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Article history: In this work, the cutting parameters are optimized in hard turning of ADI using carbide inserts based on
Received 19 February 2016 Taguchi method. The cutting insert CVD coated with AL2O3/MT TICN. Experiments have been carried out
Received in revised form 9 June 2016 in dry condition using L18 orthogonal array. The cutting parameters selected for machining are cutting
Accepted 23 June 2016
speed, feed rate and depth of cut with each three levels, nose radius in two levels maintaining other cut-
Available online 24 June 2016
ting parameters constant. The ANOVA and signal to noise ratio are used to optimize the cutting param-
eters. The cutting speed is the most dominant factor affecting the surface roughness and tool wear. In
Keywords:
optimum cutting condition, the confirmation tests are carried out. The optimum cutting condition results
Austempered ductile iron
Surface roughness
are predicted using signal to noise ratio and regression analysis. The predicted and experimental values
Taguchi for surface roughness and tool wear adhere closer to 9.27% and 1.05% of deviations respectively.
Tool wear 2016 Elsevier Ltd. All rights reserved.
1. Introduction and literature review Austempering results the microstructure consists of ferrite in high
carbon austenite matrix [4].
Hard Turning is a turning of hard material with a hardness ADI is difficult to machine compared to ductile cast irons in the
range from 45 to 68 HRC. Generally, coated carbide, cubic boron austempered condition, because of relatively high hardness and
nitride (CBN), Ceramic and polycrystalline cubic boron nitride high strength. In machining, the material is strained hardening
(PCBN) inserts are used to turn the hard materials in CNC lathe. takes place due to the presence of retained austenite. The strain
The machining of hardened materials using CBN, PCBN and cera- hardening of retained austenite increases mechanical loads and
mic tools are generally used and it is a good alternative to expen- reduces the contact length on the cutting insert tools edge [5].
sive grinding operations [1]. Hard turning has many advantages The higher cutting tool wear was observed in machining of ADI
other than the cost advantage such as faster metal removal rate, in austempered condition, when compared to other hardened
reduced cycle time, good surface finish and environmental free [2]. material. The higher tool wear occurs at the cutting tools edge
ADI materials have been used in many engineering applications due to high temperature, adhesion resting on the cutting tool
because of their high strength, high hardness, ductility and tough- and higher ductility of ADI [6]. In turning of ADI, the cutting tools
ness. These materials have been widely used for many applications edge subjected thermal softening due to higher cutting tempera-
such as automotive, agricultural, railroad, construction and mining tures and low thermal diffusivity of ADI [7]. The aim of the new
industries due to their excellent mechanical properties, such as machining industries is to produce components at low product
high strength to weight ratio, high wear resistance and inexpensive cost with good quality in minimum time. To achieve a good cutting
material compared to other materials [3]. Austempered ductile performance in turning, selection of optimum cutting parameters
iron (ADI) is a comparatively latest material for industrial applica- is important. Machinability of hardened materials is evaluated by
tions. ADI is a heat treated form of as cast Ductile Iron. The cutting force, surface roughness and tool wear.
Austempering process consists of three stages they are austenitiz- Turning the hard material to get a minimum surface roughness
ing, isothermal quenching and cooling to room temperature. with minimum tool wear is difficult. The following literature sur-
vey indicates that most of the hard material is turned by CBN,
PCBN and ceramic inserts. Katuku et al. [8] conducted experimen-
Abbreviations: CVD, Chemical Vapor Deposition; ADI, Austempered ductile iron; tal work in dry cutting condition on austempered ductile iron
HRC, Rockwell hardness measured on C scale.
(ASTM grade 2). The cutting forces, chip characteristics and tool
Corresponding author.
wear were analyzed with PcBN cutting tools. The result revealed
E-mail address: manivelpsg@yahoo.co.in (D. Manivel).
http://dx.doi.org/10.1016/j.measurement.2016.06.055
0263-2241/ 2016 Elsevier Ltd. All rights reserved.
D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116 109
that the optimum cutting speed for better tool life and flank tool stainless steel by coated carbide cutting inserts. The cutting
wear is 150500 m/min. In another work Marcelo Vasconcelos de parameters were optimized for surface roughness, tool wear and
Carvalho et al. [3] investigated machinability of ADI (ASTM grades cutting force. The results revealed that the surface roughness and
2 and 3). It has been reported that minimum surface roughness and cutting force was mostly dominated by feed rate where as tool
higher tool wear observed when turning ADI grade 3 with higher wear was mostly dominated by the cutting speed. In another work,
tool nose radius. In another work, zel and Karpat [9] developed Palanikumar [17] optimized the drilling parameters for glass
the prediction model using regression and neural networks in hard fiber-reinforced plastics, composites by Taguchi method with grey
turning for surface roughness and tool wear by CBN inserts. Mini- relational study. The result indicated that feed rate was the most
mum surface roughness was obtained at high work piece hardness dominant parameter than the spindle speed. Munawar et al. [18]
with high cutting speed. Higher tool wear were obtained with studied the effect of cutting parameters in internal turning.
higher cutting speed at lower feed rate. Lowered feed rate gives Taguchi method was applied. Turning was carried out using L18
the good surface finish. orthogonal array. It was noted that low cutting speed and high feed
Hessainia et al. conducted experimental work on hard turning. rate developed minimum surface roughness.
The surface roughness was predicted with the use of cutting The cost of the CBN, PCBN and ceramic inserts are very high
parameters and tool vibrations. The mixed ceramic cutting tool compared to coated carbide inserts. Turning of hard material by
Al2O3/TiC was used. They found that feed rate was the most dom- coated carbide insert reduces the production cost. Some of the
inating factor than the tool vibration in affecting the surface rough- researcher used carbide inserts for turning of hard material as fol-
ness. [10]. Gunay and Yuce applied Taguchi for cutting conditions lows, Ucun and Aslantas [19] studied the effects cutting speed,
optimizing for surface roughness in turning of white cast iron (high depth of cut and feed rate on surface roughness in hard turning.
alloy). The hardness of the material was 50 HRC and 62 HRC. The The hard material used for experimental was bearing steel with
turning was carried out by ceramic and cubic boron nitride. The the grade of AISI 52100. The hard material was turned by coated
Taguchi orthogonal array L18 was used. Optimum cutting condi- carbide inserts. They observed that, in the hard turning process,
tions were calculated using the signal-to-noise (S/N) ratio based carbide cutting tools were not fit especially at high cutting speed.
on the-smaller-the-better approach. It was noted that cutting Asilturk and Akkus applied the Taguchi method in the hard turning
speed and feed rate was the dominant factor disturbing the surface process using coated carbide tools; the experimental result indi-
roughness [11]. Saini et al. [12] studied the Influence of cutting cated that the feed rate was the dominant factor effect on surface
parameters in hard turning. The AISI H11 tool steel material and roughness [20]. In another work, AISI D2 steel a hardness of 66 HRC
the ceramic inserts were selected for hard turning. The effect of was machined with coated carbide insert decreases in surface
cutting parameters were analyzed by response surface methodol- roughness with the increase in cutting speed and surface rough-
ogy on tool wear and surface roughness. They found that the depth ness increased with increased feed rate and depth of cut [2]. Chou
of cut had no effect on tool wear and surface roughness. Insert nose and Song have investigated the effect of tool nose radius on hard-
radius and cutting speed have the maximum effect on surface ened steel (AISI 52100) in hard turning; the better surface finish
roughness. In higher cutting speed the tool nose radius subjected was obtained in larger tool nose radius [21].
to maximum pressure and temperature results in increased tool The literature survey shows that CBN, PCBN, and ceramic tool
wear. More et al. [13] have been conducted the experiments and were widely used for turning of hardened materials, but the hard
compared the performance of CBNTiN coated and PCBN inserts turning using coated carbide insert is very limited. In this work,
on hardened AISI 4340 steel about HRC = 53. The performance of the coated carbide tool is used for turning the hard material. It is
cutting tools was compared in terms of tool wear, surface rough- a cost effective method. In this experimental work, the surface
ness, and cutting forces. The result indicated that PCBN insert roughness and tool wear only were considered. In this study, the
has better tool life, lower cutting force, and minimum surface effect of machining parameters such as nose radius, cutting speed,
roughness than the cBNTiN coated carbide inserts at given cutting feed rate and depth cut on the surface roughness and tool wear in
conditions. But the cBNTiN coated carbide tool has less cost than the turning of ADI (grade 3) with CVD coated carbide inserts was
the PCBN; therefore, it reduces the machining cost based on a sin- investigated. Experiments were conducted using Taguchis L18
gle cutting edge. orthogonal array. Analysis of variance (ANOVA) and S/N ratio were
The surface quality of the machined part is significant. The sur- used to analysis, cutting conditions (Nose radius, cutting tool, cut-
face quality depends on the surface finish. The good surface finish ting speed and feed rate) for surface roughness and tool wear.
increases fatigue strength, wear resistance and minimizes the cor- Analysis of variance (ANOVA) was used to find out the significant
rosion attack of the finished parts. The surface finish depends on factors. S/N ratio was used to calculate the optimum cutting factors
various parameters like material hardness, type of inserts, type of and their levels. In addition, the measured values were predicted
coating, heat transfer and cutting parameters. Therefore the opti- by using regression analysis. At the end, the confirmation experi-
mization of surface roughness and tool wear is important. The opti- ments were used to check the reliability of the developed models
mized parameter gives a good surface finish in the first machining reliability.
itself, increases the production rate and decreases the production
cost. Some of the following literature survey about optimization.
2. Experimental details
Mandal et al. [14] investigated that optimization of cutting param-
eter for tool flank wear using newly developed cutting tool Zirconia
The experimental work details, measurements, calculations and
Toughened Alumina (ZTA). Taguchi method and regression analy-
procedure for this experimental study are discussed in following
sis were used to optimize the cutting parameters. It has been
chapters.
observed that the tool wear was highly affected by the depth of
cut. Asiltrk and Neseli [15] conducted the experiment on austeni-
tic stainless steel. The cutting parameters were multi optimized by 2.1. Material
Taguchi method and response surface analysis. It found that the
feed rate has the most effect on surface roughness. It was most The work material used for experimental work is austempered
leading parameters affecting the surface roughness comparability ductile iron ASTM grade 3. The material is austenitized at 880 C
to other parameters. In another work Selvaraj et al. [16] applied for 2 h. After austenitizing the specimens were quenched in the
the Taguchi method for dry turning of nitrogen alloyed duplex salt bath of 50% of sodium nitrate (NaNO3) and 50% potassium
110 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116
inserts. The material 1 mm depth was removed to avoid oxidiza- Symbol Cutting parameter Unit Level 1 Level 2 Level 3
tion, decarburization and also to remove irregularities before test- r Nose Radius mm 0.8 0.4
ing. The cutting parameter ranges selected as per cutting tool V Cutting speed m/min 50 100 150
manufacturers recommendation, machine capability and litera- f Feed rate mm/rev 0.04 0.08 0.12
ture review [2,10,20]. The design involves the variation of four cut- d Depth of cut mm 0.2 0.3 0.4
Table 1
Chemical composition of ADI ASTM grade 3.
Table 3 cut on surface roughness and tool wear. This analysis was done
L18 orthogonal array. with 95% confidence level and 5% significance level. The ANOVA
S.N Nose radius Cutting speed Feed rate Depth of table consists of degrees of freedom, mean square, sum of square,
(mm) (m/min) (mm/rev) cut (mm) F ratio and % of contribution. In ANOVA, the F values of each control
1 1 1 1 1 factor were compared to determine the significance each control
2 1 1 2 2 factors. The higher F contribution, the higher the influence a factor
3 1 1 3 3 has in the result. F ratio is the ratio between mean square and the
4 1 2 1 1
5 1 2 2 2
mean square of the experimental error. Table 4 shows the ANOVA
6 1 2 3 3 results for surface roughness and tool wear. The percentage contri-
7 1 3 1 2 butions of the nose radius 14.6%, cutting speed 49.1%, feed rate
8 1 3 2 3 21.6% and depth of cut 9.7% on the surface roughness is found.
9 1 3 3 1
The cutting speed (49.1%) is the most predominant factor affecting
10 2 1 1 3
11 2 1 2 1 the surface roughness. From the ANOVA results, the percentage
12 2 1 3 2 contribution of the nose radius 5%, cutting speed 50.2%, feed rate
13 2 2 1 2 30.2% and depth cut 11.3% on the tool wear is found. The cutting
14 2 2 2 3 speed (50.2%) is the most predominant factor affecting the tool
15 2 2 3 1
wear. The percent of error for surface roughness 5% and tool wear
16 2 3 1 3
17 2 3 2 1 3.3% is considerably low.
18 2 3 3 2
4.2. Analysis of the S/N ratio for surface roughness (Ra) and tool wear
(Vb)
4.1. Analysis of variance (ANOVA) for surface roughness (Ra) and tool
wear (Vb) As per Taguchi technique, the experiments were conducted for
every combination of all the control factors. The surface roughness
Analysis of variance (ANOVA) can be useful in calculating the and tool wear measured in off line. Signal to noise ratios was cal-
influence of given input parameters and also used to interpret culated using the condition of smaller is the better. Table 5
experimental data. In this work, ANOVA was used to analyze the shows the values of observed S/N ratios for every combination of
effect of cutting tool nose radius, cutting speed, feed rate and depth surface roughness and tool wear. The average surface roughness
Start
Objective
Definition of Problem
Factors & Levels
OA
Experimental Design
Conduct Experiment
ANOVA & S/N ratio
Results analysis
Contour Plot
No
Results Validated?
Yes
End
Table 4
Analysis of variance results for surface roughness and tool wear.
Cutting parameter Degrees of freedom Sum of square Mean square F ratio P Contribution (%)
Surface roughness
Nose radius 1 0.11940 0.11940 29.46 0.000 14.6
Cutting speed 2 0.40080 0.20040 49.44 0.000 49.1
Feed 2 0.17605 0.08803 21.72 0.000 21.6
Depth of cut 2 0.07891 0.03946 9.73 0.005 9.7
Error 10 0.04053 0.00405 5
Total 17 0.81570 100
Tool wear
Nose radius 1 0.0001125 0.0001125 15.32 0.003 5
Cutting speed 2 0.0011254 0.0005627 76.62 0.000 50.2
Feed 2 0.0006774 0.0003387 46.12 0.000 30.2
Depth of cut 2 0.0002528 0.0001264 17.21 0.001 11.3
Error 10 0.0000734 0.0000073 3.3
Total 17 0.0022416 100
112 D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116
Table 5
The experimental layout for the L18 orthogonal array and cutting condition.
S.N Nose radius Cutting speed Feed rate Depth of cut Surface roughness S/N for Ra Tool wear S/N for (Vb)
(mm) (m/min) (mm/rev) (mm) (Ra) (lm) (dB) (Vb) (mm) (dB)
1 0.8 50 0.04 0.2 0.274 11.2450 0.137 17.2656
2 0.8 50 0.08 0.3 0.324 9.7891 0.124 18.1316
3 0.8 50 0.12 0.4 0.438 7.1705 0.118 18.5624
4 0.8 100 0.04 0.2 0.364 8.7780 0.126 17.9926
5 0.8 100 0.08 0.3 0.340 9.3704 0.110 19.1721
6 0.8 100 0.12 0.4 0.508 5.8827 0.104 19.6593
7 0.8 150 0.04 0.3 0.803 1.9057 0.134 17.4579
8 0.8 150 0.08 0.4 0.470 6.5580 0.132 17.5885
9 0.8 150 0.12 0.2 0.704 3.0485 0.124 18.1316
10 0.4 50 0.04 0.4 0.338 9.4217 0.128 17.8558
11 0.4 50 0.08 0.2 0.421 7.5144 0.125 18.0618
12 0.4 50 0.12 0.3 0.709 2.9871 0.108 19.3315
13 0.4 100 0.04 0.3 0.585 4.6569 0.104 19.6593
14 0.4 100 0.08 0.4 0.446 7.0133 0.112 19.0156
15 0.4 100 0.12 0.2 0.614 4.2366 0.104 19.6593
16 0.4 150 0.04 0.4 0.836 1.5559 0.132 17.5885
17 0.4 150 0.08 0.2 0.636 3.9309 0.135 17.3933
18 0.4 150 0.12 0.3 1.106 0.8751 0.116 18.7108
Mean 0.550889 5.788311 0.120722 18.40208
18.6
Surface roughness 18.3
1 7.083 8.021 6.261 6.459 18.0
Fig. 4. The effect of cutting parameters on average S/N ratio for tool wears.
Main Effects Plot for SN ratios
Data Means
Nose Radius Cutting Speed The optimal level for each control factor was calculated based on
8
highest S/N and shown in Table 6 as bolded values for surface
6 roughness and tool wear. According to this, the factors giving
Mean of SN ratios
values were calculated as 0.550889 lm and the average values of 4.3. Evaluation of experimental results
tool wear were calculated as 0.120722 mm during the end of the
turning tests. Similarly, the S/N ratio average values are calculated The variation in the surface roughness and flank wear were
for surface roughness is 5.788311 dB and the S/N ratio average obtained from experimental work as shown in Figs. 5 and 6 respec-
values are calculated for tool wear is 18.40208 dB. tively. The contour plot is a graphical representation of the rela-
The surface roughness and tool wear response table for S/N are tionships between three numeric variables in two dimensions.
shown in Table 6. According to the Taguchi, to get optimum cutting From the contour plot, larger tool nose radius had the better finish
condition the S/N ratio should have a maximum value. In than the smaller nose radius in hard turning. However, in flank
Figs. 3 and 4 and Table 6 indicates the level of S/N response and wear, smaller nose radius showed better flank wear resistant than
cutting parameters effect on surface roughness and tool wear. larger tool nose radius. In both the nose radius, surface roughness
D. Manivel, R. Gandhinathan / Measurement 93 (2016) 108116 113
Contour Plot of Surface Roughness vs Nose Radius, Cutting Speed Contour Plot of Tool Wear vs Nose Radius, Cutting Speed
0.8 0.8
Surface Tool Wear
Roughness < 0.105
< 0.4 0.105 0.115
0.7 0.7
0.4 0.6 0.115 0.125
Nose Radius
Nose Radius
0.5 0.5
0.4 0.4
50 75 100 125 150 50 75 100 125 150
Feed Rate
Feed Rate
0.09 0.09
0.8 1.0 > 0.135
0.08 > 1.0 0.08
0.07 0.07
0.06 0.06
0.05 0.05
0.04 0.04
50 75 100 125 150 50 75 100 125 150
Contour Plot of Surface Roughness vs DoC, Cutting Speed Contour Plot of Tool Wear vs Nose Radius, Feed Rate
0.8
0.40 Tool Wear
Surface
< 0.105
Roughness
0.105 0.115
< 0.4 0.7
0.35 0.115 0.125
Nose Radius
0.4 0.6
0.125 0.135
0.6 0.8
> 0.135
0.8 1.0
0.6
DoC
0.5
0.25
0.4
0.20 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12
50 75 100 125 150
Feed Rate
Cutting Speed
Contour Plot of Tool Wear vs DoC, Cutting Speed
Contour Plot of Surface Roughness vs Nose Radius, Feed Rate 0.40
Tool Wear
0.8 < 0.105
Surface
0.105 0.115
Roughness 0.35
0.115 0.125
< 0.4
0.7 0.125 0.135
0.4 0.6
> 0.135
Nose Radius
0.6 0.8
DoC
0.30
0.8 1.0
0.6 > 1.0
0.25
0.5
0.20
50 75 100 125 150
0.4 Cutting Speed
0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12
4.4. Surface roughness and tool wear prediction R-Sq 99:59% R-Sq adj 98:25%
In Figs. 7 and 8 show the relationship between the predicted
The relationship between a one dependent and several indepen-
values by regression and experimental values. There is good adher-
dent variables were calculated and analyzed by Regression analysis
ence between regression predicted values and experimental val-
[24]. Surface roughness and tool wear is dependant variables and
ues. The R2 value was obtained by full quadratic regression
the independent variables are tool nose radius, cutting speed, feed
model for surface roughness was found 90.90% and tool wear
rate and depth cut. Regression analysis was used to calculate pre-
was found 98.25%.
dictive equations for surface roughness and tool wear. The predic-
tive equations were prepared with full quadratic regression
models. The predictive equations for the full quadratic regression 4.5. Optimum surface roughness and tool wear prediction
of surface roughness are given in Eq. (4) and tool wear given in
Eq. (5): In Figs. 9 and 10 and Table 7 show the surface roughness and
tool wear values of the S/N means response. The optimized values
Quadratic regression equation for surface roughness for the surface roughness and tool wear were calculated as
0:198452 0:0890224 r 0:00646256V 15:1912 f r1v1f2d1 and r2v2f3d2 respectively. Eq. (6) was used for calcula-
2
7:23537d 0:0000482308V2 102:775 f
2 Main Effects Plot for Means
13:3059d 0:000558974 r V 0:0981571 r f Data Means
1:08926 r d 0:0155000V f 0:00660000 V d 0.8
Nose Radius Cutting Speed
8:49359 f d: 4 0.7
0.6
Mean of Means
R-Sq 97:86% R-Sq adj 90:90% 0.5
0.4
1 2 1 2 3
Quadratic regression equations for Tool wear : Feed Rate Depth of Cut
0.8
0:201192 0:0536327 r 0:00107598V 0:409075 f 0.7
2
0:470971 d 0:00000644872V2 2:52445 f 0.6
2 0.5
0:843816 d 0:0000878205r V 0:335391 r f 0.4
0:0192526r d 0:0000265152V f 0:000343939V d 1 2 3 1 2 3
0:0384615 f d: 5 Fig. 9. The effect of cutting parameters on means response characteristics for
surface roughness.
0.8 0.120
Mean of Means
0.115
0.7
0.110
0.6 1 2 1 2 3
0.5 Feed Rate Depth of Cut
0.130
0.4 0.125
0.3 0.120
0.2 0.115
2 4 6 8 10 12 14 16 18 0.110
Samples 1 2 3 1 2 3
Fig. 7. Comparison of the regression model and experimental results for surface Fig. 10. The effect of cutting parameters on means response characteristics for tool
roughness. wear.
0.14 Table 7
Variable
Predicted Tool Wear The effect of cutting parameters on means response table for surface roughness and
Actual Tool Wear tool wear.
0.13 Levels Control factors
Tool Wear
Table 8
Comparison of predicted and confirmation test result.
tion of optimized surface roughness and Eq. (7) used for calculation ting parameters. Based on the ANOVA and S/N ratio analysis, the
of optimized tool wear. following conclusions can be made
where the F-ratio required for 95 % CI, F (a, 1, fe), a is the significance In this work, it was found that the Taguchi method was success-
level = 0.05, fe is the error of degrees-of-freedom = 10, Vc is error fully used in the reduction of production cost and production time
variance = 0.00405, R is the confirmation experiments number of in the turning of ADI. The results obtained in this work can be used
replications = 3, Neff is effective no. of replication, N is total number as standards both academic research and industrial applications. In
of trails in the experiment = 18 and Tdof is total main degrees of future, the other factors could be considered like different coating
freedom = 7. F (0.05, 1, 10) = 4.9646 (from standard F table). Substi- materials, lubricants, and cutting tool geometry, all these factors
tuting the above values in Eqs. (8) and (9), we calculated that would affect on the surface roughness and tool wear.
Neff = 2.25 and CIRa = 0.0177 and CIVb = 0.0032. The predicted
optimal surface roughness is to be 0.176 0.125 lm and tool wear Acknowledgement
is to be 0.094 0.0053 mm at 95% confidence level.
The authors acknowledge with thanks to M/s Indoshell Cast
4.6. Confirmation test (Pvt) Limited, Coimbatore, India for providing castings, technical
ideas and help in this experimental work.
Table 8 shows the comparison of confirmation test results and
predicted results calculated by Taguchi and full quadratic regres-
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