International Journal of Applied Engineering Research ISSN 0973-4562 Volume 10, Number 7 (2015)

Research India Publications ::: http://www.ripublication.com

OPTIMIZATION OF MACHINING PARAMETERS OF Al-SiC NANO

COMPOSITES USING DOE
S.Vijayraj a,*, A.Arivazhagan b , G.Prakash b , G.Prahbu c
a

Department of Automobile Engineering , Tamilnadu College of Engineering, Coimbatore

Department of Mechanical Engineering, Vels University
c
Department of Automobile Engineering, Karpagam University
b

ABSTRACT:
Low hardness and poor wear resistance are
the main obstacles for the high performance
mechanical and tribological applications. Hard
reinforcement phases such as particulates, fibers, and
whiskers are introduced into Al-based matrix in
order to improve their high specific strength,
stiffness, wear resistance, fatigue resistance.
Increased strength and wear resistance with reduced
weight increased the applications of Al/SiC based
composites. The problem machining process due to its
increased hardness is encountered. Addition nano SiC
composites increase the yield strength, ultimate
strength of the composition, increased with increasing
volume fraction of nano- particles. High energy ball
milling was used to produce a nanostructured SiC.
The hardness of the composites is higher than the
carbide tool. So Polycrystalline Diamond Tool (PCD)
is used for machining (Turning), which is four times
harder than Al/SiC composites, and has better life
period and reduced tool wear. Cutting parameters
(spindle speed, feed rate and depth of cut) have been
optimized to minimize tool wear and for better
surface roughness. Material removal rate is
calculated for obtaining optimization. Spindle speed
and feed was identified as the more significant
parameters influencing the tool wear. The signal-tonoise ratio and the analysis of variance were applied
to the experimental data in order to determine the
effect of the process variables on the surface
roughness and material removal rate.
Keywords: Al/SiC, nano , PCD, Surface roughness and
MRR, ANOVA

1.INTRODUCTION
The increased demand in weight reduction
in the material and fuel consumption in the
automobile and aerospace industries made us to
choose a material from the tremendous types
available Aluminium alloys. The uses are to a great
extend as they gave low density, high thermal
conductivity and high specific strength and it
increased its usage in the mechanical field. The
main obstacles of using aluminium are its low
hardness and poor wear resistance. To overcome
this problem, aluminium alloys are reinforced with
particulates, fibres and whiskers to improve the
specific strength, stiffness and wear resistance.
There are many different techniques
available to for particle reinforcing. Here we are

using stir casting method as it is an attractive

casting method for MMCs and also relatively
inexpensive. Generally in this method, metal
matrix is melted to liquid state and particulates are
added at the end. Here particulate selected is SiC.
The study shows that the addition of SiC enhances
the wear resistance and material strength. The hard
particles resist the destruction and gives better wear
and abrasive resistance [5]. Also the ultimate
tensile and yield strength also increases due to the
incorporation of SiC. The size of SiC is chosen in
nanometers as reduced particulate size increased
the mechanical properties of the material[4].
The turning operation is performed to
check the optimal level in machining. Ordinary
ceramic tools have poor thermal and shock
resistance and are not recommended for high speed
turning [3]. In order to do so, brazed
Polycrystalline Diamond tool (PCD) was selected
which is suitable for machining MMCs containing
high percentage of Al2o3[6]. PCD tools are 4 times
harder than that of SiC, so it is selected as turning
tool. Feed rate , depth of cut and spindle speed are
considered as machining parameters.
The hard abrasive reinforcement causes
rapid tool wear and it affects the surface quality of
the workpiece and decreases the tool life. Because
of this, its application is significantly affected by
their poor machinability and high machining costs.
Polycrystalline Diamond (PCD) is the best choice
cutting tool material and typically used in
machining MMCs [5] as it is harder than Al2O3 and
SiC and does not have a chemical tendency with
the work material. Also it is four times harder than
the composite. Also, the best machining
performance has been obtained using cubic boron
nitride tools for machining of Al/SiC MMC
reported by Looney et al. [6]. Weinertet et al., [7]
suggested PCD and CVD inserts in machining
MMCs as tool have low wear rate. Fetecau and
Stan [8] investigated
the turning of PTFE
composites using a polycrystalline diamond tool.
Results indicate that the cutting speed significantly
influenced by feed rate, depth of cut, and the
interaction of feed rate and depth of cut, while
cutting speed and insert radius also have a small
influence. The surface roughness of the material is
significantly influenced by the feed rate, the insert
radius, and the interaction of feed rate and insert

radius. Ozben et al. [9] investigated on the

mechanical and machinability properties of silicon
carbide particle (SiC-p) reinforced aluminium
metal matrix composite. Machinability of the
selected material is studied and higher SiC
reinforcement produced a higher tool wear surface
roughness was generally affected by feed rate and
cutting speed. Basheer et al. [10] present an
experimental work on surface quality on Al/SiC
composites leading to an artificial neural networkbased (ANN) model to predict the surface
roughness of the material. The roughness of
machined surfaces based on the ANN model was
found to be in very good agreement with the
unexposed experimental data set.
Manna and Bhattacharayya [11] observed
that the flank wear rate is high at low cutting speed
due to the generation of high cutting forces and
formation of BUE during machining of Al/SiC
MMC. High cutting speed, low feed and low depth
of cut are recommended for better surface finish.
Ding et al. [13] evaluated the performance of MMC
using various types of PCBN and PCD cutting tool
during machining of aluminium alloy reinforced
with SiC metal matrix composites. It is observed
that fracture are being occurred on the rake face of
the PCBN cutting tools and also the adhesion of the
workpiece material on the cutting tools have a
major influence on decreasing surface finish of
workpiece. It affects the tool life due to improper
fracture in the tool. EI-Gallab and Sklad [14]
investigated the surface integrity and sub surface
damage of machined Al/SiC-MMC containing
weight 20% of silicon carbide particulate using
PCD tools. Luliano et al. [15] performed an
experimental study on the behaviour of high rake
angle of uncoated and CVD diamond-coated
carbide tools on tool wear and surface finish during
high speed machining of metal matrix composite.
From the previous studies it is found that find the
incorporation of nano-particles into the aluminum
matrix could enhance the hardness, the yield and
ultimate tensile strength considerably, while the
ductility is retained [16, 17]. More than 50%
improvement in yield strength of A356 alloy was
observed with only 2.0% nano-sized SiC particles
[18]. ZHAO et al [19] characterized the properties
and deformation behaviour of aluminum matrix
nano-composites. It was reported that the tensile
strength and yield strength of nano-composites are
enhanced with increasing the particulate volume
fraction, which are higher than those of Al
composites synthesized by micro size particles.

0.4% fe 1% reinforced with 20% volume fraction

of SiC in nano size. The size of SiC is reduced to
30nm by using high speed ball milling machine..
The tool selected is PCD which has better wear
resistance and better machining. Single crystal
diamond tools with rake angle of 25o, front
clearance angle of 10o and tool nose radius of 0.762
mm were used throughout the experiments.Ball
milling operation is performed to reduce the
particle size. Milling machine with weight of
100kg and power of 0.55 to 11kW is used. Four
numbers of balls is used in the machine and milling
operation is continued for 16 hrs. SEM analysis is
performed to measure the particle size.
B.Turning operations
Turning operation for 30mm x 100mm
work piece will be carried out. Here we consider
depth of cut, spindle speed and feed rate of the
machining. By performing turning operation we
optimize the tool life and surface roughness values
for better machining operation. The machine used
for turning is a LOKESH TL20 CNC lathe having
the control system FANUC Series and equipped
with maximum spindle speed of 3500 rpm, feed
rate 15-20 mm/rev and KVA rating-16 KVA. For
generating the turned surfaces, CNC part programs
for tool paths were created with specific
commands.
C.Die design:
For manufacturing the work piece, an
appropriate die has been made up of suitable cast
iron material with internal diameter 25mm, external
diameter 75mm and 75mm long. It is then used as a
core cavity of the work piece which we had a
casting in it. Figure shows the photographic image
of the die which we had used for making the work
piece specimen.
D.Taguchi and selection of trails:
Taguchi method is based on performing
evaluation or experiments to test the sensitivity of a
set of response variables to a set of control
parameters (or independent variables) by
considering experiments in orthogonal array with
an aim to attain the optimum setting of the control
parameters. There are different standard orthogonal
arrays from which the trails can be decided.
In this project we are selecting L9 through
which 9 different trails is considered and
machining process is performed and different
experimental results are obtained.
Number of Parameters : 3

II. EXPERIMENTAL PROCEDURE

Number of Levels

A. Materials and Experimentation:

Total number of trails

In order to achieve the objective of this

experimental work, aluminium with Si 7%, Mg

E.ANOVA Optimization:

:3
:9

By performing all the 9 experiments we

will get 9 different types of results and values.
From the experiments it is important to optimize
the best suitable machining parameters. In order to
do so we are using ANOVA analysis. Different
factors obtaining by the decomposition of variance
is called as analysis of variance (ANOVA).

S.No
1
2
3
4
5
6
7
8
9

v
(rpm)
f
(mm/r
ev)
d
(mm)

Depth of
Cut
0.5
1.0
1.5
0.5
1.0
1.5
0.5
1.0
1.5

III RESULTS AND DISCUSSIONS

The values of surface roughness and
material removal rates are measured and they are
considered in the ANOVA calculation to predict
the level of significance in the operation. ANOVA
plays a vital role in deciding the optimized result
from the taken set of values.
Table 3 ANOVA for surface roughness
Sour
ce
v
(rpm)
f
(mm/
rev)

D
F

Seq
SS

Adj
SS

Adj
MS

0.57
556

0.57
556

0.28
778

0.28
222

0.282
22

0.141
11

0.002
22

0.001
11

0.00
889

0.004
44

d
(mm)

Error

Total

0.0
022
2
0.0
088
9
0.8
688
9

F
64.
75
31
.7
5
0.25

R2 = 98.98% R2(adj) = 95.91%

Table 4 ANOVA for Material removal rate

Sour
ce

Table 1 Parameters selected for Turning

Operation
Levels
Parameters
L1
L2
L3
Feed rate
0.10
0.15
0.20
(mm/rev)
Spindle speed
30
60
90
(rpm)
Depth of cut
0.5
1.0
1.5
(mm)
Table 2 Design Matrix
Spindle
Feed
speed (rpm)
( mm/rev)
30
0.10
30
0.15
30
0.20
60
0.10
60
0.15
60
0.20
90
0.10
90
0.15
90
0.20

The ANOVA for surface roughness

clearly states that speed plays a significant role in
the machining operation. Also feed rate takes
certain part in the influence of machining
operation.

P
0.0
15
0.0
31
0.8
00

D
F

Seq
SS

Adj
SS

Adj
MS

0.06
110

0.06
110

0.03
055

0.09
197

0.091
97

0.045
99

0.01
820
0.02
816

0.018
20
0.02
816

0.009
10
0.014
08

Error

Total

F P
2.
17
3.
2
7
0.6
5

0.3
15
0.2
34
0.6
07

0.1994
4

R2= 85.88% R2(adj) = 43.52%

ANOVA table of material removal rate
gives the influence levels of each factor. In MRR,
feed rate is important factor which plays higher
significance in the operation. Next to feed rate,
speed is an important influence factor. Depth of cut
plays very minimal significance and so least
priority is given to it.
The turning operation is performed for the
taken 9 workpieces using CNC machine. The
surface roughness of the each experiment is
measured and the values are tabulated in Table 5.
Also the material removal rate of each operation is
calculated and is listed. Signal to Noise ratio is
found for smaller is better for surface roughness
and larger is better for material removal rate. The
S/N ration is considered to optimize the parameters
with graphical results.
The criteria for optimization of the response
parameters was based on the smaller the better S/N
ratio.

(i)
Yi represents the measured value of the response
variable i.
The S/N ratio with a higherthe-better
characteristic can be expressed as:

(ii)

Yi represents the measured value of the response

variable.

Table 5 Experimental results and their

corresponding S/N ratio
Exp
No
1
2
3
4
5
6
7
8
9

v
(rp
m)
30
30
30
60
60
60
90
90
90

f
(mm/
rev)
0.10
0.15
0.20
0.10
0.15
0.20
0.10
0.15
0.20

D
(mm)

Ra
( m)

S/N
(Ra)

MRR
(cm3/min)

S/N
(MRR)

0.5
1.0
1.5
1.0
1.5
0.5
1.5
0.5
1.0

1.8
2.1
2.3
1.4
1.5
1.8
1.3
1.5
1.7

-5.10545
-6.44439
-7.23456
-2.92256
-3.52183
-5.10545
-2.27887
-3.52183
-4.60898

0.015780
0.059520
0.144118
0.053333
0.140909
0.183330
0.072727
0.187500
0.544440

-36.0379
-24.5067
-16.8257
-25.4601
-17.0212
-14.7353
-22.7661
-14.5400
-5.2810

A. Parametric optimization for surface roughness:

The term signal represents desirable value
and noise being undesirable and response of the
value with highest S/N ratio is considered to be
optimal result. The mean S/N ratio of surface
roughness for spindle speed, feed rate and depth of
cut can be calculated by averaging the S/N ratio for
experiments conducted. Based on the mean results,
the ranking for each factor is selected based on
their significant. Mean for each level is calculated
and difference between maximum and minimum
mean values are calculated for ranking the
significant of parameters. The mean S/N ratio is
listed in table:
Table 6 Mean S/N ratio for Ra
Symb
ol
v
(rpm)
f
(mm/
rev)
d
(mm)

Proces
s
param
eters
Spindle
speed
Feed
rate
Depth
of cut

Mean S/N ratio

(0.10mm/rev) and depth of cut at level 3 ( 1.5mm)

ie., v3-f1-d3
The difference to maximum and minimum
of mean S/N is considered to predict the rank of the
factors in the optimization. As per the investigation
through S/N ratio, spindle speed is given the top
rank as most of the influence is take by it. The
change in speed gives major changes in all the
operations. Feed rate in considered as it also plays
influence in optimization but does not plays as
important as speed.
S/N plot for surface roughness is plotted
by considering the mean of S/N ratio and
optimization results are taken from the plot Figure
1, considering the highest value of S/N as that is
the most suitable optimum value of the operation.

Figure 1 Main effect plots for S/N ratio (Ra)

B.Parametric optimization for Material Removal
Rate
The mean S/N ratio for each level of process
parameters for MRR is listed below:
Table 7 Mean S/N ratio for MRR

Ra
nk

Symb
ol

2.79
16

v
(rpm)

2.21
304

0.59
488

Leve
l1

Leve
l2

Leve
l3

Max
-Min

6.26
146
3.43
562
4.93
996

3.84
994
4.49
601
4.65
864

3.46
989
5.64
966
4.34
508

The mean S/N graph for surface roughness

It shown in figure as main effect plot. It shows the
main effects on surface roughness which is
primarily due to spindle speed and feed. The depth
of cut is found be to very less significant. Greater
the S/N ratio, smaller is the variance of surface
roughness around the desired value. Optimal results
could be found out from the main effect plot
selecting the highest levels of S/N ratio values.
Based on the S/N analysis, the optimal process
parameters for surface roughness are: Spindle
speed at level 3 (90rpm), feed at level 1

f
(mm/
rev)
d
(mm)

Proces
s
param
eters
Spindle
speed
Feed
rate
Depth
of cut

Mean S/N ratio

Level
1

Level
2

Lev
el 3

25.79
01
28.08
80
21.77
106

19.07
22
18.68
93
18.41
593

14.1
957
12.2
806
18.8
71

Max
Min
11.5
944

Ra
nk

15.8
074

3.35
513

Figure 2 shows the main effect on material

removal rate which is primarily due to spindle
speed and feed. Depth of cut is found to be less
significant from the main effect plot figure 2.
Therefore from the plot, optimal process
parameters for removal rate is: spindle speed at
level 3 (90 rpm), feed at level 3 (0.20 mm/rev) and
depth of cut at level 2 (1.0 mm) ie., v3-f3-d2.

presented high determination coefcient (R2= 0.88

close to unity) explaining 88% of the variability of
surface roughness which indicates the goodness of
t for the model and high signicance of the
model.
Table 8 Analysis of variance for Ra model

Figure 2 Mean effect plot for S/N ratio (MRR)

C.Development of regression model
Utilizing
the
experimental
data,
mathematical model for surface roughness and
material removal rate have been developed using
multiple linear regressions (MLR) analysis. The
dependent variable surface roughness (Ra) and
material removal rate (MRR) can be conceived as a
linear combination of the independent variables,
namely spindle speed, feed and depth of cut. The
data was analyzed by MINITAB 16 software. The
adequacy of model has been checked using
correlation coefcients (R2) and acceptance was
based on high to very high coefcients of
correlation (R2). Developed models can be used to
predict values of surface roughness and MRR from
any combinations within the ranges of variable
studied.
D.Surface roughness model
When a regression analysis is employed
applying the least squares method to the
experimental data in order to obtain the coefcients
of this equation, the following equation is attained
for surface roughness.
Ra = 1.62778 - 0.00944444 v + 4.33333 f
- 4.83921x10-17 d
(iii)
R2= 87.85%
R2(adj) = 80.56%
Models are developed using uncoded
units. ANOVA is useful for identifying the level of
signicance of model developed. The F test was
used to determine the signicance test. If the
calculated value of F-ratio is higher than the
tabulated value of F-ratio, then the model is
signicant at desired level. Depending on Fvalue, P-value (Probability of signicance) is then
calculated. If P-value for a term appears less than
0.05 (for 95% condence level) then it can be
concluded that the model is also signicant on the
selected response.
Result of ANOVA for the surface
roughness model is shown in Table. This analysis
is carried out for a level of condence of 95%.
From linear model, regression is signicant as Pvalue is less than 0.05. The regression model

Sour
ce

D
F

Regre
ssion

v
(rpm)

f
(mm/
rev)

d
(mm)

Error

Total

Seq
SS

Adj
SS

Adj
MS

0.76
333
3
0.48
166
7
0.2
81
66
7
0.0
00
00
0
0.1
05
55
6
0.8
68
88
9

0.76
333
3

0.25
444
4

0.48
1667

0.481
667

0.28
1667

12.
052
6
22.
81
58

0.0
100
1
0.0
049
9

0.28
1667

13.34
21

0.0
147
1

0.00
000
0

0.00
000

0.0
00
00

1.
00
0

0.10
555
6

0.02
1111

The ANOVA for regression of surface

roughness is calculated. The regression model
gives the values of F at 95% of confident level. The
values calculated in table 8 are below the required
set of value and P which is less than 0.05. So the
values are significant and they can be considered
for the calculation of predicted values of machining
operation.

Figure 3 Probability plot of Ra

The probability plot for Ra has been
plotted for 95% of confident level. The figure 3
shows how the roughness is distributed over entire
plot. The straight line shows that the values are
adequate and are independent of other variables.

The significance of each level of

parameters is selected based on the calculated P
value. It gives wheather the result is adequate to
consider for the optimization of the material. It as
an important sccenario that to be considered for
each level of optimization.

Figure 4 Experimental values verses predicted

values of surface roughness
The comparison of experimental and
predicted values is shown in the figure 4. The
surface roughness for each trial has been plotted.
From the figure 4 it is clear that there is no much
changes in the roughness and more or less they are
nearly equal to each other.
Figure 5 Probability plot for material removal
rate
The probability plot for MRR is
plotted in the probability plot for 95% confident
level. The value of F for MRR is less than 0.05. So
the values are considered significant and the P
value is 0.010 which is acceptable for the
considered MRR. Also the plot is relatively straight
which implies that the error is distributed equally.

E.MRR model
Similar analysis has been done to develop
regression model and the following equation is
attained.
MRR = -0.394749 + 0.00325139 v +
2.43349 f 0.0096188 d
(iv)
R2 = 73.23%
R2(adj) = 57.17%
From linear model regression is signicant
as P-value is less than 0.05. The regression model
presented high determination coefficient (R2= 0.74)
which indicates the goodness of t for the model
and high signicance of the model. The actual
versus predicted values of material removal rate is
shown and found to be very close to each other.
Table 9 Analysis of variance for MRR model
Sour
ce

D
F

Regr
essio
n

v
(rpm
)

f
(mm/
rev)

d
(mm)

Seq
SS

Adj
SS

Adj
MS

0.1
460
53
1
0.0
570
86
0.0
88
82
8
0.0
00
13
9

0.14
605
3

0.04
8684
4

4.5
597
5

0.06
7876

0.05
7086

0.057
0861

5.3
46
66

0.06
8711

0.08
8828

0.088
8282

8.31
960

0.03
4412

0.00
013
9

0.000
1388

0.0
13
00

0.9
13
66
7

0.05
338
5

0.010
6770

Erro
r

0.053
385

Total

0.1
99
43
8

Figure 6 Experimental values verses predicted

values of material removal rate
Same time, MRR values of the
experimental and predicted values is compared in
figure 6. The plot goes equally from the start of
graph and ends with relatively same values. So
there is no much change of values over
experimental to the predicted.

IV CONCLUSION
The methodology of Taguchi for design
and
Response
surface
methodology for
optimization is utilized and studied. Al/SiCn
machining process is performed by considering
surface roughness and material removal rate as the
optimization
parameters.
The
following
conclusions are obtained from the investigations.

Surface roughness and material removal rate are

strongly correlated with cutting parameters such as
speed, feed rate and depth of cut. Hence the
optimization of cutting parameters based on
parameter design of Taguchi method in employed.
The optimal level of process parameters is the level
with the highest signal to noise ratio for taken
Taguchis orthogonal array design. Also best
optimal combination is selected from response
surface methodology. Based on the S/N analysis,
the optimal process parameters for surface
roughness is Spindle speed at level 3 (90rpm), feed
at level 1 (0.10mm/rev) and depth of cut at level 3 (
1.5mm) ie., v3-f1-d3. It is evident that the spindle
speed is the most significant parameters for surface
roughness followed by feed rate. The depth of cut
is found to be insignificant from the ANOVA
calculation. Based on the S/N analysis, the optimal
process parameters for material removal rate is
spindle speed at level 3 (90 rpm), feed at level 3 (
0.20 mm/rev) and depth of cut at level 2 (1.0 mm)
ie., v3-f3-d2.It is revealed that feed rate and speed
plays an significant role in material removal rate.
The depth of cut is found to be very insignificant
from the ANOVA.
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