MACHINING PARAMETERS IN

A TURNING OPERATION OF ALUMOINIUM 6063 TO

MINIMIZE SURFACE ROUGHNESS AND POWER
CONSUMPTION

A report submitted as part of Industrial Development Project for semester V

Bachelor of Technology
In
Mechanical Engineering
By
Abhey Gupta (171030012001)
Akshay Kumar (171030012006)
Aman Shukla (171030012007)

Under Guidance of
Dr. Navneet Khanna

Department of Mechanical Engineering

Institute of Infrastructure Technology, Research and
Management
Ahmedabad-380026
November 2019
ACKNOWLEDGMENT

We wish to express my gratitude to Dr. Navneet Khanna, Head of Department,

Department of Mechanical Engineering, Institute of Infrastructure Technology Research
and Management, Ahmedabad for giving me this golden opportunity to carry out the
project under his supervision. We are greatly indebted to him for his inspiring guidance,
constructive suggestion and criticism from time to time during the course of progress of
the work. We convey my sincere thanks to him for providing necessary facilities in the
department to carry out my project.

We would also like to majorly thank all staff members of central workshop who have
extended all sorts of help for accomplishing this undertaking.

Last but not the least; We would like to thank from the bottom of my heart, everyone else
involved directly or indirectly in assisting me to accomplish the objectives of this project.
Their help and support are highly appreciated.

Abhey Gupta
Akshay Kumar
Aman Shukla

Department of Mechanical Engineering

Institute of Infrastructure Technology, Research and Management,

Ahmedabad-380026
Abstract

Advanced makers, looking to stay focused in the business sector, depend on their
assembling architects and creation work force to rapidly and adequately set up
assembling procedures for new items. Taguchi Parameter Design is an intense and
effective technique for enhancing quality and execution yield of assembling procedures,
along these lines a capable apparatus for meeting this test. Concerned with optimizing
the process or say input parameters of a CNC machine which in turn helps us to get a
better and optimised output. Optimised in terms of technology, economics and
knowledge.

Into this project we have went through a number of research work done by various
researchers over a variety of materials on CNC machine through various machining
operations. In our project our material under operation turning is an Aluminium 6063
alloy which we have selected due to its various applications in the various different
industries and also due to cost effectiveness and availability. The machine over which we
have performed our turning operation is 3 axis CUB/XXZ semi-automatic CNC turret
lathe having 8 tool inserting positions. We have also worked upon Minitab 2019 software
for the statistical analysis of our project by calculating the means, and signal-to-noise
ratios for each turning operation we have performed. Also, a L27 orthogonal array was
used to decide the combination of values for each turning operation on Aluminium 6063
T6. The process parameters we have considered under our project for an optimised
output are feed rate (in mm per spindle revolution), depth of cut (in mm) and spindle
speed (in rpm). With the help of an L27 orthogonal array we have decided a set of
combination of values for our considered process parameters for an optimised surface
roughness and power consumption.
 Contents

Acknowledgement ii
Abstract iii
Contents iv
Chapter 1: - Introduction
1. Background of CNC
2. Introduction of CNC
3. Basic Principle of CNC
4. Classification of CNC
a. Point-to-point system
b. Contouring system
5. Parameters of CNC
a. Cutting parameters for CNC turning
i. Cutting speed
ii. Cutting feed
iii. Spindle speed
iv. Feed rate
v. Axial Depth of Cut
vi. Radial Depth of Cut
6. Advantages of CNC
7. Limitations of CNC
8. Applications of CNC
Chapter 2: - Experimental Set-up
1. Investigational set-up
a. Machine Specification
b. Workpiece Specification
i. Material Name
ii. Physical Properties
iii. Temper Sorts
c. Tool Specification
2. Selection of Process Parameters
3. Measurement of Surface Roughness
a. Amplitude Parameters
b. Measurements
Chapter 3: - Methodology
1. Taguchi Method
2. Taguchi Design Methodology
a. Static Problems
i. Smaller is better
 ii. Larger is Better
iii. Nominal is Better
b. Dynamic problems
i. Sensitivity
ii. Linearity
3. Steps of Taguchi Methodology
4. Data Analysis
a. Minitab Software
5. Advantages of Taguchi Design
6. Disadvantages of Taguchi Design
Chapter 4: - Experimentation and Analysis
1. Orthogonal array and L-27 matrix
2. Levels of control factors
3. Analysis
a. Interpretation
Chapter 5: - Results and Conclusions
References
 Chapter 1
Introduction

1. Background of CNC

Today, Computer Numerical Control is an extension of what was once Numerical

Control. It refers essentially to the concept of controlling automated machine tools via
programmable computers. Clearly, with the older system of Numerical Control, a
computer wasn’t involved, but today the technology has advanced in leaps and
bounds (and continues to advance every year). CNC has set the stage for a
tremendous upsurge in productivity – it’s an environment where machine tools can
operate automatically, and without the attention and oversight of an operator.
Historically, the first commercial Numerical Control machines were used in the early
1950’s, and operated with “punch tape”. And although a proven method, the so-called
“new” technology was not readily accepted by manufacturers. In the late 1950’s,
Numerical Control began to capture the interest of more and more manufacturers, but
still with some problems and issues that required attention. Things became more
manageable when industry groups standardized the operational aspects of NC,
bringing some order and commonality to the manufacturing sector.
Over the years, as CNC technology gained acceptance (with proven results),
manufacturers began to replace older technologies and manual machining methods
with Computer Numerical Control. And while the United States launched the CNC
technology revolution, Germany and Japan became more successful in enhancing the
technologies and bringing down unit costs. In more recent years, microprocessors
have brought down unit costs even more, and have made CNC technology much more
accessible to smaller manufacturing companies, as well as individuals. Whether its
metal cutting machines, or woodworking machines, the technology is being used
universally, and with advanced applications emerging every year. As for the CNC
machinist, CAD programs, CAM programs, and other computer software are the basis
for designing and fabricating almost every product that consumers use on a daily
basis. Indeed, like the 1950’s and 1960’s, advances and innovations in technology
will continue to revolutionize throughout the 2000’s.
2. Background of CNC

The term “CNC” is a generic term which can be used to describe many types of
device, this would include plotters, vinyl cutters, 3D printers, milling machines and
others. CNC stands for Computer Numerically Controlled and basically means that
the physical movements of the machine are controlled by instructions, such as co-
ordinate positions that are generated using a computer.
The term “CNC Machine” is typically used to refer to a device which uses a rotating
cutting tool which moves in 3 or more axes (X, Y and Z) to cut-out or carve parts in
different types of materials. The information on these pages will focus on what are
typically referred to as “CNC Routers” although it would be applicable to most CNC
milling and engraving machines too.

Fig 1.1 Schematic diagram of CNC

CNC’s are incredibly versatile and allow you to cut a variety of different types of
product and materials. The exact abilities of a machine will vary with size, rigidity
and power. Typically, most CNC Routers can cut soft and hard wood, plastics, other
composites and non-ferrous metals. Signage, custom furniture, plaques, trophies,
chocolate & cookie molds, awards, folk-art, toys, wall-hangings, plates & bowls,
lithophones, memorials, cabinets, doors, boxes, clocks, religious carvings, panel
goods, architectural millwork & moldings, picture frames, mantels, archways,
prototypes, remote control vehicle parts, face plates, heirloom gifts, military awards,
education projects, movie & theatre props, coasters, chests, bottle totes, pool cues,
rustic carvings and many other applications.
3. Basic Principles of CNC

Movements of X, Y, Z axis are controlled by motor which supplies either AC/DC.

Movement of machine is done by giving commands.
All the operations are carried out by codes like speed, feed, depth of cut, etc. For each
operation separate code is available.
Warning system is available to save guard the various operations and components.

4. Classification of CNC

There are two main types of machine tools and the control systems required for use
with them differ because of the basic differences in the functions of the machines to be
controlled. They are known as point-to-point and contouring controls.
a. Point-to-point systems: Some machine tools for example drilling, boring and
tapping machines etc., require the cutter and the work piece to be placed at a
certain fixed relative position at which they must remain while the cutter does
its work. These machines are known as point-to-point machines and the
control equipment for use with them are known as point-to-point control
equipment. Feed rates need not to be programmed. In these machine tools,
each axis is driven separately. In a point-to-point control system, the
dimensional information that must be given to the machine tool will be a
series of required position of the two slides. Servo systems can be used to
move the slides and no attempt is made to move the slide until the cutter has
been retracted.
b. Contouring systems (Continuous path systems): Other type of machine
tools involves motion of work piece with respect to the cutter while cutting
operation is taking place. These machine tools include milling, routing
machines etc. and are known as contouring machines and the controls
required for their control are known as contouring control.

Contouring machines can also be used as point-to-point machines, but it will be

uneconomical to use them unless the work piece also requires having a
contouring operation to be performed on it. These machines require
simultaneous control of axes. In contouring machines, relative positions of the
work piece and the tool should be continuously controlled. The control system
must be able to accept information regarding velocities and positions of the
machines slides. Feed rates should be programmed.
 Fig 1.2 Point-to-point system [2] Fig 1.3 Contouring system [2]

Fig 1.4 Contouring Systems [2]

5. Parameters of CNC

There are various kinds of CNC machines used today. One of them is CNC turning
machines, which are used to produce cylindrical parts. In these machines, a work
piece keeps on rotating, and the cutting tool moves in a linear fashion.
a. Cutting Parameters for CNC Turning Machines:
Right cutting parameters produce a precise output, which helps in reducing
cycle times, and machine costs. The speed and motion of the cutting tool are
specified through several parameters that can be modified for different
operations based upon the workpiece material and tool size.
i. Cutting Speed:
This criterion measures the number of feet the tool passes over the
surface of the work piece per minute in Surface Feet per Minute
(SFM). The material and the process often decide the cutting speed. For
example, grooving requires slower cutting speed for accurate results.
ii. Cutting Feed:
This parameter measures the distance undertaken by the cutting tool for
every single revolution. It is measured in Inches per Revolution (IPR).
 Depending upon the mode of operation, the tool is either fed into the
workpiece or the workpiece is fed into the tool.

iii. Spindle Speed:

The spindle speed is obtained when the cutting speed is divided by
the circumference of the work piece in Revolutions per Minute
(R.P.M). The speed varies depending upon several factors like the
diameter of the cut or the surface area.
iv. Feed Rate:
It is defined as the speed of the cutting tool when it cuts through the
material. It is the product of the cutting and spindle speed measured
in Inches per Minute (IPM).
v. Axial Depth of Cut:
This parameter measures the depth of a tool as it cuts towards the axis
of the material. A large axial depth of cut is needed to overcome the
high load on the tool.
vi. Radial Depth of Cut:
This parameter measures the depth of the tool as it cuts along the
radius of the material. To enhance the quality of the cutting tool, a
lower feed rate is needed.

6. Advantages of CNC

CNC machines can be used continuously 24×7 throughout the year and only need
to be switched off for occasional maintenance.
CNC machines are programmed with a design which can then be manufactured
hundreds or even thousands of times. Each manufactured product will be exactly the
same.
Less skilled/trained people can operate CNC machines unlike manual lathes milling
machines etc. which need skilled engineers.
CNC machines can be updated by improving the software used to drive the
machines.
Training for correct use of CNC machines is available through the use of ‘virtual
software’. This software is like a computer game that allows the operator to practice
using the CNC machine on the screen of a computer.
Modern design software allows the designer to simulate the manufacture of his/her
idea. There is no need to make a prototype or a model. This saves time and
money.
One person can supervise many CNC machines as once they are programmed, they
can usually be left to work by themselves. Only the cutting tools need replacement
occasionally.

7. Limitations of CNC

CNC machines are more expensive than manually operated machines, although costs
are slowly coming down.
The CNC machine operator only needs basic training and skills, enough to supervise
several machines. In years gone by, engineers needed years of training to operate
centre lathes, milling machines and other manually operated machines. This means
many of the old skills are being lost.
Fewer workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.
Many countries no longer teach pupils / students how to use manually operated lathes
/ milling machines etc… Pupils / students no longer develop the detailed skills
required by engineers of the past. These include mathematical and engineering skills.

8. Application of CNC
a. Metal Removal Industries
CNC machines are extremely useful in metal removal industries such as
automotive industries, aerospace industries, and in making jewellery. This
technology removes excess metal from raw materials to attain desired end
product. CNC machines can also be used to create shaped products in the
manufacturing industries, which may include threaded, rounded,
rectangular, square, or even three-dimensional products.
b. Industries for Fabricating Metals
There are several industries that require thin metal plates such as steel
plates, to create end products. Several metal fabrications tasks such as
drilling precision holes, flame or plasma cutting, welding and shearing have
been made easier with CNC machines. There are several industries for
fabricating metals that would benefit from CNC machines, for instance:
i. Electronics:
Electronics: Computers and motherboards have brains with millions
of tiny parts that must be made with precision.
ii. Firearms:
Firearms: CNC machines are used to create barrels, ammunition clips,
pins, triggers, and several components of the gun.
 c. Electrical Discharge Machining (EDM) Applications
The EDM machines generate sparks that burn the unwanted metal away.
Through CNC automation, EDM machining can be done in two ways;
Vertical EDM that requires an electrode with a similar size and shape as that
of the cavity that is to be carved out, and Wire EDM that is used to create
the punch as well as die combinations for the dies set, which are used in
metal fabrication industries.
CNC machines can also be applied in woodworking industries, lettering and
engraving systems, electrical industry, the pharmaceutical industry, food and
beverage industry, and much more. Whatever industry you are in, you’ll definitely
find some type of CNC machine that suits your needs. At Stoney CNC, we provide
a wide range of high performance, quality and easy to use CNC machining and
CNC plasma equipment. All of our products are vetted and tested to ensure
performance to the highest standards, plus our after-sale support is impeccable.
 Chapter 2
Experimental Set-up
1. Investigational Set-up

Numerical control (NC) is a system for naturally working an assembling machine in

view of a code letters, numbers and exceptional characters. The numerical information
needed to create a section is given to a machine as system, called part program or CNC
(PC numerical control). The system is interpreted into the proper electrical signs for
info to engines that run the machine. A CNC machine is a numerical control machine
with the included component of a board PC. The PC is alluded to as the machine control
unit (MCU).
a. Machine Specification
Mac Power CNC VX200
Machine Specifications

DESCRIPTION Units VX 200

CAPACITY

Std. Turning Dia. mm 200

Max. Turning Dia. mm 300

Swing Over Bed 400

Max. Turning Length mm 400

Dist. Between Centre mm 550

SLIDES

Cross (X axis) Travel mm 160

Longitudinal (Z axis) Travel mm 450

Rapid Feed (X & Z axis) m/min 24

MAIN SPINDLE
Spindle Nose A2-5

Spindle Bore mm 47

Max. Bar Capacity mm 36

Chuck Size mm 200

Speed Range rpm 50 - 3500

Full Power Speed Range rpm 1500 - 2250

Spindle Motor (Cont. Rating)

kW 5.5 / 7.5

(15 Min. Rating) (Fanuc)

TURRET

No. of Stations - 8

Tool Size mm 25 x 25

Max. Boring Bar Capacity mm 40

ACCURACY
Positioning mm 0.008

Repeatability mm 0.007
 TAIL STOCK

Quill Diameter 80

Quill Stroke 100

Tapper in Quill MT4

OTHER DATA

Weight (Approx.) Kg 3100

3040 x
Machine Dimensions (WxDxH) mm
1630 x 1800

SYSTEMS
Fanuc --- Oi TF
Siemens --- 828D Basic

b. Workpiece Specification
An Aluminium alloy has been selected as the workpiece of choice to perform
turning operation with the aimed objective of the project. It is Aluminium 6063-
T6 alloy have Aluminium, Magnesium and silicon as its major constituent.
i. Material name- Aluminium 6063-T6/UNS A96063/ISO AlMg0.5Si

Workpiece Specification
Component Wt.%
Al Max. 97.5
Cr Max. 0.1
Cu Max. 0.1
Fe Max. 0.35
Mg 0.45-0.9
Mn Max. 0.1
Si 0.2-0.6
Ti Max. 0.1
Zn Max. 0.1
Other, each Max. 0.05
Other, each Max. 0.15
ii. Physical Properties
Apart from its metallurgical characteristics, the physical properties of
Aluminium 6063 T6 alloy is also having a major role in calculating the
values of various responses one can obtain from a machining operation
using a CNC turret lathe.

Physical Properties of workpiece

Hardness, Brinell 79
Hardness, Knoop 9
Hardness, Vickers 83
Ultimate Tensile Strength 241 MPa
Tensile yield strength 214 MPa
Elongation at break 12%
Modulus of Elasticity 68.9 GPa
Ultimate bearing strength 434 MPa
Bearing yield strength 276 MPa
Poisson’s ratio 0.33
Fatigue strength 68.9 MPa
Machinability 70%
Shear modulus 25.8 GPa
Shear strength 152 Pa

iii. Temper sorts: The most well-known tempers for 6082 aluminium are:
T6 - Solution warmth treated and misleadingly matured
0-Soft
T4 - Solution warmth treated and normally matured to a considerably
stable condition
T651 - Solution warmth treated; anxiety assuaged by extending then
falsely matured
 c. Tool Specification
Item Turning Insert
Insert Shape Diamond
Insert Style CNMG
Insert Size 432
Chip-Breaker CQ
Grade CA515
Insert Application Finishing
Workpiece Compatibility Steel (P)
Relief Angle 0 Degrees
Inscribed Circle 0.500"
Insert Thickness 0.1875"
Nose Radius 0.0313"
CNMG432CQ-
ANSI Number
CA515
ISO Number CNMG120408CQ

Insert Material Carbide

Coating TiCN/Al2O3/TiN
Cutting Direction Right Hand
Rake Negative
Toolholders, Boring
For Use With
Bars
No. of Edges 4
Mounting Hole Dia. 0.203"
Mounting Style Clamp

2. Selection of Process Parameter

The three key mechanical inputs in metal evacuation operations are bolster, rate, and
profundity of cut. Controlling the food, rate and profundity of cut can amplify the
advantages of a specific cutting liquid and can expand efficiency. Be that as it may, as
most choices, the decision of food, pace and profundity of cut must be in light of the
client's targets. What is their objective in this application? Would they like to make
parts quicker or augment instrument life? How critical is the surface completion and
dimensional exactness of the part? Answers to these inquiries will drive their choices
on bolsters, velocities and profundity of cut.
Some of the process parameters are: -
 1. Speed: Speed is the rate of turn of the axle where the device is held. It is
measured in cycles every moment (RPMs).
2. Feed: Feed is the rate at which the instrument is moved into the part or the part
into the device. Food is measured in feet, inches or millimetres per time period.
3. Depth of Cut (DOC): The estimation typically in inches or millimetres) of
how wide and profound the apparatus cuts into the work piece. Speed, food and
DOC
4. Spindle speed - The rotational velocity of the shaft and the work piece in
cycles every moment (RPM). The axle pace is equivalent to the cutting rate
partitioned by the perimeter of the work piece where the cut is being made.
With a specific end goal to keep up a steady cutting speed, the shaft speed must
shift taking into account the breadth of the cut. In the event that the shaft pace
is held consistent, then the cutting rate will change.
5. Feed rate - The rate of the slicing apparatus' development in respect to the
work piece as the instrument makes a cut. The food rate is measured in
millimetre per unrest (RPM).
6. Tool life: For the most part, expanding the food rate lessens apparatus life.
Uprooting more material makes more warmth. Warmth debases the work piece
and the tooling. On the off chance that you lessen your food rate, the
instrument life enhances on the grounds that it is not functioning as hard.
7. Surface finish: It might be justified, despite all the trouble to the client to build
the expense of the coolant (with a somewhat higher fixation or higher lubricate
liquid) to enhance the surface completion at higher paces. Obviously, this
implies that surface completion must be worth something to your client.
Expanding the DOC can advance prattle as a result of higher strengths. The
machine device must be sufficiently inflexible to withstand these powers.
Vibrations in the machine apparatus can have an expansive impact on surface
completion. Machine apparatuses composed and built for rapid machining have
enhanced solidness to minimize the vibration that effects surface completion.
8. Material Removal Rate: It can be defined as the amount of material removed
per unit machining time. For a turning operation it can also be mathematically
depicted as the product of feed rate, depth of cut and cutting speed. That is,
MRR = Feed x Depth of Cut x Cutting Speed……………………………. (F1)

3. Measurement of Surface Roughness

Surface unpleasantness, regularly abbreviated to harshness, is a measure of the

composition of a surface. It is evaluated by the vertical deviations of a genuine
surface from its optimal structure. On the off chance that these deviations are
expansive, the surface is harsh; in the event that they are little the surface is smooth.
Harshness is ordinarily thought to be the high recurrence, short wavelength part of a
deliberate surface.
a. Amplitude Parameters
Sufficiency parameters portray the surface in light of the vertical deviations of
the harshness profile from the mean line. A considerable lot of them are firmly
identified with the parameters found in insights for describing populace tests.
For instance, Ra is the number juggling normal of the outright values and Rt is
the scope of the gathered harshness information focuses. The normal harshness,
Ra, is communicated in units of tallness. In the Imperial (English) framework,
1 Ra is normally communicated in "millionths" of an inch. This is additionally
alluded to as "small scale crawls" or once in a while generally as "miniaturized
scale". The plentifulness parameters are by a long shot the most well-known
surface unpleasantness parameters found in the United States on mechanical
designing drawings and in specialized writing.
b. Measurement
The accompanying instruments are mechanically utilized for measuring surface
unpleasantness. There are numerous makers executing these innovations into
items,
i. Profilometer, customarily called a stylus and works like a
phonograph
ii. Atomic power magnifying instrument.
iii. Surface Roughness Tester
Roughness is an important parameter when trying to find out whether a surface
is suitable for a certain purpose. Rough surfaces often wear out more quickly
than smoother surfaces Rougher surfaces are normally more vulnerable to
corrosion and cracks, but they can also aid in adhesion. A roughness tester is
used to quickly and accurately determine the surface texture or surface roughness
of a material. A roughness tester shows the measured roughness depth (Rz) as
well as the mean roughness value (Ra) in micrometres or microns (µm).
Measuring the roughness of a surface involves applying a roughness filter.
Different international standards and surface texture or surface finish
specifications recommend the use of different roughness filters. For example, a
Gaussian filter often is recommended in ISO standards. Roughness tester is an
ideal instrument for fast and simple checking of the surface roughness in shop
floor, metalworking, manufacturing, quality control, inspection, automotive and
aerospace engineering. It is a portable and pocket-sized instrument, which
provides you with highly accurate measurements of surface finish.
This instrument is compatible with four standards of site to measure surface
roughness of various machinery-processed parts, calculate corresponding and
clearly display all measurement parameters. When measuring the roughness of a
surface, the sensor is placed on the surface and then uniformly slides along the
surface by driving the mechanism by the sharp built-in probe. This roughness
causes displacement of the probe which results in change of inductive amount of
induction coils so as to generate analogue signal, which is in proportion to the
surface roughness at output end of phase-sensitive rectifier.
• The exclusive DSP processes and calculates and then outputs the
measurement results on LCD.
• Multiple parameter measurement: Ra, Rz, Rq, Rt
• Highly sophisticated inductance sensor
• Four wave filtering methods: RC, PC-RC, GAUSS and D-P
• Built-in lithium ion rechargeable battery and control circuit with high
capacity
• Can communicate with PC computer for statistics, printing and analysing
by the optional cable and the software for RS232C interface.
• Manual or automatic shutdown. The tester can be switched off by pressing
the Power key at any time.
• On the other hand, the tester will power itself off about 5 minutes after the
last key operation.
 Chapter 3
Methodology
1. Taguchi Method

Dr. Taguchi of Nippon Telephones and Telegraph Company, Japan has developed a
method based on “ORTHOGONAL ARRAY” experiments which gives much
reduced “variance” for the experiment with “optimum settings” of control parameters.
Thus, the marriage of Design of Experiments with optimization of control parameters
to obtain BEST results is achieved in the Taguchi Method. "Orthogonal Arrays" (OA)
provide a set of well balanced (minimum) experiments and Dr. Taguchi's Signal-to-
Noise ratios (S/N), which are log functions of desired output, serve as objective
functions for optimization, help in data analysis and prediction of optimum results.
Numerous Japanese firms made awesome progress by applying his routines. Taguchi
has gotten a percentage of the Japan's most prestigious honours for quality
accomplishment, including the Deming Prize.
Pignatiello has recognized two unique parts of Taguchi method.
a. The method of Taguchi
b. Strategies of Taguchi procedure is the theoretical casing work for arranging
a procedure or item outline test. Taguchi strategies allude to the gathering of
particular systems utilized by Taguchi. Taguchi has tended to Design,
Engineering (disconnected from the net) and also Manufacturing (online)
quality. This idea separates Taguchi strategy from Statistical Process
Control (SPC) which is absolutely an online quality control method.
Taguchi thoughts can be lessened into two major ideas.
a. Quality misfortunes ought to be characterized as deviation from target, not
conformance to self-assertive details.
b. To accomplish high framework quality levels financially obliges quality to
be outlined into item. Quality is outlined, not fabricated, into the item.
Taguchi strategies speak to rationality. Quality is measured by the deviation
of a useful trademark from its objective worth. Clamours (wild components)
will bring about such deviations which bring about loss of Quality. Taguchi
procedures try to evacuate the impact of Noises. The most essential piece of
the Taguchi strategy is quality misfortune capacity. Taguchi has observed
that a quadratic capacity (parabola) approximates the conduct of misfortune
by and large. When the quality normal for hobby is to be expanded or
 minimized, the misfortune capacity will turn into a half parabola. Loss
happens not just when the item is outside its determination additionally
when item falls inside of its detail. Taguchi has prescribed sign to
commotion proportion (S/N proportion) as execution insights. Sign alludes
to the adjustment in quality attributes of an item under scrutiny in light of an
element presented in the trial configuration. Clamour alludes to the impact
of outside variables (wild parameters) on the result of the quality attributes.

2. Taguchi Methodology

Taguchi Method treats optimization problems in two categories,

a. Static Problems
Generally, a process to be optimized has several control factors which directly
decide the target or desired value of the output. The optimization then involves
determining the best control factor levels so that the output is at the target
value. Such a problem is called as a "STATIC PROBLEM".

This is best explained using a P-Diagram which is shown below ("P" stands for
Process or Product). Noise is shown to be present in the process but should
have no effect on the output! This is the primary aim of the Taguchi
experiments - to minimize variations in output even though noise is present in
the process. The process is then said to have become ROBUST.

P-diagram for static problems

There are 3 Signal-to-Noise ratios of common interest for optimization of Static
Problems;
i. Smaller the Better
n = -10 Log10 [mean of sum of squares of measured data] ……(F2)
This is usually the chosen S/N ratio for all undesirable characteristics
like " defects " etc. for which the ideal value is zero. Also, when an
ideal value is finite and its maximum or minimum value is defined (like
maximum purity is 100% or maximum Tc is 92K or minimum time for
making a telephone connection is 1 sec) then the difference between
measured data and ideal value is expected to be as small as possible.
The generic form of S/N ratio then becomes,
n = -10 Log10 [mean of sum of squares of {measured ideal}] ……(F3)
ii. Larger the Better
n = -10 Log10 [mean of sum squares of reciprocal of measured data]
…………(F4)
This case has been converted to SMALLER-THE-BETTER by taking
the reciprocals of measured data and then taking the S/N ratio as in the
smaller-the-better case.
iii. Nominal the Better
n = 10 Log10 (square of mean/variance) ………………(F5)
This case arises when a specified value is MOST desired, meaning that
neither a smaller nor a larger value is desirable.
b. Dynamic Problems
If the product to be optimized has a signal input that directly decides the output,
the optimization involves determining the best control factor levels so that the
"input signal / output" ratio is closest to the desired relationship. Such a
problem is called as a "DYNAMIC PROBLEM".
This is best explained by a P-Diagram which is shown below. Again, the
primary aim of the Taguchi experiments - to minimize variations in output even
though noise is present in the process- is achieved by getting improved linearity
in the input/output relationship.
 P-diagram for dynamic problems

In dynamic problems, we come across many applications where the output is

supposed to follow input signal in a predetermined manner. Generally, a linear
relationship between "input" "output" is desirable. There are 2 characteristics of
common interest in "follow-the-leader" or "Transformations" type of
applications,
• Slope of the I/O characteristics
• Linearity of the I/O characteristics (minimum deviation from
the best-fit straight line)
The Signal-to-Noise ratios for these 2 characteristics have been defined as,
i. Sensitivity
The slope of I/O characteristics should be at the specified value
(usually 1). It is often treated as Larger-The-Better when the output is a
desirable characteristic (as in the case of Sensors, where the slope
indicates the sensitivity).
n = 10 Log10 [square of slope or beta of the I/O characteristics] …(F6)
On the other hand, when the output is an undesired characteristic, it can be
treated as Smaller-the-Better. n = -10 Log10 [square of slope or beta of the I/O
characteristics]
ii. Linearity
Most dynamic characteristics are required to have direct proportionality
between the input and output. These applications are therefore, called
as "TRANSFORMATIONS". The straight-line relationship between
I/O must be truly linear i.e. with as little deviations from the straight
line as possible.
n= 10Log10 (Square of slope or beta/variance) …………. (F7)
 Variance in this case is the mean of the sum of squares of deviations of
measured data points from the best-fit straight line (linear regression).

3. Steps in Taguchi Method

Taguchi method is a scientifically disciplined mechanism for evaluating and

implementing improvements in products, processes, materials, equipment, and
facilities. These improvements are aimed at improving the desired characteristics and
simultaneously reducing the number of defects by studying the key variables
controlling the process and optimizing the procedures or design to yield the best
results. The method is applicable over a wide range of engineering fields that include
processes that manufacture raw materials, sub systems, products for professional and
consumer markets.

Taguchi proposed a standard 8-step procedure for applying his method for optimizing
any process,
a. IDENTIFY THE MAIN FUNCTION, SIDE EFFECTS, AND FAILURE
MODE
b. IDENTIFY THE NOISE FACTORS, TESTING CONDITIONS, AND
QUALITY CHARACTERISTICS
c. IDENTIFY THE OBJECTIVE FUNCTION TO BE OPTIMIZED
d. IDENTIFY THE CONTROL FACTORS AND THEIR LEVELS
e. SELECT THE ORTHOGONAL ARRAY MATRIX EXPERIMENT
f. CONDUCT THE MATRIX EXPERIMENT
g. ANALYZE THE DATA, PREDICT THE OPTIMUM LEVELS AND
PERFO RMANCE
h. PERFORM THE VERIFICATION EXPERIMENT & PLAN THE
FUTURE ACTION

4. Data Analysis

a. Minitab Software
Minitab is a measurable Analysis programming that permits to effortlessly lead
examinations of information. This is one of the proposed programming for the
class. This aide is expected to guide you through the essentials of Minitab and
help you begin with it.
Utilizing Minitab as a part of Harper and Gleacher Centre.
Minitab has two fundamental sorts of records, undertakings and worksheets.
Worksheets are documents that are comprised of information; think about a
spread sheet containing variables of information. Undertakings are comprised
of the summons, charts and worksheets. Each time you spare a Minitab venture
you will be sparing charts, worksheets and orders. However, every one of the
components can be spared separately for utilization in different records or
Minitab ventures. Similarly, you can print ventures and its components.
Minitab records are sorted out as "undertakings". Every venture will contain all
the information you utilize and the charges and examination you perform on
the information. You can open another, unfilled worksheet whenever. In this
unfilled worksheet you can duplicate, glue and sort the information you require
by just chipping away at the worksheet as you would on any spread sheet.
Approaches to Analyse Data- Examination in Minitab should be possible in
two ways: utilizing the Built-As a part of schedules or utilizing charge dialect
as a part of the Session window. These two can be utilized conversely. Most of
the capacities required is essential and more progressed measurable
investigation are found as Minitab Built-in schedules. These schedules are
gotten to through the menu bar. To utilize the menu orders, click on a thing in
the menu bar to open a menu, click on a menu thing to execute a charge or
open a submenu or dialog box. Charge Language: To have the capacity to sort
summons in the Session window, you must acquire the "MTB>" brief. All
orders are then entered after the FALL 2009 BUSINESS STATISTICS 41000
GUIDE TO MINITAB 15 9 "MTB>" brief. All order lines are free
arrangement, at the end of the day, all content may enter in upper or lowercase
letters anyplace in the line. Descriptively,
To acquire spellbinding insights of a variable or set of variables, go to
• Details - > DISPLAY DESCRIPTIVE STATISTICS
• Furthermore, a brief window ought to show up. In the window select the
variable(s) you need to investigate and click alright.
• Results will be displayed in the Session window as takes after.

Chart attracting assembled schedules in Minitab can be found under the

GRAPH menu in the menu bar. On the Graph Menu you have a few sorts of
plots that you can look over, and that you can use to deliver your coveted plot.
The following is a clarification of how to utilize the most well-known chart
schedules. Minitab charts will show up as particular windows that are
considered piece of the venture, on the other hand they can be spared and
replicated for utilization in reports. Plots can be altered by adjusting the plot
choices.
With a specific end goal to figure essential insights for sets of variables, similar
to covariance and connection, go to STAT - > BASIC STATISTICS In this
record cases of measurements are computed accepting just two variables are
being examined, however combine savvy measurements for more than two
variables can be ascertained by basically adding all the craved variables to the
"VARIABLES" enclose the dialog windows.
• Pick COVARIANCE to acquire the accompanying dialog box. Pick the
pair of variables you wish to examine and click OK.
• The outcome will be exhibited in the Session window as introduced
beneath.
• Pick CORRELATION and acquire the accompanying dialog box. Pick
the pair of variables to be investigated.
• Results are shown in the Session window as displayed beneath. Adding
variables.
• To include variables, name the variable where you need to store the
outcomes.
• Select the first variable, press the "+" sign and select the second variable
(thus on for more than two variables). You ought to acquire something
like the window in the privilege.
• The outcome will then be indicated in the worksheet window Taking
logarithms another helpful capacity in factual investigation is to take logs
of variables.
• Search for the "Characteristic LOG" or "LOG BASE 10" (contingent
upon the one you require) in the capacity list. An alternate way to
discovering the capacities is to pick "LOGARITHM" from the capacity
drop down menu.
• Inside the bracket, change number for the variable name. Highlighting
"NUMBER" and after that selecting the variable you need to change
does this.
• Verify that you have characterized a variable where you need to store
results, by putting the name in the "STORE RESULT IN VARIABLE"
box.
• The outcome will show up in the worksheet window. Logical capacities
Some measurable investigation should separate by gatherings as
indicated by qualities that are contained in the information. Consistent
capacities are especially helpful in these cases. A straightforward case on
the best way to utilize them is portrayed underneath.
• Pick the variable you need to do the sensible test to. Here we are taking a
gander at the variable.
 • Pick the sensible test you need to utilize. Here we need to see which
perceptions have the variable equivalent.
• Verify that you have shown a variable in which to store your outcomes,
by writing the name of your outcome variable in the "STORE RESULT
IN VARIABLE" box.
• The outcome variable will be a double (variable of 1s and 0s)

5. Advantages of Taguchi Method

• It emphasizes a mean performance characteristic value close to the target value

rather than a value within certain specification limits, thus improving the
product quality.
• Additionally, Taguchi's method for experimental design is straightforward and
easy to apply to many engineering situations, making it a powerful yet simple
tool.
• It can be used to quickly narrow down the scope of a research project or to
identify problems in a manufacturing process from data already in existence.
• Also, the Taguchi method allows for the analysis of many different parameters
without a prohibitively high amount of experimentation. For example, a
process with 8 variables, each with 3 states, would require 6561 (38)
experiments to test all variables.
• However, using Taguchi's orthogonal arrays, only 18 experiments are
necessary, or less than .3% of the original number of experiments. In this way,
it allows for the identification of key parameters that have the most effect on
the performance characteristic value so that further experimentation on these
parameters can be performed and the parameters that have little effect can be
ignored.

6. Disadvantages of Taguchi Method

• The main disadvantage of the Taguchi method is that the results obtained are
only relative and do not exactly indicate what parameter has the highest effect
on the performance characteristic value. Also, since orthogonal arrays do not
test all variable combinations, this method should not be used with all
relationships between all variables are needed.
• The Taguchi method has been criticized in the literature for difficulty in
accounting for interactions between parameters.
• Another limitation is that the Taguchi methods are offline, and therefore
inappropriate for a dynamically changing process such as a simulation study.
Furthermore, since Taguchi methods deal with designing quality in rather than
correcting for poor quality, they are applied most effectively at early stages of
process development. After design variables are specified, use of experimental
design may be less cost effective.
 Chapter 4
Experimentation and Analysis

1. Orthogonal array and L-27 matrix

To choose a suitable orthogonal exhibit for analyses, the aggregate degrees of

opportunity should be processed. The degrees of opportunity are characterized as the
quantity of examinations between procedure parameters that should be made to figure
out which level is better and particularly how much better it is. For instance, a Three-
level procedure parameter means four degrees of flexibility. The degrees of
opportunity connected with collaboration between two procedure parameters are
given by the result of the degrees of flexibility for the two procedure parameters.

2. Levels of Control Factors

Minitab Windows
Level Feed (mm/rev) Depth of Cut Speed (rpm)
(mm)
1 0.12 0.25 1600
2 0.18 0.5 1900
3 0.24 0.75 2200
Levels of control component

Run Speed (RPM) Depth of Feed

Cut (mm) (mm/rev)
1 1600 1600 1600
2 1600 0.25 0.18
3 1600 0.25 0.24
4 1600 0.5 0.12
5 1600 0.5 0.18
6 1600 0.5 0.24
7 1600 0.75 0.12
8 1600 0.75 0.18
9 1600 0.75 0.24
10 1900 0.25 0.12
11 1900 0.25 0.18
12 1900 0.25 0.24
13 1900 0.5 0.12
14 1900 0.5 0.18
15 1900 0.5 0.24
16 1900 0.75 0.12
17 1900 0.75 0.18
18 1900 0.75 0.24
19 2200 0.25 0.12
20 2200 0.25 0.18
21 2200 0.25 0.24
22 2200 0.5 0.12
23 2200 0.5 0.18
24 2200 0.5 0.24
25 2200 0.75 0.12
26 2200 0.75 0.18
27 2200 0.75 0.24
L-27 exhibit framework
Mac Power CNC VX200
 Result framework for surface roughness
Speed Depth of
(RPM) Cut(mm) Feed(mm/rev) Ra(µm) SNRA1
1600 0.25 0.12 0.45 6.935749724
1600 0.25 0.18 0.75 2.498774732
1600 0.25 0.24 0.95 0.445527894
1600 0.5 0.12 0.4 7.958800173
1600 0.5 0.18 0.8 1.93820026
-
1600 0.5 0.24 1.15 1.213956807
1600 0.75 0.12 0.7 3.0980392
1600 0.75 0.18 0.7 3.0980392
-
1600 0.75 0.24 1.1 0.827853703
1900 0.25 0.12 0.4 7.958800173
1900 0.25 0.18 0.8 1.93820026
1900 0.25 0.24 0.95 0.445527894
1900 0.5 0.12 0.45 6.935749724
1900 0.5 0.18 0.9 0.915149811
1900 0.5 0.24 1 0
1900 0.75 0.12 0.65 3.741732867
1900 0.75 0.18 0.7 3.0980392
1900 0.75 0.24 0.95 0.445527894
2200 0.25 0.12 0.55 5.19274621
2200 0.25 0.18 0.75 2.498774732
2200 0.25 0.24 1 0
2200 0.5 0.12 0.6 4.436974992
2200 0.5 0.18 0.85 1.411621486
-
2200 0.5 0.24 1.1 0.827853703
2200 0.75 0.12 0.65 3.741732867
2200 0.75 0.18 0.8 1.93820026
-
2200 0.75 0.24 1.2 1.583624921
 Result Framework for Power Consumption
Speed Depth of Power
(RPM) Cut(mm) Feed(mm/rev) (KW) SNRA2
1600 0.25 0.12 1.45 -3.227360045
1600 0.25 0.18 1.5 -3.521825181
1600 0.25 0.24 1.52 -3.636871759
1600 0.5 0.12 1.72 -4.710568938
1600 0.5 0.18 1.73 -4.760922063
1600 0.5 0.24 1.87 -5.436832131

1600 0.75 0.12 1.82 -5.20142776

1600 0.75 0.18 1.97 -5.889324523
1600 0.75 0.24 2.05 -6.235077221
1900 0.25 0.12 1.71 -4.659922208
1900 0.25 0.18 1.76 -4.910253356
1900 0.25 0.24 1.78 -5.008400046
1900 0.5 0.12 1.94 -5.756034599
1900 0.5 0.18 2.01 -6.063921148
1900 0.5 0.24 2.12 -6.526717219
1900 0.75 0.12 2.13 -6.567592069
1900 0.75 0.18 2.23 -6.966097261
1900 0.75 0.24 2.4 -7.604224834
2200 0.25 0.12 1.81 -5.153571497
2200 0.25 0.18 1.83 -5.249021795
2200 0.25 0.24 1.88 -5.483156985
2200 0.5 0.12 2.11 -6.485649106
2200 0.5 0.18 2.21 -6.887845474
2200 0.5 0.24 2.31 -7.272239598
2200 0.75 0.12 2.31 -7.272239598
2200 0.75 0.18 2.41 -7.640340851
2200 0.75 0.24 2.54 -8.096674332
3. Analysis
At first the analysis is done for surface roughness and thereafter moving towards
power consumption. When you add a signal factor to an existing static design,
Minitab adds a new signal factor column after the factor columns and appends new
rows (replicates) to the end of the existing worksheet. For example, if you add a
signal factor with 2 levels to an existing L4 (23) array, 4 rows (1 replicate of 4 runs)
are added to the worksheet. If you add a signal factor with 3 levels, 8 rows (2
replicates of 4 runs) are added to the worksheet. A replicate is the entire set of runs
from the static design. In a usual Taguchi robust parameter design experiment, you
would subject each control factor combination to each of the noise conditions and
measure the response variable. If you are doing a dynamic experiment, the response is
measured at each level of the signal factor. Record the results for each noise condition
in a separate response column in the worksheet.
Use the response tables to select the best level for each factor. Usually you have the
following objectives with a Taguchi design:
• Minimize the standard deviation Maximize the S/N ratio
• Meet a target with the mean (static design)
• Meet a target with the slope (dynamic design)
Use the delta and rank values to identify the factors that have the largest effect on
each response characteristic. Then, determine which levels of these factors meet your
objectives. Sometimes, the best level of a factor for one response characteristic is
different from the best level for a different response characteristic. To resolve this
issue, it may help to predict the results for several combinations of factors levels to
see which one produces the best result.
a. Interpretation
• Average response characteristics- For each factor, Minitab calculate the
average of the response characteristic at each level of the factor. For
example, the design includes factor A at 2 levels (1 and 2) and 4
measurements at each level. Minitab calculates the mean of the 4 S/N
ratios at level 1 and the mean of the other 4 S/N ratios at level 2.
• Signal-to-Noise Ratio- Minitab calculates a separate signal-to-noise ratio
(S/N) for each combination of control factor levels in the design. You
can choose from different S/N ratios, depending on the goal of your
experiment. In all cases, you want to maximize the S/N ratio.
• Means (for static designs)- Minitab calculates a separate mean for each
combination of control factor levels in the design.
• Slopes (for dynamic designs)- Minitab calculates a separate slope for
each combination of control factor levels in the design.
• Standard deviations- Minitab calculates a separate standard deviation for
each combination of control factor levels in the design.
• Delta- Measures the size of the effect by taking the difference between
the highest and lowest characteristic average for a factor.
• Rank- The ranks in a response table help you quickly identify which
factors have the largest effect. The factor with the largest delta value is
given rank 1, the factor with the second largest delta is given rank 2, and
so on.
Analysis in the case of Surface Roughness
From the response table for S/N ratio in the case of surface roughness we can
conclude that Feed has higher delta value so its effect is highest followed by
depth of cut and speed. And optimized parameters for surface roughness are
Speed (rpm): 2200, Depth of Cut (mm): 0.75 and Feed (mm/rev): 0.24.

Analysis in the of Power Consumption

From the response table for S/N ratio in the case of power consumption we can
conclude that Depth of Cut has higher delta value so its effect is highest
followed by speed and feed. And optimized parameters for surface roughness
are Speed (rpm): 2200, Depth of Cut (mm): 0.75 and Feed (mm/rev): 0.24.

Turned workpiece
 Chapter 5
Results and Conclusion
In the investigation, the aggregate of squares and fluctuation are ascertained. F-test
quality at 95% certainty level is utilized to choose the critical elements influencing the
procedure and rate commitment is as curtained.
• DF- The total degrees of freedom (DF) are the amount of information in
your data. The analysis uses that information to estimate the values of
unknown population parameters. The total DF is determined by the number
of observations in your experiment. The DF for a term shows how much
information that term uses. Increasing your sample size provides more
information about the population, which increases the total DF. Increasing
the number of terms in your model uses more information, which decreases
the DF available to estimate the variability of the parameter estimates.
• Seq. SS- Sequential sums of squares are measures of variation for different
components of the model. Unlike the adjusted sums of squares, the
sequential sums of squares depend on the order the terms are entered into
the model. In the Analysis of Variance table, Minitab lists the sequential
sums of squares for the main effects, interactions, and error term.
• Adj. SS- Adjusted sums of squares are measures of variation for different
components of the model. The order of the predictors in the model does not
affect the calculation of the adjusted sum of squares. In the Analysis of
Variance table, Minitab separates the sums of squares into different
components that describe the variation due to different sources.
• Adj. MS- Adjusted mean squares measure how much variation a term or a
model explains, assuming that all other terms are in the model, regardless of
the order they were entered. Unlike the adjusted sums of squares, the
adjusted mean squares consider the degrees of freedom. The adjusted mean
square of the error (also called MSE or s2) is the variance around the fitted
values.
• F-value- The Analysis of Variance table lists an F-value for each term. The
F-value is the test statistic used to determine whether the term is associated
with the response.
• P-Value- The p-value is a probability that measures the evidence against the
null hypothesis. Lower probabilities provide stronger evidence against the
null hypothesis.
The ANOVA investigation for rate adjustment is demonstrated in the table

Analysis of Variance for Ra (μm), using Adjusted SS for Tests

Analysis of Variance for PC (KW), using Adjusted SS for Tests

It is evident from table-1 that feed rate (p=0.0000000002782929) makes the largest
contribution to the total sum of squares having 84.19% effect on surface roughness.
ANOVA in table-2 shows that the depth of cut (p=0.0) have 55.72% influence on Power
Consumption.

Conclusion
This work presented an experimentation approach to study the effect of input parameters
on the surface roughness and Power Consumption. The following conclusions are drawn
on the experimental investigations carried out:
• Feed has higher delta value so its effect is highest with 84.19% contribution
followed by depth of cut and speed. And optimized parameters for surface
roughness are Speed (rpm): 2200, Depth of Cut (mm): 0.75 and Feed (mm/rev):
0.24.
• Depth of Cut has higher delta value so its effect is highest with 54.12% followed
by speed and feed. And optimized parameters for surface roughness are Speed
(rpm): 2200, Depth of Cut (mm): 0.75 and Feed (mm/rev): 0.24.
• As shown in this study of Al6063 turning with Taguchi’s easy-to-use approach for
process optimization may be extended to other aluminium alloys considering the
growing importance of such alloys. Present work may pave the way for further
research with process variables like tool vibration, power consumption, and
temperature effects etc. on the same alloy.
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