Journal of Cleaner Production 42 (2013) 159e166

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Journal of Cleaner Production

journal homepage: www.elsevier.com/locate/jclepro

Optimization of cutting uids and cutting parameters during end milling by using D-optimal design of experiments
Emel Kuram a, Babur Ozcelik a, *, Mahmut Bayramoglu b, Erhan Demirbas c, Bilgin Tolga Simsek a
a

Department of Mechanical Engineering, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey Department of Chemical Engineering, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey c Department of Chemistry, Gebze Institute of Technology, 41400 Gebze-Kocaeli, Turkey
b

a r t i c l e i n f o
Article history: Received 5 August 2012 Received in revised form 31 October 2012 Accepted 2 November 2012 Available online 15 November 2012 Keywords: Milling Optimization Cutting uids D-optimal Specic energy Surface roughness Tool life

a b s t r a c t
The use of synthetic cutting uids is nowadays limited due to the adverse effects such as health of the operator, environmental and economic reasons. In order to diminish these negative effects, bio-based cutting uids are used. Bio-based or vegetable based cutting uid is considered environmentally friendly and sustainable. Vegetable based cutting uids have some characteristics such as biodegradability, less toxicity and renewability. This study deals with the assessment of vegetable based cutting uids for end milling. For this purpose, effects of cutting uid types are investigated as a function of three milling factors (cutting speed, depth of cut and feed rate) on process responses (specic energy, tool life and surface roughness). D-optimal method is conducted to develop mathematical models for process responses. Variance analysis shows that specic energy, surface roughness and tool life can be predicted effectively with quadratic models. Furthermore, mono and multi objective optimization studies are conducted using specic energy, surface roughness and tool life as primary or secondary objectives. From results of the optimization, various conclusions are drawn about effects of the milling parameters and the cutting uid types on the milling performance criteria. The most appropriate cutting uid during milling of AISI 304 material is selected in accordance with energy, tool life and surface roughness. 2012 Elsevier Ltd. All rights reserved.

1. Introduction The machinability of AISI 304 is difcult and high cutting force, high tool wear and poor surface quality can be observed during machining of this material since it has high strength, high ductility and low thermal conductivity. Cutting uids are utilized to eliminate these adverse effects. Today a wide variety of cutting uids (soluble oils, straight oils, synthetic and semi-synthetic uids) are commercially available. But, the use of cutting uids is being questioned due to the health and environmental impacts (Shashidhara and Jayaram, 2010; Tawakoli et al., 2011) and usage of large amount of cutting uids during machining is considered one of the main environmental pollution sources (Fratila, 2009). Marksberry (2007) used a micro-ood technology for minimizing the use of cutting uid during machining which was atomization-less and occupational friendly. Sanchez et al. (2010) investigated a new approach based on the use of a hybrid minimum quantity of lubrication (MQL) e low temperature CO2 systems to the elimination of cutting uids in

* Corresponding author. E-mail address: ozcelik@gyte.edu.tr (B. Ozcelik). 0959-6526/$ e see front matter 2012 Elsevier Ltd. All rights reserved. http://dx.doi.org/10.1016/j.jclepro.2012.11.003

machining. Fratila and Caizar (2011) used near-dry techniques during milling process to meet cleaner manufacturing. Zhang et al. (2012) combined the advantages of the cryogenic air and MQL method in order to meet the demands for environmental-friendly machining processes. Cutting uids are contaminated with metal particles and tramp oil during their life cycle and this contamination diminishes the effectiveness of cutting uids. When cutting uids lose their quality, the disposal of them is mandatory. Waste disposal is expensive and affects the environment negatively. In order to minimize the adverse environmental effects with the use of cutting uids, the hazardous substances in their formulations have to be eliminated or diminished to the acceptable value. In addition, petroleum based cutting uids can be replaced with bio-based cutting uids (Ozcelik et al., 2011a, 2011b). Bio-based cutting uids reduce the health risks as compared to the petroleum based cutting uids and have higher biodegradability. They have also good lubrication capability as compared to others (John et al., 2004). Vegetable based cutting uids can be considered environmentally friendly because these types of uids are renewable, less toxic and possess high biodegradability. Studies about vegetable based cutting uids (VBCFs) on various mechanical processes have been focused on drilling, turning,

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tapping and reaming. In these studies tool life, tool wear, force, torque and surface quality are taken into consideration. The use of VBCFs in other metal cutting operations has gained more attention nowadays. Belluco and De Chiffre (2001) investigated the effect of different lubricants on cutting forces and power. AISI 316L stainless steel were machined with drilling, core drilling, reaming and tapping. VBCFs gave equal or better performance than a reference commercial mineral oil. In another study, Belluco and De Chiffre (2002) presented the effect of new formulations of vegetable oils on surface integrity (roughness, microhardness) and part accuracy in reaming and tapping with AISI 316L. They found that cutting uids have a signicant effect on surface integrity and part accuracy. They also stated that VBCFs resulted in comparable or better performance than that of mineral oils. Belluco and De Chiffre (2004) evaluated the performance of six cutting uids (a commercial mineral oil, and ve VBCFs) in drilling of AISI 316L stainless steel using conventional HSS-Co tools. Tool life, tool wear, chip formation and cutting forces were studied as performance criteria and results showed better with VBCF than that of mineral cutting uid because tool life was increased by 177 percent and thrust force was reduced by 7 percent. Xavior and Adithan (2009) measured for tool wear and surface roughness as a performance criterion, and studied performances of coconut and neat cutting uids during turning of AISI 304 with carbide tool. Results from coconut cutting uid showed a better performance than that of mineral based cutting uids. In another study, Xavior and Adithan (2010) investigated the effect of coconut oil on tooleshim interface temperature and cutting force during turning of AISI 304 material with carbide tool. It was found that coconut oil outperformed the other cutting uids (soluble oil and straight cutting oil). Cetin et al. (2011) investigated the role of extreme pressure (EP) additive on VBCFs in terms of surface roughness, cutting and feed forces during turning of AISI 304L with carbide insert tool using Taguchis mixed level parameter design. Sunower and canola oils with different ratios of EP additives and commercial semi-synthetic and mineral cutting uids were used. Results showed that VBCFs performed better than the rest. Characterizations of chemical and physical analyses of VBCFs were presented in detail by Kuram et al. (2011). They also investigated the performance of VBCFs developed from crude and rened sunower oils for thrust force and surface roughness during drilling of AISI 304 using Taguchi method. Rahim and Sasahara (2011) used palm oil in a high speed drilling of Ti-6Al-4V. In this study, synthetic ester using minimum quantity of lubrication method, air blow and ood conditions were used. The palm oil and synthetic ester showed a comparable performance with the ood conditions and palm oil performed better than synthetic ester on the cutting forces, temperature, power and specic cutting energy. Kuram et al. (2012a) investigated the effects of blended VBCFs with EP additive on tool wear and force components in turning of Al 7075-T6 material. It was concluded that blending of two vegetable oils (sunower and canola oils) improved cutting performance. Considerable amount of energy is consumed for chip formation during metal cutting process which should be optimized. In rough milling, high material removal rate (MRR) is important without enhancement of tool wear. In nish milling the prime objective is the minimization of surface roughness. Cutting parameters affect the surface roughness and cost in machining, so the optimization of these parameters is very important. The modelling and optimization of machining have been investigated by various researchers. Various analytical methods are developed and used for predicting of surface roughness, tool wear and force in milling (Ozcelik and Bayramoglu, 2006; Razfar et al., 2011; Zain et al., 2011). Iqbal et al. (2008) studied effect of microstructure, cutting speed, radial depth of cut (step over) and

workpiece inclination angle on surface roughness and tool life under MQL environment using the D-optimal method. Kuram et al. (2012b) used D-optimal experimental design method to develop the model equations of surface roughness and machining forces in turning process. An average error between developed models and experimental results was found as <7%. Concepts for sustainable and cleaner production concern on the formation of products using processes and systems that are nonpolluting and conserving the natural resources (Fratila and Caizar, 2011). It is essential to manufacture products using sustainable methods and to reach this ecological aim it is mandatory to determine optimum machining conditions, while increasing tool life, decreasing surface roughness and consumed energy. This work focuses on the role of environmentally friendly method (VBCFs) in milling which includes three main issues: effects of VBCFs on the tool life, the energy consumed in the milling operation, and workpieces surface roughness. In this paper, D-optimal method is used to plan the experiments.

2. Experimental design 2.1. Vegetable-based cutting uids The efciency of cutting process is improved by cutting uids (CFs). CFs combine two properties, the lubrication of oil and the cooling of water. It is usually diluted with water in the range of 92e 97% depending on the cutting operations. Although a vegetable based oil emulsion is environmentally friendly and biodegradable, there are few references on this emulsion as cutting uids in the literature. This work focuses on the development of vegetable based oil emulsions that can be utilized in milling operation to replace semisynthetic cutting uids. The general composition of water miscible VBCFs consists of base oil from rened sunower oil or canola oil and a mixture of emulsier(s). Other components such as corrosion and rust inhibitors, neutralization agents, lubricating additive (EP), fungicides, biocides, and foam inhibitors may be added to the cutting uid. pH, density, viscosity, ash point and refractive index are measured to characterize the VBCFs. Characterization of CFs is given in Table 1. pH values are measured by a pH meter (Hach Lang HQ 40d) and changed from 8.92 to 9.18. In general, pH values of cutting uids vary from 8.5 to 10.0. Too high or too low pH values can be dangerous to operator and cause some problem in waste disposal. Density of cutting uid should be compatible with density of water. In this work, density of cutting uids is measured by a pycnometer and density values are 0.96e0.98 g/ml. Viscosity of a cutting uid is also an important parameter and determines the effectiveness of cutting uids. Viscosity is measured by a Brookeld LDV-E viscometer and the viscometer is calibrated with pure water. Viscosities of the cutting oils and their emulsions are 75e110 and 1.7e4.1 mm2/s. In the machining at high temperature the usability of cutting uid is determined by ash point and ash point is measured with a K16500 rapid ash closed-cup tester. In ash
Table 1 Characterization of vegetable based cutting uids. pH Density Viscosity Viscosity, Metal Flash Refractive 40  C 40  C (mm2/s) point index cutting (Emulsion 8%) (g/ml) uida (mm2/s) (Emulsion 8%) ( C) SCF-II CCF-II CSSF 8.92 9.00 9.18 0.96 0.97 0.98 91 110 75 4.1 3.9 1.7 217 232 235 1.4775 1.4770 1.4825

a SCF-II: sunower cutting uid with 8% EP additive; CCF-II: canola cutting uid with 8% EP additive; CSSF: Commercial semi-synthetic cutting uid.

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point measurement, a sample of the cutting uid was placed in the cup and the temperature is increased with time during measurement. The value of the cutting uids ignited is saved as the ash point. Flash points of cutting uids are varied in the range of 217e 235  C. Refractive index is measured by an Abbe refractometer and values are varied in the range of 1.4770e1.4825. Cutting uids utilized in current work are named as follows: SCF-II: sunower cutting uid with 8% EP additive CCF-II: canola cutting uid with 8% EP additive CSSF: Commercial semi-synthetic cutting uid EP additives reduce chip welding under high pressures and improve lubrication function at high temperatures (Stachowiak and Batchelor, 2005). In current work, sulphur based EP additive is used. It is reported that sulphur based EP additive might induce less serious environmental concern such as health, disposal, air and soil pollution issues than EP additives contained in, for instance, antimony, iodine or chlorine (Mendes et al., 2006). For instance, cutting uids with chlorine based EP additive are hazardous to human life and to the environment. EP additives containing chlorine are difcult to dispose of and classied after use as hazardous waste (Sokovi c and Mijanovi c, 2001). Newly developed VBCFs are environmentally friendly and contain no harmful substances. These VBCFs also have higher rate of biodegradability (>95%) which is the most important aspect of the environmental compatibility. 2.2. Experimental design In this study, D-optimal method was used to design the experiments. D-optimal experimental design is response surface based methodology, used for conducting the design of experiments, the analysis of variance, and the empirical modelling, and this method has some advantages compared to other response surface methods. D-optimal method gives smaller number of experiment with respect to response surface method and can tackle categorical factors included in the design of experiment. Among various experimental design alternatives for second order models, optimal designs are preferred owing to their successful applicability to mixed type mixed level factorial experimentation requiring in most situations fewer runs than conventional methods. Various criteria are proposed to search the optimal plan, among which D-optimality is the most popular one seeking to maximize determinant of the information matrix, (XX) providing the best simultaneous estimate of the model parameters. Here, X is the design matrix with n rows representing the experiments in the design and p columns representing the model coefcients. Further information about D-optimal method can be found in the literature (Eriksson et al., 2008; Myers et al., 2009). Table 2 presents statistical results of the D-optimal plan obtained from Design-Expert (trial version 7.0) statistical package.

The experimental design has three numeric factors (cutting speed, depth of cut and feed rate) and a categorical (qualitative) factor such as type of cutting uid. For the modelling and optimization purposes, a second order model is chosen, which is sufciently complicated to approximate the main features of the data. The experimental planning and the statistical analyses are performed using Design-Expert (trial version 7.0) statistical package. The full second order model for the case of three numeric factors (X) and one categorical factor (Z) at three levels is given in the form of

Y b0;k

3 X i1

bi;k Xi

3 X 3 X i1 i1 isj

bi;j Xi Xj

3 X i1

bi;i Xi2

(1)

where k is the cutting uid index, i and j refer to numeric factors. As seen in Eq. (1), the model contains pure linear terms for both quantitative and qualitative factors, two-term interactions and second-order terms for only quantitative factors. The total number of parameters for the second order model is 17. An experimental plan with 27 experiments is chosen to allocate four and ve degrees of freedom for lack of t and pure error. Various algorithms are proposed to nd the optimum design. In the current study, a point exchange algorithm is utilized for this purpose and the program is restarted ten times to select the globally optimal design with the lowest determinant value. In the point exchange algorithm, a random design is created from the possible design points, called a candidate set. Then new designs are created by iteratively replacing individual points with the best replacement available from the candidates and this procedure is repeated for all design points until no improvements are possible. The whole procedure is repeated several times for different random initial designs and the best overall design from all the starts is selected (Myers et al., 2009). The candidate points used by the program consist of 8 vertices, 12 centre of edges, 18 interior points and 1 overall for each level of the categorical factor. Important statistical indicators of the nal plan are as follows: Table 3 shows the low and high levels of factors which are selected on practical considerations, while Table 4 shows the D-optimal experimental plan in term of actual factor values. 1, 2 and 3 in Table 4 represent as CCF-II, SCF-II and CSSF. 2.3. Machining conditions The cutting uids are applied to the tool via two nozzles (Fig. 1). The coolant ow rate of each nozzle is 10 L/min and held constant throughout the experiments. Down milling method is employed owing to some pros such as less tool wear, better surface quality and less heat. The step over is selected as 10 mm. The length of each cutting path is 1040 mm. 2.4. Workpiece materials and cutting tools The tests are conducted on Deckel Maho CNC machine and experimental set up is showed in Fig. 2. As a workpiece material, AISI 304 with a chemical composition of 0.032% C, 18.410% Cr,

Table 2 Statistical results of the D-optimal plan. Statistics Maximum Prediction Variance (at a design point) Average prediction variance Condition number of coefcient matrix Scaled D-optimality Criterion Determinant of (XX)1 Trace of (XX)1 Value 0.921 0.667 7.42 2.388 1.094E-19 2.570

Table 3 Numeric factor levels. Factors Cutting speed (m/min) Feed rate (mm/rev) Depth of cut (mm) Low level 150 0.20 0.20 High level 200 0.30 0.40

162 Table 4 D-optimal experimental design with 27 runs. Cutting speed (V) (m/min) 200.00 150.00 200.00 150.00 200.00 150.00 166.67 150.00 150.00 150.00 166.67 200.00 200.00 175.00 150.00 187.50 150.00 166.67 166.67 200.00 150.00 200.00 183.33 150.00 166.67 183.33 150.00 Feed rate (f) (mm/rev) 0.27 0.30 0.30 0.20 0.20 0.25 0.20 0.30 0.20 0.30 0.30 0.20 0.30 0.20 0.20 0.25 0.25 0.30 0.30 0.30 0.30 0.20 0.20 0.20 0.23 0.20 0.30

E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166

T
Depth of cut (ap) (mm) 0.20 0.27 0.40 0.20 0.30 0.40 0.33 0.27 0.20 0.20 0.40 0.40 0.20 0.20 0.40 0.30 0.30 0.40 0.20 0.33 0.40 0.20 0.40 0.30 0.20 0.40 0.40 CF type

0 :3 VVB

(2)

1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3

where VVB is tool wear rate in mm/min and T is tool life in min. The maximum ank wear is 0.3 mm in nish milling process. 2.6. Force measurement The forces generated are measured using Kistler 9257B dynamometer which is mounted under the workpiece. Resultant force (total cutting force) is computed using Eq. (3).

Fc

q 2 F2 F2 Fx z y

(3)

The cutting power utilized for milling is calculated by multiplying the total cutting force by the cutting speed (Eq. (4)).

Pc Fc$v

(4)

where Pc is cutting power (W), Fc is force (N) and v is cutting speed (m/s). On the other hand, the specic energy is computed from Eq. (5).

Pc MRR

(5)

7.740% Ni, 1.930% Mn, 0.660% Cu, 0.580% Si, 0.373% Mo and Fe balance is utilized. The dimension of workpieces is 165 104 30 mm. The milling tests are conducted by using two inserts (Iscar HM90 APKT100304PDRIC908) coupled to 16 mm diameter shrink holder. After milling operation, two inserts being utilized are changed with new inserts. The ank wears of two inserts are measured and the averages of these values are used. 2.5. Tool wear measurement The ank wear is measured with an optical microscope (NIKON SMZ800) at 50 magnication. The milling process is interrupted for each experiment after completion and then value of the wear is measured. Example tool wear result can be seen in Fig. 3. Tool wear rate is computed by dividing wear by the milling time. Eq. (2) is used to calculate the tool life.

where U is specic energy in J/mm3 and MRR is material removal rate in mm3/s. In machining process most of the environmental impact stems from the energy consumed. In order to calculate the energy requirement for material removal, the specic cutting energy is often used (Fratila, 2010), therefore in this study specic energy is estimated. 2.7. Surface roughness measurement Surface roughness (Ra) is measured in transverse feed directions using Mitutoyo Surf Test 301. Number of sampling and cut-off length are chosen as 5 and 0.8 mm. The measurement of surface roughness is repeated three times and average values of these three measurements are taken into consideration to make further analysis. 3. Results and discussion 3.1. Modelling results Variance analysis conducted on the experimental results suggests quadratic models for surface roughness, specic energy and tool life. Table 5 shows the models for surface roughness, specic energy and tool life. In these models interaction terms are independent from the cutting uid type, while linear terms are dependent on the cutting uid type. These dependent coefcients are shown in Table 5 for each type of cutting uid. Table 6 shows various statistics about the statistical validity of the models. Various statistical indicators given in Table 6 can be commented briey as follows: - R2 and Adj R2 values (accounting for the number of predictors in the models) indicate that the model ts the data well. Especially, pred R2 is in agreement with adj R2 which supports prediction power of the model. - Signal to noise ratio is measured by Adeq precision. Adeq precisions are greater than 4 for all models which are usually desirable and these models can be used.

Fig. 1. Applying of cutting uids.

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163

Fig. 2. Experimental set up.

3.2. Optimization results In the following sections, rstly, the results of three mono objective optimization studies are presented, and later various multi objective optimization results are given and commented from various perspectives of the end milling including the impact of the cutting uid on the operation performance. 3.2.1. Mono objective optimization Various response models obtained in this study are considered further for optimization of the end milling operation. These responses may be used alone in optimization studies as objective function. This is a constrained optimization problem with both numerical and categorical variables shown in Eq. (6):

cutting uids. High values of these cutting parameters cause inevitably very low tool life and high surface roughness.  The values of the other important responses, tool life and surface roughness, do not show the similar trends with the minimum energy values. For examples, CCF-II consumes considerably lower energy than SCF-II, but gives lower tool life. Furthermore, the surface roughness values are comparable for CCF-II and SCF-II.  In conclusion, if the main objective is to minimize the specic energy, CCF-II should be preferred as the best cutting uid. Moreover, if the cost of machining operation is important, the relative weight of costs of consumed energy and cutting tool in the total cost will determine the most appropriate cutting uid. In such a case, a choice between CCF-II and SCF-II can be considered. In brief, use of VBCFs can save energy and meet the demands for cleaner production.

Optimize y f X ; Z s:t: Li Xi Ui i 1:3

(6)
3.2.1.2. Minimization of the surface roughness. Table 7 presents the surface roughness minimization results. The following conclusions are extracted from this table:

Z CCF II; SCF II; CSSF

where L and U are lower and upper bounds of the numerical factors. 3.2.1.1. Minimization of the specic energy. Energy generation is amaincontributortocarbondioxideemissionsandclimatechange,thus reducing energy consumption is an essential consideration in sustainable manufacturing (Pusavec et al., 2010; Rajemi et al., 2010) and cleaner production (Hana et al., 2012). So in this study minimization of specic energy is considered and the minimization results are summarized in Table 7 from which the following conclusions can be drawn:  Minimum specic energy values considerably depend on the cutting uid type; the optimal value obtained with CCF-II (1.32 J/mm3) is 105% lower than the worst case (2.71 J/mm3) obtained with SCF-II. Meanwhile, optimum cutting conditions depend weakly on the cutting uid type; optimum cutting conditions are the same for CCF-II and SCF-II. Moreover, the optimum value of depth of cut (0.3 mm) is the same irrespective of the uid type. In the case of CSSF, optimum feed rate and cutting speed are 25% and 15% higher than those of other

Fig. 3. Example tool wear result.

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Table 5 Modelling results for specic energy, surface roughness and tool life. P 2 2 2 2 U b0;k 3 i 1 bi;k Xi 5:03*V *f 1:06*V *ap 1550:49*f 295:34*ap 9:81*V *f 1:71*V *ap P 5 *V 2 5:24*f 2 3:52*a2 b Ra b0;k 3 X 0 : 007 * V * f 0 : 005 * V * a 0 : 21 * f * a 7 : 46 * 10 p p p P i 1 i;k i 2 T b0;k 3 i 1 bi;k Xi 0:50*V *f 272:78*f Coefcients of linear terms of models Type of cutting uid Specic energy CCF-II SCF-II CSSF Surface roughness CCF-II SCF-II CSSF Tool life CCF-II SCF-II CSSF

b0,k
71.02 69.63 68.08 2.71 2.67 2.57 51.22 56.38 57.76

b1,k
0.484 0.476 0.467 0.029 0.028 0.027 0.16 0.16 0.16

b2,k
791.63 791.63 791.63 2.86 2.41 2.79 219.77 239.01 244.02

b3,k
183.74 183.74 183.74 2.29 2.90 2.99 18.00 18.00 18.00

 Minimum surface roughness is achieved with CCF-II and the worst result belongs to CSSF. Optimum feed rate value is independent of the cutting uid type, while other cutting parameters differ more or less for each cutting uid type, affecting strongly the surface quality.  While CCF-II gives minimum surface roughness, its tool life is the worst as compared to other cutting uids. Higher specic energies obtained with SCF-II and CSSF are due to higher depth of cut values. Lower cutting speed in the case of CSSF favours a longer tool life and moderate specic energy when compared to SCF-II.  From the above results, if the main goal is to minimize surface roughness, CCF-II should be preferred as a cutting uid. When the cutting economy is also considered, the most appropriate uid type would be selected by a compromise between nished surface quality and operating cost. 3.2.1.3. Maximization of the tool life. The maximization result of the tool life is presented in Table 7 and the below results can be obtained:  To maximize the tool life, cutting speed, feed rate and depth of cut must be selected as 150 m/min, 0.2 mm/rev and 0.2 mm, respectively.Themaximumtool lifevalues ofCSSFandSCF-IIareofsimilar magnitude. Surprisingly, the optimum cutting conditions are independent of the cutting uid type and they are at their lowest levels.  The uid type inuences also the other response values at the same cutting conditions. CCF-II consumes less energy and performs better in terms of the surface quality. Thus, if the main goal is to maximize the tool life, CSSF is the preferred uid type. But, this conclusion is not very obvious if the other responses are also taken into account. From the numerical optimizations, it is seen that CCF-II performs globally better than the rest. Moreover, following

general results can be achieved on the cutting conditions, independent of the uid type  To minimize the consumed energy, low cutting speed and feed rate are required.  To minimize the surface roughness, low feed rate must be selected.  All the cutting parameters must be selected at their low levels to maximize the tool life. 3.2.2. Multi objective optimization The optimization problem may be considered in a more general context; different objectives may be dened by taken into consideration the performance of the process for a multi objective optimization; the surface quality of the nished product is usually the primary objective which is expressed by the surface roughness. Meanwhile, other objectives reecting the economy of the process may be also considered for a more effective end milling. In this context, tool related responses such as tool wear and tool life reect the tool cost, while specic energy reects the electrical energy cost. These two cost items account for an important part of the direct operating cost. A multi objective optimization problem may be dened in various ways. In this study, the problem is dened in the context of implicitly constrained optimization: One of responses is selected as
Table 7 The results of specic energy, surface roughness minimization and tool life maximization. Cutting uids Cutting Feed rate Depth of Specic Surface Tool life speed (mm/rev) cut (mm) energy roughness (min) (m/min) (J/mm3) (mm) Specic energy CCF-II SCF-II CSSF 150 150 175 0.2 0.2 0.25 0.2 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.208 0.292 0.300 0.2 0.2 0.2 1.3200a 2.7100 1.9507 2.1033a 3.2962 2.4979 1.8520a 3.2420 2.7716 0.3031 0.2887a 0.3815 0.2013a 0.2630 0.2935 0.2853a 0.3286 0.3597 3.4770 4.7878a 1.9027 3.5827 3.7538 4.2393a 5.2767 6.5875 6.9690a

Table 6 Statistical results for proposed models. Response Specic energy Surface roughness Tool life Std. dev. 0.093 0.026 0.70 R2 0.9750 0.9605 0.9163 Adj R2 0.9500 0.8859 0.8720 Pred R2 0.8625 0.7079 0.8070 Adeq precision 30.128 12.957 12.645

Surface Roughness CCF-II 175 SCF-II 169 CSSF 165 Tool Life CCF-II SCF-II CSSF
a

150 150 150

optimum values of surface roughness, specic energy and tool life.

E. Kuram et al. / Journal of Cleaner Production 42 (2013) 159e166 Table 8 Multiobjective optimization results. Cutting uids Cutting speed (m/min) Feed rate (mm/rev) Depth of cut (mm) Specic energy (J/mm3) Surface roughness (mm)

165

Tool life (min)

Specic energy selected as primary objective function CCF-II SCF-II CSSF 150 150 170 0.2 0.2 0.2 0.268 0.300 0.268 0.212 0.300 0.300 0.200 0.240 0.272 1.4057 2.7100 2.6093 1.9897 2.9845 2.4979 1.8520 2.9806 2.4728 0.2897 0.2887 0.2999 0.2176 0.2699 0.2935 0.2853 0.2984 0.2998 4.0529 4.7878 4.5052 4.0067 4.2298 4.2393 5.2767 5.7436 4.9912

Surface roughness selected as primary objective function CCF-II 167 0.2 SCF-II 159 0.2 CSSF 165 0.2 Tool life selected as primary objective function CCF-II 150 0.2 SCF-II 152 0.2 CSSF 161 0.2

primary objective function y to be optimized, while the others are used as implicit constraints f:

Optimize y f X ; Z s:t: Li Kj fj Xi Hj Ui i 1:3

(7)

Secondly, the surface roughness is selected as primary objective function, while specic energy and tool life are used as the implicit constraints. These results are given in Table 8 and the following conclusions are extracted:  Minimum surface roughness and the worst quality are obtained with CCF-II and CSSF. Optimum feed rate value is independent of cutting uid type, while other cutting parameters differ for each uid type.  While CCF-II gives minimum surface roughness, its tool life is the worst as compared to the rest of the cutting uids.  In conclusions, if the primary objective is to minimize surface roughness, CCF-II should be preferred as a cutting uid. The most appropriate uid type also would be determined by the operating cost. Finally, tool life is selected as primary objective function, while specic energy and surface roughness are used as the implicit constraints. The following conclusions are drawn from Table 8:  Maximum tool life is obtained with SCF-II and CSSF gives minimum tool life. Optimum feed rate value is independent of cutting uid type, while other cutting parameters are dependent of the cutting uid type.  While SCF-II gives maximum tool life, its consumed energy is the highest with respect to the rest of the cutting uids.  The magnitudes of minimum surface roughness values of CCFII, SCF-II and CSSF are similar.  The values of the other important responses, specic energy and tool life, do not show the similar trends. CCF-II consumes considerably lower energy than SCF-II, but gives lower tool life. From the multi objective numerical optimizations, it is seen that CCF-II performs globally better than the rest. 4. Conclusions In this study, vegetable based cutting uids are developed to meet the demands for environmentally friendly machining processes. Effects of the machining variables (cutting speed, feed rate and depth of cut) and cutting uids on the milling of stainless steel are investigated for the experimental study. D-optimal experimental design is used to investigate the effect of these variables on specic energy, surface roughness and tool life. The following conclusions from mathematical models and mono objective optimizations are drawn: The relationship between responses and the variables utilized in the current work is well represented by the proposed models.

j 1:2

Z CCF II; SCF II; CSSF

K and H are lower and upper bounds on the implicit constraints which are selected based on mono objective optimization results as follows:

U Ra

3 J=mm3 0:3 mm

(8)

T ! 4 min
These constraints are for illustrative purpose which may be decided with respect to the special application. First, specic energy is chosen as the primary objective function, while tool life and surface roughness are used as the implicit constraints. These results are presented in Table 8. The following conclusions are depicted from this table:  Minimum specic energy is obtained with CCF-II and SCF-II gives the worst result. The optimal specic energy value obtained with CCF-II is 92.78% lower than obtained with SCF-II. Optimum feed rate value is independent of cutting uid type.  While CCF-II gives minimum specic energy, its tool life is the worst. Higher specic energy obtained with SCF-II is due to higher depth of cut value with respect to rest of the cutting uids.  The minimum surface roughness values of CCF-II, SCF-II and CSSF are of similar magnitude.  The values of the other important responses, specic energy and tool life, do not show the similar trends. CCF-II consumes considerably lower energy than that of SCF-II, but gives lower tool life.  In conclusion, if the primary objective is to minimize the specic energy, CCF-II should be preferred as the best cutting uid. On the other hand, the proportion of costs of consumed energy and cutting tool in the total cost will determine the most appropriate cutting uid. Under these circumstances, CCF-II or SCF-II can be used as a cutting uid.

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Minimum specic energy considerably depends on the cutting uid type. If the main aim is to minimize the specic energy, CCF-II should be preferred as a cutting uid because cost of the machining process is important. The proportion of cost of consumed energy and cutting tool in total determines the most appropriate cutting uid. In such a case, CCF-II or SCF-II can be selected as a type of cutting uid. If the main goal is to minimize the surface roughness, CCF-II should be preferred as a cutting uid. When total cost is taken into consideration, a choice between CCF-II and CSSF can be considered. If the main objective is to maximize the tool life, CSSF should be preferred as a cutting uid. On the other hand, from the multi objective numerical optimizations, it is seen that CCF-II performs globally better than the others. From environmental and machining performance points of view, vegetable based cutting uids meet the cleaner manufacturing demands, can improve the machining performance and VBCFs can be considered as an alternative cutting uids to semi synthetic cutting uids. Further research study could help to develop for reducing both environment impact and health issues from the cutting uids by improving its formulae and rate of biodegradability. Then attention have to focus on developing new kinds of vegetable based cutting uids for variety of machining operations (milling, drilling, tapping, reaming, grinding, etc.) and different types of metals (aluminium, titanium, copper, brass, etc.) in the machining area. Reduction in consumption of vegetable based cutting uid unlike the conventional ooding method leads to minimize the machining cost and environmental impacts. Acknowledgement The authors are grateful to TUBITAK (Project number: 107M164). References
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