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Measurement
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a r t i c l e
i n f o
Article history:
Received 2 March 2013
Received in revised form 4 November 2013
Accepted 12 December 2013
Available online 27 December 2013
Keywords:
Milling
PVD/CVD coating
Surface roughness
Flank wear
Taguchi method
a b s t r a c t
In this paper, the Taguchi method and regression analysis have been applied to evaluate
the machinability of Hadeld steel with PVD TiAlN- and CVD TiCN/Al2O3-coated carbide
inserts under dry milling conditions. Several experiments were conducted using the L18
(2 3 3) full-factorial design with a mixed orthogonal array on a CNC vertical machining
center. Analysis of variance (ANOVA) was used to determine the effects of the machining
parameters on surface roughness and ank wear. The cutting tool, cutting speed and feed
rate were selected as machining parameters. The analysis results revealed that the feed
rate was the dominant factor affecting surface roughness and cutting speed was the dominant factor affecting ank wear. Linear and quadratic regression analyses were applied to
predict the outcomes of the experiment. The predicted values and measured values were
very close to each other. Conrmation test results showed that the Taguchi method was
very successful in the optimization of machining parameters for minimum surface roughness and ank wear in the milling the Hadeld steel.
2013 Elsevier Ltd. All rights reserved.
1. Introduction
Hadeld steel (austenitic manganese steel) is a very
tough and non-magnetic alloy and having excellent wear
resistance with high strength and ductility [1]. In recent
years, due to its excellent wear resistance properties this
steel has been widely used in various engineering applications including excavators, mining equipment, pumping
equipment, railways, rolling mill parts for steel factories
and wear-resistant components of machining elements.
However, the machining of this steel is very difcult due
to its extreme hardness, low thermal conductivity and
strain hardening behavior. Consequently, greater cutting
forces, higher cutting temperatures and wearing are present making the control of dimension precision difcult
during machining [24].
Tel.: +90 0380 542 11 33; fax: +90 0380 542 11 34.
E-mail address: turgaykivak@duzce.edu.tr
0263-2241/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2013.12.017
20
2. Experimental methods
2.1. Milling experiments
The milling experiments were carried out in dry cutting
conditions using a First MCV 350 model three-axis CNC
milling machine equipped with a maximum spindle speed
of 8000 rpm and a 7.5-kW drive motor. The experimental
21
Spindle
Ra3
Workpiece
Ra2
Ra1
Cutting
tool
Surface roughness
measuring device
Table 1
Chemical composition of Hadeld steel (wt.%).
C
Si
Mn
Ni
Cr
Mo
Cu
1.22
0.521
13.5
0.133
1.19
0.038
0.088
0.003
0.018
Table 2
Properties of cutting tools and coating materials.
Coated materials
Hardness (Hv)
PVD
TiAlN
C20 (GC1020)
1600
CVD
TiCN/Al2O3
C40 (GC3040)
1350
Coated method
22
Table 3
Milling parameters and their levels.
Parameters
Symbol
Level 1
Level 2
Level 3
Cutting tools
Cutting speed (m/min)
Feed rate (mm/rev)
A
B
C
PVD
90
0.09
CVD
120
0.12
150
0.15
Table 4
Full factorial design with orthogonal array of Taguchi L18 (21 32).
Experiment no.
Factor A
Factor B
Factor C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
1
1
1
2
2
2
3
3
3
1
1
1
2
2
2
3
3
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Control factors
A
Cutting tool
(Ct)
B
Cutting speed
(V)
C
Feed rate
(f)
PVD
PVD
PVD
PVD
PVD
PVD
PVD
PVD
PVD
CVD
CVD
CVD
CVD
CVD
CVD
CVD
CVD
CVD
90
90
90
120
120
120
150
150
150
90
90
90
120
120
120
150
150
150
0.09
0.12
0.15
0.09
0.12
0.15
0.09
0.12
0.15
0.09
0.12
0.15
0.09
0.12
0.15
0.09
0.12
0.15
Surface roughness, Ra
(lm)
Flank wear, Vb
(mm)
0.51
0.57
0.76
0.50
0.55
0.66
0.47
0.55
0.67
0.50
0.58
0.71
0.46
0.52
0.66
0.45
0.50
0.59
5.849
4.883
2.384
6.021
5.193
3.609
6.558
5.193
3.479
6.021
4.731
2.975
6.745
5.680
3.609
6.936
6.021
4.583
0.22
0.23
0.24
0.21
0.23
0.26
0.27
0.28
0.33
0.14
0.15
0.18
0.17
0.21
0.22
0.22
0.25
0.30
13.152
12.765
12.396
13.556
12.765
11.701
11.373
11.057
9.630
17.077
16.478
14.895
15.391
13.556
13.152
13.152
12.041
10.458
Table 6
S/N response table for Ra and Vb factor.
Levels
Control factors
Surface roughness (Ra)
Level 1
Level 2
Level 3
Delta
4.796
5.256
0.459
4.475
5.143
5.461
0.988
6.355
5.283
3.440
2.915
12.04
14.02
1.98
14.46
13.35
11.28
3.18
13.95
13.11
12.04
1.91
C, [f (mm/rev)]
6.5
Mean of SN ratios
6.0
5.5
5.0
4.5
4.0
3.5
PVD
CVD
90
120
150
0.09
0.12
0.15
24
B, [V (m/min)]
C, [f (mm/rev)]
14.5
Mean of SN ratios
14.0
13.5
13.0
12.5
12.0
11.5
11.0
PVD
CVD
90
120
150
0.09
0.12
0.15
0.75
0.50
0.52
0.54
0.56
0.58
0.70
0.65
0.60
0.55
PVD
0.50
150
120
Cuttin
90
g Spee
d (m /m
in)
CVD
g
tin
ut
ols
To
Surface Roughness, Ra (
m)
0.75
0.50
0.55
0.60
0.65
0.70
0.70
0.65
0.60
0.55
PVD
0.50
0.15
0.12
Feed R
ate (m
m
0.09
CVD
ng
tti
Cu
o
To
ls
/rev)
0.30
0.28
0.26
0.24
0.22
0.20
0.18
PVD
ls
0.16
150
120
Cuttin
g Spee
90
d (m /m
in)
CVD
Cu
ng
tti
o
To
0.16
0.18
0.20
0.22
0.24
0.26
0.28
0.30
0.32
0.16
0.18
0.20
0.22
0.24
0.26
0.28
0.30
0.32
0.30
0.28
0.26
0.24
0.22
0.20
0.18
PVD
0.16
0.15
Fe e d R
0.12
ate (mm
/rev)
0.09
CVD
Cu
T
ng
tti
ls
oo
rates on surface roughness and tool wear. The ANOVA results for the surface roughness and ank wear are shown
in Table 7. This analysis was carried out a 5% signicance
level and a 95% condence level. The signicance of control
factors in ANOVA is determined by comparing the F values
of each control factor. The last column of the table shows
the percentage value of each parameter contribution
which indicates the degree of inuence on the process performance. According to Table 7, the percent contributions
of the A, B and C factors on the surface roughness were
found to be 2.55%, 9.33% and 82.38% respectively. Thus,
the most important factor affecting the surface roughness
was feed rate (factor C, 82.38%). According to the ANOVA
results, the percent contributions of the A, B and C factors
25
F ratio
Ra
A
B
C
Error
Total
1
2
2
12
17
0.004050
0.014044
0.116578
0.005689
0.140361
0.004050
0.007022
0.058289
0.000474
8.54
14.81
122.95
2.55
9.33
82.38
5.74
100
Vb
A
B
C
Error
Total
1
2
2
12
17
0.0102722
0.0212333
0.0076
0.0029444
0.04205
0.0102722
0.0106167
0.0038000
0.0002454
41.86
43.27
15.49
23.84
49.33
16.91
9.92
100
R Sqadj 87:67%
0.8
0.35
0.30
Actual Vb
0.7
Actual Ra
R Sqadj 95:50%
Here Raq and Vbq show the predictive equations for surface
roughness and ank wear. In Fig. 8 test results and the
comparison of predicted values which were obtained by
the quadratic regression model are shown. As seen from
the gure, there is a very good relation between predicted
values and test results. The R2 values of the equations obtained by the quadratic regression model for Ra and Vb
0.6
0.5
0.25
0.20
0.15
0.4
0.4
0.5
0.6
Predicted Ra
0.7
0.8
0.10
0.10
0.15
0.20
0.25
Predicted Vb
Fig. 7. Comparison of the linear regression model with experimental results for Ra and Vb.
0.30
0.35
26
0.35
0.30
Actual Vb
Actual Ra
0.7
0.6
0.25
0.20
0.5
0.15
0.4
0.4
0.5
0.6
0.7
0.8
0.10
0.10
0.15
Predicted Ra
0.20
0.25
0.30
0.35
Predicted Vb
Fig. 8. Comparison of the quadratic regression model with experimental results for Ra and Vb.
CIRa;Vb
s
1
1
F a;1;fe V e
neff R
and
N
1 T dof
Raopt A2 T Ra B3 T Ra C 1 T Ra T Ra
neff
Vbopt A2 T Vb B1 T Vb C 1 T Vb T Vb
Here, Fa,1,fe is the F ratio at a 95% condence, a is the significance level, fe is the degrees-of-freedom of error, Ve is error
variance, neff is the effective number of replications, R is the
number of replications for conrmation experiments (Eq.
(8)). N is the total number of experiments, and Tdof is the
total main factor degrees of freedom (Eq. (9)).
F0.05,1,12 = 4.747 (from F test table), VeRa = 0.000474 and
VeVb = 0.0002454 (Table 6), R = 3 (Eq. (8)). N = 3, Tdof = 5
and neff = 3 (Eq. (9)).
By using the Eqs. (8) and (9) the condence intervals
were calculated as CIRa = 0.039 and CIVb = 0.028 The
estimated average optimal surface roughness and ank
wear with the condence interval at 95% condence is:
Here, (A2, B3, C1) and (A2, B1, C1) represent the optimum level average values of surface roughness (Raopt) and ank
wear (Vbopt) respectively (Table 3). TRa and TVb state the
Table 8
Mean response table for Ra and Vb factor.
Levels
Level 1
Level 2
Level 3
Delta
Control factors
Surface roughness (Ra)
0.5822
0.5522
0.300
0.6050
0.5583
0.5388
0.0667
0.4817
0.5450
0.6750
0.1933
0.2522
0.2044
0.0478
0.1933
0.2167
0.2750
0.0817
0.2050
0.2250
0.2550
0.0500
Raopt CIRa < Raexp < Raopt CIRa ; i:e:; 0:433 0:039
< 0:45 < 0:433 0:039 0:394 < 0:45
Bold values shows the Ra and Vb values obtained from the experimental
study.
< 0:472
Table 9
Predicted values and conrmation test results by Taguchi method and regression equations.
Level
Ra (lm)
A2B3C1 (Optimum)
A1B1C3 (Random)
Vb (mm)
A2B1C1 (Optimum)
A1B1C1 (Random)
Exp.
Pred.
Error (%)
Exp.
Pred.
Error (%)
Exp.
Pred.
Error (%)
0.45
0.76
0.433
0.722
3.78
5.00
0.45
0.76
0.422
0.712
6.22
6.32
0.45
0.76
0.449
0.739
0.22
2.76
0.14
0.22
0.143
0.191
2.14
13.18
0.14
0.22
0.139
0.186
0.71
15.45
0.14
0.22
0.144
0.216
2.86
1.82
Vbopt CIVb < Vbexp < Vbopt CIVb ; i:e:; 0:143 0:028
< 0:14 < 0:143 0:028 0:115 < 0:14
< 0:171
The Raexp and Vbexp values, obtained from the experimental
study stayed within the condence interval limits. Thus,
the system optimization for surface roughness and ank
wear was achieved using the Taguchi method at a signicance level of 0.05.
27
5. Conclusion
In this study, the Taguchi method was used to determine optimal machining parameters in the milling of
Hadeld steel with PVD- and CVD-coated carbide inserts
under dry milling conditions. The experimental results
were evaluated using ANOVA. The following conclusions
may be drawn:
The optimum levels of the control factors for minimizing the surface roughness and ank wear using S/N
rates were determined. The optimal conditions for surface roughness and ank wear were observed at A2B3C1
(i.e., cutting tool = CVD, cutting speed = 150 m/min and
feed rate = 0.09 mm/rev) and A2B1C1 (i.e., cutting
tool = CVD, cutting speed = 90 m/min and feed
rate = 0.09 mm/rev), respectively.
CVD TiCN/Al2O3-coated carbide inserts exhibited better
performance than PVD TiAlN-coated carbide inserts and
could be recommended for use in the milling of
Hadeld steel.
According to the results of statistical analyses, it was
found that the feed rate was the most signicant
parameter for surface roughness with a percentage contribution of 82.38% and that the cutting speed was the
most signicant parameter for ank wear with a percentage contribution of 49.33%.
Developed quadratic regression models demonstrated a
very good relationship with high correlation coefcients (Ra = 0.962 and Vb = 0.955) between the measured and predicted values for surface roughness and
ank wear.
According to the conrmation test results, measured
values were within the 95% condence interval.
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