Journal of Cleaner Production xxx (2014) 1e11

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Journal of Cleaner Production

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Multi-response optimization of MQL parameters using Taguchi-based

GRA in turning of difficult-to-cut alloy Haynes 25
Murat Sarıkaya a, *, Abdulkadir Güllü b
a
Department of Mechanical Engineering, Sinop University, 57030 Sinop, Turkey
b
Manufacturing Department, Technology Faculty, Gazi University, 06500 Ankara, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: In manufacturing industry, the effect of cutting fluids has been known on the health, environment and
Received 9 January 2014 productivity in machining operations such as turning, milling, drilling, etc. Minimum Quantity Lubri-
Received in revised form cation (MQL) is an effective tool to minimize the damage of cutting fluids on health and environment in
28 November 2014
cutting processes. Thus, optimal process parameters must be determined under MQL cooling/lubrication
Accepted 4 December 2014
Available online xxx
condition to determine the maximum productivity. This paper presents an approach for optimization of
machining parameters with multi-response outputs using design of experiment in turning. For experi-
mental design, tests were planned based on Taguchi's L9 orthogonal array. During the turning of cobalt
Keywords:
Minimum quantity lubrication
base super alloy Haynes 25 which is a difficult-to-cut material, process performance indicators such as
Multi-response optimization flank wear, notch wear and surface roughness were measured. The process parameters which are cutting
Grey relational analysis fluid (CFs), fluid flow rate (Q) and cutting speed (Vc) were simultaneously optimized by taking the multi-
Difficult-to-cut material response outputs by Taguchi based grey relational analysis (GRA) into consideration. Taguchi's signal to
Cleaner production noise ratio was applied with larger-the-better approach to obtain the best combination. Three mathe-
matical models were created using response surface regression methodology. According to the multi-
response optimization results, which were obtained from the largest signal to noise ratio of the grey
relational grade (GRG), the optimum combination was vegetable base cutting fluid, 180 mL/h fluid flow
rate and 30 m/min cutting speed to simultaneously minimize the tool wear patterns and surface
roughness. In addition, it was found out that the percentage improvement in GRG with the multiple
responses is 39.4%. It was clearly shown that the performance indicators are significantly improved using
this approach.
© 2014 Elsevier Ltd. All rights reserved.

1. Introduction
Super alloys have been developed to obtain the better strength-
to-weight ratio and they provide higher heat and corrosion resis-
tance compared to conventional alloys. The alloys are extensively
used in applications such as turbine and furnace parts, aerospace,
dental, orthopedic, heat-treating and chemical handling equip-
ment, and petroleum refining components where low thermal
conductivity, wear resistance, heat resistance, corrosion resistance
and high strength in working conditions under high temperature is
required (Ezugwu, 2007).
* Corresponding author.
E-mail addresses: msarikaya@sinop.edu.tr (M. Sarıkaya), agullu@gazi.edu.tr
(A. Güllü).
Super alloys are divided into three main groups: nickel (Ni), iron
(Fe) and cobalt (Co) based super alloys. Co-based super alloys are
employed widely in practices because of wear, corrosion, and heat
resistance properties. In the structure of Co-based super alloys,
there are significant amounts of cobalt, nickel, chrome and tung-
sten. For example, Stellite, Haynes 188 and Haynes 25 are the most
commonly used Co-based super alloys. Co-based Haynes 25 alloy
collects many excellent properties such as: high-temperature
strength with good resistance to oxidizing environments up to
980
C for prolonged exposures, and excellent resistance to sulfi-
dation. Co-based Haynes 25 alloy has been utilized by aerospace
and military industry, commercial gas turbine engines and bearing
material for both balls and races (Haynes, 2004; Tungaloy).
Turning operation is one of the most common methods of metal
cutting to produce different components in machining operations.
General machining of super alloy materials or advanced engineer-
ing materials is more difficult compared to conventional steels, so

http://dx.doi.org/10.1016/j.jclepro.2014.12.020
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Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
2 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11
they are often expressed as difficult-to-machine alloy or difficult-
to-cut alloy. Some elements such as Co, Ni, Cr and Ti provide such
a high strength and corrosion resistance that these properties
prevent the machinability of super alloy. One of the major problems
is the heat generation at cutting region during machining of
difficult-to-cut alloys. The cutting needs more energy, so high
temperatures occur during the deformation process at the tool-chip
and tooleworkpiece interfaces. The low thermal conductivity of
Haynes 25 alloy (about 10 W/m
C) also causes to a substantial
increase in temperature at the cutting tool and the material during
cutting (Ezugwu, 2007, 2005). Machining process of the super alloy
brings two main problems. The first is a short tool life or rapid tool
wear due to the work hardening and attrition properties of the
super alloy. The second is poor surface quality of the machined
surface due to heat generation and plastic deformation (Aykut et al.,
2007). The simultaneous improvement or optimization of these
two criteria is very important for high efficiency in the machining
of super alloy.
Recently, various cutting fluids have been employed to replace
the “dry machining” in order to increase the machining perfor-
mance of difficult-to-cut alloys. Because the cutting fluids improve
the tool life and it generates a better surface quality, the efficiency
of cutting process increases significantly (Davim et al., 2007).
Despite these advantages of the cutting fluids, several negative
effects such as environmental pollution and health effects have
been discussed lately. Besides, the recycling of cutting fluids is
difficult and expensive (Dhar et al., 2006). In order to increase the
tool life and the surface quality, researchers have investigated the
machining processes by reducing the use of cutting fluids. With the
increasing requirements for environment-friendly production, new
methods like the use of MQL or even the complete suppression of
cutting fluids were being tested by manufacturers (Zhang et al.,
2012).
MQL is an option to the utilization of conventional metal cutting
fluids (MCFs) for cleaner production and worker health in
manufacturing industry. Conventional MCFs are implemented in
flood fashion to the cutting zone to spread the heat caused by the
friction of the machining process, MQL provides an alternative
method and implements an thin layer lubricant and diminishes the
friction and heat between the cutting insert and the material
(Skerlos et al., 2008).
The use of MQL provides an interesting opportunity in the
machining of hard materials (Zhang et al., 2012; Settineri et al.,
2008). Zhang et al. (2012) investigated the tool life and cutting
forces under dry and MQL conditions in milling of Inconel 718. The
experimental results showed that MQL with biodegradable vege-
table oil has satisfied the increasing demands for cleaner
manufacturing of Inconel 718. Kamata and Obikawa (2007) applied
the MQL in turning of Inconel 718, which is nickel-base super alloy,
with three different types of coated carbide tools. The study
revealed that there is the optimum air pressure life in finish-
turning of Inconel 718 with MQL. Hadad and Sadeghi (2013) stud-
ied the effects of the machining parameters on turning perfor-
mance such as machining forces, surface roughness and
temperature. The use of MQL improved the surface quality thanks
to the reduction of wear and damage at the tool tip. Sarikaya and
Gullu (2014) studied Taguchi design and response surface meth-
odology based analysis of machining parameters in CNC turning
under MQL. It was found out that cooling conditions are signifi-
cantly effective on the surface roughness. They reported that MQL is
an effective way to increase the machined surface quality for cut-
ting operations. Lawal et al. (2013) explored through the literature
the effect of lubrication techniques in machining processes. Their
surveys showed that MQL technique with vegetable oil-based
lubricant in machining processes provides an alternative to
Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
conventional cooling method which uses mineral-based lubricants
to minimize the environmental problems. Sharma and Sidhu (2014)
investigated the effects of dry and near dry machining (NDM) on
AISI D2 steel by using an environmental friendly vegetable oil as a
lubricant and to completely eliminate the mineral and petroleum
based harmful lubricants from turning processes. They suggested
NDM to avoid environmental harms and NDM can also help to
improve the desirable machinability characteristics up to a certain
extent. Sayuti et al. (2014) studied the novel uses of SiO2 nano-
lubrication system in hard turning process of hardened steel AISI
4140 for less tool wear, surface roughness and oil consumption.
Their work, which offered the excellent performance over pure oil
and drastic reduction in cutting oil consumption, has led to the
conclusion that MQL oil mixed with a nanoparticle additive is
feasible to augment the machining process. Emami et al. (2014)
investigated the MQL technique to minimize the amount of cut-
ting fluid and to simultaneously utilize ecologically friendly lubri-
cants in grinding processes. They reported that the MQL system
could be applied efficiently in the grinding processes, providing
environmentally friendly and technologically relevant gains in
cutting conditions.
Productivity in turning, when was defined as metal removal
rate, can be optimized with many different methods. Choosing the
right cutting tool and optimal cutting parameters for the machining
is important, but also the choice of cutting conditions is equally
critical. From the available literature, it was observed that MQL is a
good tool to increase the cutting productivity and to decrease the
negative effects on health and environment in machining opera-
tions. Thus, optimal process parameters must be determined under
MQL cooling/lubrication condition to determine the maximum
productivity in turning. This study focused on the optimal MQL
parameters considering the multiple quality characteristics such as
machined surface quality and cutting tool wear using Taguchi based
the Grey Relational Analysis.
Taguchi based the Grey Relational Analysis (GRA) offers a
different approach from the traditional mono-optimization for
multi-optimization processes. It was proposed by Deng (1989) to
measure the degree of approximation among the sequences with
the help of Grey Relational Grade. Recently, some researchers have
investigated the optimization of process parameters using Taguchi
based GRA. For example, Tzeng et al. (2009) reviewed the optimi-
zation of turning operations with multiple performance charac-
teristics using the Taguchi method and GRA. Kuram and Ozcelik
(2013) employed the Taguchi method and the GRA to multi-
optimize with multiple response outputs in the micro-milling.
Yan and Li (2013) applied the GRA to optimize the milling param-
eters for simultaneous optimization of the energy, production rate
and cutting quality. Lin (2004) implemented the Taguchi method
and the GRA to optimize the process parameters in turning oper-
ations. Caydas and Hascalik (2008) studied the GRA to determine
the optimum laser cutting parameters with multi-response out-
puts. Dabade (2013) made the multi-objective process optimization
with GRA to develop the surface integrity in turning of Al/SiCp
metal matrix composites.
As mentioned above, GRA and Taguchi method has been
employed quite successfully by researchers for experimental design
and multi-response optimization in engineering applications.
Therefore, this study applied a Taguchi L9 orthogonal array to plan
the experiments in turning of cobalt base super alloy Haynes 25.
The experimental design was organized for three parameters
including cutting fluid, fluid flow rate and cutting speed with three
levels for each factor. This study presented the multi-response
optimization of MQL parameters to simultaneously minimize the
tool wear and surface roughness using Taguchi based GRA in
turning of cobalt-based alloy Haynes 25. The GRA was then
 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11 3

employed to explain how the MQL parameters influence the quality Table 2
targets such as minimum tool wear and maximum surface quality. Mechanical properties of material.

Mathematical models were created to predict the results of Test temperature Ultimate tensile strength 0.2% Yield % Hardness
different input parameters using response surface regression. (
C) (MPa) (MPa) Elong (HB)
Additionally, analysis of variance (ANOVA) was conducted to Room 943 444 50 207
determine the effect of process parameters on the grey relational
grade.
Table 3
2. Experimental design Physical properties of material (Haynes 25) at room temperature (Davis, 2000).

Parameters and unit Value

2.1. Workpiece material, machine tool, and cutting tool 3
Density (g/cm ) 9.13
Thermal conductivity (W/m K) 9.4
Cobalt-based super alloy Haynes 25 (also known as alloy L-605) Specific heat (J/g K) 0.420
workpiece material was used in the turning experiments. The Dynamic modulus elasticity (Gpa) 225
material hardness of Haynes 25 is 207 HB. The chemical composi- Melting (
C) 1320e1410
tion, mechanical and physical properties of workpiece are pre-
sented in Tables 1e3, respectively. Dimension of the workpiece was
Ø75 mme200 mm. All the turning tests were performed by using a
Falco Fl-8 model (Taiwan) CNC lathe machine that is equipped with
a maximum spindle speed of 4800 rpm and a 15 kW drive motor.
The uncoated carbide (H13-A), type: SNMG 12 04 08-QM tool insert
and PSBNR 2020K-12 tool holder assembly produced by Sandvik
were employed as a main tool arrangement with tool geometry as
follows: rake angle: 6
which is negative; clearance angle: 0
;
major edge cutting angle: 75
; cutting edge inclination angle: 6

and nose radius: 0.8 mm. The same type and a new cutting insert
were utilized for each experimental parameter. Photograph of
experimental set-up is shown in Fig. 1.

2.2. Cutting conditions and design of experiment

MQL allows an aerosol spray, which is very minimum quantity,

with balanced mixture of lubricant and air to the cutting zone
(Skerlos et al., 2008). Cutting fluid in MQL system was mixed with
air through a nozzle and an air compressor at 6 bars and it was
transferred to the interface of workpiece-cutting tool as shown in Fig. 1. Photography of experimental setup.
Fig. 2. In turning experiments, three different types of lubricant
(mineral oil, mineral oil with synthetic ester and vegetable oil),
three different levels of lubricant flow rate (60, 120, 180 mL/h) and
three different levels of cutting speed (30, 40, 50 m/min) were
employed under MQL machining. In the turning experiments, a
constant feed rate, f ¼ 0.15 mm/rev, and a constant depth of cut,
ap ¼ 1 mm, were used. The values of process parameters were
selected from the manufacturer's handbook recommended and the
preliminary experiments for the tested material. In each experi-
ment, a constant volume chip on material, MRR ¼ 7500 mm3, was
removed. Overall the experimental conditions are given in Table 4.
According to a full factorial design, experimental design for three
parameters with their three levels requires twenty seven experi-
ments. Machining time increases and cost raises an increase in
process parameters or their levels. Taguchi's orthogonal array offers
an opportunity to reduce the number of test compared to con-
ventional design of experiment approach. In this study, according
to control factors and their levels in Table 4, Taguchi's L9 orthogonal
array (OA) was employed from the Minitab as shown in Table 5 for
design of experiment. It has nine rows and three columns. The rows
correspond to the number of tests; the columns correspond to the

Table 1
Chemical composition of material.

% Weight

C Co Cr Fe Ni P S Si W

0.10 Balance 20.3 1.58 10.20 <0.005 0.0008 0.01 14.7

Fig. 2. Nozzle position of MQL system in turning.

Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
4 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11

Table 4 (VBavg), the maximum flank wear (VBmax), and notch wear at the
Experimental conditions. depth-of-cut-line (VBnotch or VNmax). In this study, maximum flank
Item Description wear (VBmax), and notch wear (VNmax) were considered and these
Cutting insert Uncoated carbide, SNMG 120408-QM (S-15 grade)
measurements were kept on workpiece material until all experi-
Sandvik H13A quality ments in machining process and an average value of the wear were
Tool Holder PSBNR2020K12 calculated. The insert was removed from the tool-holder and wear
Working tool inclination angle: 6
, clearance angle: 0
, was accurately determined through a professional microscope.
geometry rake angle: 6
, major edge cutting angle: 75

nose radius: 0.8 mm
Process parameters 3. Results and discussion
Cutting speed (Vc) 30, 40, 50 m/min
Feed rate (f) 0.15 mm/rev 3.1. Evaluation of process parameters using 3D-surface plots on
Depth of cut (ap) 1 mm
responses
Material removal 7500 mm3
rate (MRR)
Cutting fluid (CFs) MQL condition Rapid tool wear is one of the most important problems in
Vegetable oil; viscosity at 40
C: 32 mm2/s, density at machining of difficult-to-cut materials since tool wear is extremely
20
C: 0.85 g/cm3, flash point: 201
C, effective on the tool life and surface quality during cutting pro-
Mineral oil with synthetic ester; viscosity: 25 mm2/s,
cesses. That is why; in this study tool wear was measured in turning
density: 0.835 g/cm3, flash point: 170
C
Mineral oil; viscosity at 40
C: 30 mm2/s, density at 15
C: of cobalt-based super alloy Haynes 25. Three parameters were
0.87 g/cm3, flash point: 200
C considered as inputs: cutting speed, lubrication type and lubrica-
Cutting fluid supply MQL cooling e air: 6 bar; flow rate: external nozzle. tion flow rate. Other process parameters like feed rate, cutting tool
Fluid flow rate (Q) 60, 120, 180 mL/h. material, nose radius, and depth of cut were not taken into account
in our experimental study to analyze the effect of MQL parameters
on experimental results better. Also, the effect of some parameters
Table 5 such as feed rate and depth of cut on tool wear and workpiece
Experimental design. surface quality has previously been studied under MQL cutting
Exp. no Coded values Actual Values condition by researchers (Sarıkaya and Güllü, 2014; Kaynak et al.,
A B C CFS Q (mL/h) Vc (m/min)
2013).
Fig. 3 indicates the types of tool wear which occurred under
1 1 1 1 Mineral (1) 60 30
MQL cutting condition in the turning of 30 m/min cutting speed,
2 1 2 2 Mineral (1) 120 40
3 1 3 3 Mineral (1) 180 50 60 mL/h lubrication flow rate using mineral base lubrication. In this
4 2 1 2 Synthetic (2) 60 40 cutting condition, three types of tool wear patterns emerged: (a)
5 2 2 3 Synthetic (2) 120 50 flank wear, (b) notch wear at the depth-of-cut-line, and (c) crater
6 2 3 1 Synthetic (2) 180 30 wear at the rake surface. The measurements presented in this
7 3 1 3 Vegetable (3) 60 50
8 3 2 1 Vegetable (3) 120 40
section correspond to VBmax and VNmax which stand for flank wear
9 3 3 2 Vegetable (3) 180 30 and notch wear, respectively. 3D surface plots were drawn with the
change of two parameters and with a fixed parameter to assess the
effects of process parameters on tool wear (VBmax and VNmax) and
process parameters with three levels. In this array, the first, second surface roughness (Ra). 3D surface plots for VBmax and VNmax and
and third columns represent the cutting fluid type, fluid flow rate Ra are illustrated in Figs. 4e6.
and cutting speed, respectively. The influence of machining parameters on the tool wear pattern
is illustrated in Figs. 4 and 5. Fig. 4(a) demonstrates that the
maximum flank wear tends to increase when there is an increase in
2.3. Measurement tools the cutting speed regardless of the type of the cutting fluid. This
result supports the existing literature of conventional machining
In machining process, surface roughness or surface quality is processes (Kaynak et al., 2013). As seen in Fig. 4(b), tool wear
one of the most important quality indicators. In present work, the decreased thanks to an increase in fluid flow rate during turning of
average values of surface roughness (Ra) were measured after each cobalt base super alloy Haynes 25. This case can be explained that
experiment. TIME TR 100 profilometer was conducted for Ra an application of cutting fluid reduces the friction coefficient at the
measurements. Before the measurements of surface roughness, interface of the tool-chip (Sharma et al., 2009). Fig. 4(c) illustrated
measuring instrument was previously been calibrated with a that a significant difference in variation of tool wear under each
known calibration block. Each surface was machined with a new cutting fluid was observed. Also, it was found out that the tool wear
cutting tool. After each experiment, measurements on the work- is lower in vegetable cutting fluid application as compared to other
piece were carried out. In all tests, the values of surface roughness cutting fluid. It has been reported that fully formulated vegetable
were measured on the different locations of workpiece to minimize base oil has highly chemical and physical properties and offers a
the deviation and then a mean value of the surface roughness was lower friction coefficient and excellent boundary and hydro-
calculated. dynamic lubrication on the workpiece surface in machining pro-
One of the most important issues is the rapid tool wear in cesses at cutting zone (Ozcelik et al., 2011).
machining of difficult-to-cut materials. Because tool wear is Fig. 5 presents the 3D surface plots for notch wear (VNmax).
extremely effective on the machining efficiency and workpiece Notch wear is the dominant failure mode affecting the cutting tool
surface quality. Therefore, according to the experimental conditions life in machining of most difficult-to-cut alloys (Ezugwu, 2007).
in Table 4, tool wear values were measured after removing the chip Preventing of notch wear is very difficult as it starts and increases
at 7500 mm3 metal removal rate (MRR) from workpiece material with growing negative effects on the quality of machined surface in
Haynes 25. machining processes (Ezugwu, 2005). However, notch wear can be
Three different criteria can be used to understand the extent of minimized through cooling and lubrification methods. Fig. 5(a)
tool wear in machining. These are the average width of flank wear shows the effect of cutting speed at different cutting fluids on the

Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11 5

Fig. 3. Wear patterns in MQL machining under mineral oil at 60 mL/h flow rate and 30 m/min cutting speed.

notch wear. It indicates that the rate of notch wear increases with
an increase in cutting speed. According to Fig. 5(b) and (c),
increasing of fluid flow rate and using of vegetable base cutting
fluid the notch wear can be minimized at the lower level of the
cutting speed in turning of cobalt base super alloy Haynes 25. This
result can be explained as follows: MQL, when used vegetable base
cutting fluid in high flow rate, provides the significant improve-
ment of the friction. Moreover, it allows a more effective lubrication
at the toolechip interface, which reduced the process temperature
through the high viscosity of vegetable base cutting fluid (Ozcelik
et al., 2011). So, minimum notch wear was determined by using
the vegetable base cutting fluid at lower the level of the cutting
speed and higher fluid flow rate.
The influence of the machining parameters on the surface
roughness is illustrated in Fig 6. Fig. 6(a) indicates the effect of
cutting speed at different cutting fluids on the surface roughness.
The surface roughness decreased with an increase in the cutting
speed. The surface roughness was found to be minimal with
vegetable cutting fluid at high cutting speed. An improvement in
surface quality was observed because the increasing temperature
by heat energy as a result of increasing energy consumption with
increasing cutting speed during the cutting processes made the
plastic deformation and chip flow easier. Also, with increasing of
cutting speed the built up edge (BUE) and built up layer (BUL)
decreased and tool wear was positively affected by decreasing BUE
and BUL so this situation leads to a reduction in surface roughness.
Depending on the increase in cutting speed, an improvement in the
surface quality are generally expected and in order to improve the
surface quality to increase the cutting speed is the most common
method in the literature (Suresh et al., 2012). Surface roughness
decreased with an increase in fluid flow rate (Fig. 6(b)). This case
tells that an application of cutting fluid reduces the friction coef-
ficient at the interface of the tool-chip. There are papers of an
attempt to entry coolant/lubricant at the tool-chip interface thanks

Fig. 4. 3D surface plots for effects of (a) cutting fluid and cutting speed; (b) fluid flow rate and cutting speed; and (c) cutting fluid and fluid flow rate on flank wear (VBmax).

Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
6 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11

Fig. 5. 3D surface plots for effects of (a) cutting fluid and cutting speed; (b) fluid flow rate and cutting speed; and (c) cutting fluid and fluid flow rate cut on notch wear (VNmax).

to modified cutting tools (Sharma et al., 2009). Fig. 6(c) shows the fluid type is a mineral oil free and chlorine free product for the
interaction effect between the cutting fluids and the flow rate on minimal quantity lubrication. It is a highly active lubricant, thanks
the surface roughness. The illustration presents that the surface to the polar structure of the molecules. A significant improvement
roughness decreased by using vegetable base cutting fluids and this in friction occurs owing to fatty acid content in vegetable base

Fig. 6. 3D surface plots for effects of (a) cutting fluid and cutting speed; (b) fluid flow rate and cutting speed; and (c) cutting fluid and fluid flow rate cut on surface roughness (Ra).

Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11
cutting fluid. Furthermore, there is a flow resistance due to the high
viscosity of this fluid, so it presents more effective lubrication at the
toolechip interface, which reduces the friction between the cutting
tool and workpiece (Ozcelik et al., 2011). Thus, minimum surface
roughness was determined by using the vegetable base cutting
fluid at higher level of the cutting speed and fluid flow rate.
3.2. Multi-response optimization using grey relational analysis
(GRA)
Mono response optimization is a common and popular method
to solve the problem for optimization approaches. But the method
cannot be used to obtain the best combination of machining pa-
rameters for multi-responses. To overcome this problem in the
present work, Taguchi based grey relational analysis (GRA) for
multi-responses optimization was proposed to simultaneously
minimize the value of tool wear (VBmax and VNmax) and surface
roughness (Ra) in turning of cobalt-based super alloy Haynes 25.
Taguchi based GRA is a statistical method to analyze of complex
multi-response systems.
The GRA is principally employed to perform a relational analysis
of the ambiguity of a system model and deficiency of information. It
can create discrete sequences for the correlation analysis of such
sequences with processing uncertainty, multi-factors and discrete
data. It is a measurement method to determine the degree of
approximation among the sequences with the help of grey rela-
tional grade (GRG). So, in this paper GRG was employed to deter-
mine the optimal combination of turning parameters that
minimize three responses such as VBmax, VNmax and Ra simulta-
neously. To achieve this goal, after the normalization of the
experimental results, GRG was determined to assess the multiple
responses. In the GRA, the first step is to perform the normalization
of experimental data to make the range within 0e1. This step is
called grey relational generating. According to the importance of
quality characteristics, this can be divided into three criteria for
optimization in GRA, namely “larger-the-better,” “smaller-the-
better,” and “nominal-the-best” (Deng, 1989).
If the expectancy is larger-the-better, then the normalized value
of grey relation can be described in the following equation:
p
 performed experiment design, Table 8 and Fig. 7 demonstrate that
xi ðpÞ  min x0i ðpÞ
xi ðpÞ ¼    
max x0i ðpÞ  min x0i ðpÞ
If the expectancy is nominal-the-better, then the normalized
value of grey relation can be described in the following equation:
 0  turning process parameters is summarized and given in Table 9.
x ðpÞ  OB
h   i   i
xi ðpÞ ¼ 1 
max max x0i p  OB; OB  min x0i p
here OB is target value.
In this paper, smaller the value of tool wear patterns and smaller
the surface roughness are desirable. Therefore, calculation method
of “smaller the better” was employed since minimization of the
VBmax, VNmax and Ra is intended. So, the smaller-the-better should
be described in the following equation:



max x0i ðpÞ  x0i p
xi ðpÞ ¼    
max x0i ðpÞ  min x0i ðpÞ
here xi(p) is the value after grey relational generation, maxðx0i ðpÞÞ
and minðx0i ðpÞÞ are the largest and smallest values of x0i ðpÞ for the
pth response, respectively. The values of the VBmax, the VNmax and
Ra are set to be the reference sequence, p ¼ 1e3. The responses of
Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
7
nine tests are the comparability series x0i ðpÞ, i ¼ 1, 2, 3, …,9,
p ¼ 1e3. All sequences after application the data preprocessing
through Eq. (3) are shown in Table 6. Actually, in order to obtain the
better performance, the larger normalized results should be ex-
pected, therefore; best normalized result should be equal to one.
Further, the grey relational coefficient (xi(p)) is assigned to explain
the relation between desirable and real experimental normalized
data. Grey relational coefficient is defined as follows:
Dmin þ zDmax
xi ðpÞ ¼ (4)
D0i ðpÞ þ zDmax
 
here, D0i ðpÞ ¼ x*0 ðpÞ  x*i ðpÞ ¼ difference of the absolute value
between x0(p) and xi(p), Dmin and Dmax are respectively the mini-
mum and maximum values of the absolute differences of all
comparing sequences. z is the distinguishing or identification co-
efficient, and its value lies between 0 and 1, z ε [0,1], the aim of
which is to weaken the influence of Dmax when it gets too big and
besides enlarges the difference significance of relational coefficient.
Generally, the distinguishing coefficient is assumed as 0.5 to fit the
practical requirements. Therefore, in the present study, z was taken
as 0.5. The grey relational coefficients calculated using Eq. (4) and
Table 7 listed these coefficients. Then, grey relational coefficient
GRG expresses the level of correlation between the reference and
comparability sequences. GRG is a weighted sum of the Grey rela-
tional coefficients, and is calculated as follows:
1X n
gi ¼ xðpÞ (5)
n p¼1
here n is the number of performance characteristics (in this paper n
is 3).
The higher value of GRG is taken into consideration as the
stronger relational degree between the ideal normalized value and
the experimental value. Thus, the higher relational grade indicates
that the corresponding process parameter combination is closer to
the optimal.
In the last step of GRA, Table 8, which was calculated using Eq.
(5), identified as the highest GRG in the first order. According to the
(1) the turning parameters setting of 8 (test no. 8) has the highest GRG.
Thus, the eighth experiment gives the best multi-performance
characteristics among the other experiments to determine the
simultaneous minimum tool wear and minimum surface rough-
ness. In addition, the average of the GRG for each level of the
Furthermore, the total average of the Grey relational grade for the 9
(2)
test is calculated to be 0.6012 as shown in Table 9.
Signal to noise (often abbreviated S/N) ratio was employed by
Taguchi method for measuring the variations of the experimental
design. The term “signal” offers the desirable effect for the
Table 6
Normalized values.
Experiment no VNmax VBmax Ra
1 0.586 0.615 0.000
(3) 2 0.485 0.487 0.721
3 0.374 0.295 0.988
4 0.505 0.436 0.477
5 0.404 0.295 0.942
6 0.717 0.718 0.419
7 0.000 0.000 1.000
8 1.000 1.000 0.337
9 0.859 0.936 0.651
8 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11

" !#
Table 7
1 Xn
1
Grey relational coefficient. S=N ¼ 10 log10 2
(6)
n y
i¼1 i
Experiment no. VNmax VBmax Ra

1 0.547 0.565 0.333 In Eq. (6), yi is the ith measured test results in a run/row and n
2 0.493 0.494 0.642 explains the number of measurements in each test trial/row. Note
3 0.444 0.415 0.977 that the target value of 1/y is 0 in the larger-the-better
4 0.503 0.470 0.489
5 0.456 0.415 0.896
characteristics.
6 0.639 0.639 0.462 S/N ratios of the multiple quality characteristics were calculated
7 0.333 0.333 1.000 by using Eq. (6) and were listed in Table 8. Highest S/N ratio gives
8 1.000 1.000 0.430 the best result. As seen in Fig. 8, in the highest S/N ratio of GRG, the
9 0.780 0.886 0.589
optimal parametric combination was found as CFs (level 3) e Q
(level 3) e Vc (level 1) whose details are below:

Table 8 Cutting fluid type: Vegetable base cutting fluid

GRG, S/N ratio and its orders.
Experiment no Grade
1 0.482
2 0.543
3 0.612
4 0.487
5 0.589
6 0.580
7 0.556
8 0.810
9 0.752
Fluid flow rate: 180 mL/h
S/N ratio Orders Cutting speed: 30 m/min
6.341 9
5.309 7
4.264 3 3.3. ANOVA for grey relational grade
6.249 8
4.597 4
ANOVA is a statistical method used to detect the individual in-
4.729 5
5.105 6 teractions of all the control factors in the experimental results. The
1.830 1 significant machining parameters were identified with the help of
2.479 2 the analysis of variance (ANOVA). ANOVA analysis was performed
with a 95% confidence level and 5% significance level. F values of the
control factors indicated the significance of control factors with
ANOVA analysis. The percentage contribution of each parameter is
shown in the last column of the ANOVA table. This column proves
the influence rate of control factors on the results.
As listed in Table 10, ANOVA analysis was carried out to see the
effects of the experimental parameters on the result of the multiple
performance characteristics. The results of the ANOVA in Table 10
indicated that cutting fluid, fluid flow rate and cutting speed
influenced the GRG values with %49.5, %38.9 and %2.5 respectively.
Therefore, cutting fluid (factor A) was the most significant factor
affecting the GRG values. Another interesting finding deduced from
ANOVA table is that the cutting fluid, fluid flow rate and cutting
speed had no statistically significance on the GRG values at the
reliability level of 95%, because the P value results are higher than
0.05.

3.4. Response surface regression based modeling

Fig. 7. Grey relational grade and its S/N ratio. Response surface methodology was conducted to model and
analyze several variables, which have a relation between an output
parameter and one or more input parameters. The test results were
responses and the term “noise” offers the undesirable effect for the
responses. Thus, maximum S/N ratio gives the optimum results for
the responses. There are three different ways of calculation of S/N
ratios: nominal-is-best, smaller-the-better and larger-the-better.
In this section, the larger-the-better S/N quality characteristic
was used to obtain the optimal combination for multi-response
optimization because higher GRG was desirable. Larger-the-better
approach for higher GRG is defined as follows:

Table 9
Response table for GRG. Bold values represent the optimum level.

Symbol Parameter Grey relational grade

Level 1 Level 2 Level 3 Delta Rank

A Cutting fluid 0.5457 0.5520 0.7060 0.1603 1

B Flow rate 0.5083 0.6473 0.6480 0.1397 2
C Cutting speed 0.6240 0.5940 0.5857 0.0383 3

Total average value of the grey relational grade ¼ 0.6012. Fig. 8. Mean of S/N ratios for Grey relational grade.

Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11 9

Table 10 figures, the residuals can be judged as normally distributed;

ANOVA analysis for GRG. therefore, models proposed (VBmax, VNmax and Ra) were adequate.
Factors Degree of Sum of Mean of F ratio, P Contribution A numerical method was also used to check the mathematical
freedom DF squares SS squares MS a ¼ 0.05 (%) models employing the coefficient of determination which is R2. R2
CFs 2 0.049463 0.024731 5.49 0.154 49.5 shows how much independent variables effect the dependent
Q 2 0.038828 0.019414 4.31 0.188 38.9 variables.
Vc 2 0.002439 0.001219 0.27 0.787 2.5 R2 was calculated as in Eq. (12):
Error 2 0.009004 0.004502 9.1
Total 8 0.099734 100
SSresidual
R2 ¼ 1  (12)
SSmodel þ SSresidual

utilized to create the mathematical models with help of the
response surface methodology (RSM). In the present work, Minitab
16 was utilized to compute. In order to investigate the effect of the
turning parameters on the responses, a second order response
surface model fits into the following Eq. (7):
y ¼ b0 þ b1 $x1 þ b2 $x2 þ b3 $x3 þ b4 $x1 $x2 þ b5 $x1 $x3
þ b6 $x2 $x3 þ b7 $x21 þ b8 $x22 þ b9 $x23
where SSmodel is the sum of the squares of the model and SSresidual is
the sum of the squares of the residual. The response surface models
were developed with values of R2 higher than 0.8, say 0.9969,
0.9977 and 0.9877 for VBmax, VNmax and Ra, respectively. The R2
values in this work are high and close to 1 which are desirable.
Therefore, results from the coefficients of determination (R2) indi-
cated that mathematical models can successfully be applicable to
predict the responses.
(7)

where ‘y’ is the corresponding response, and x1, x2 and x3 are the
3.5. Confirmation experiments
value of the turning parameter. The term b is the regression coef-
ficient. The second order model can be defined as a function of the
In the final step of Taguchi based GRA, confirmation experi-
process parameters like cutting fluid, which was respectively coded
ments of the control factors at optimal and random levels were
as 1, 2 and 3 for mineral, synthetic and vegetable base cutting fluid,
employed to verify the accuracy of optimization and to determine
flow rate and cutting speed for responses. From Eq. (8) the rela-
the improvement of responses. Also, confirmation experiments
tionship is defined between the responses and the turning pa-
were repeated three times. Therefore, the estimated grey relational
rameters as given below:
grade, namely gestimated, at the optimal level of the design param-
eters can be expressed as (Sahoo and Sahoo, 2013):
VBmax ; VNmax ; Ra ¼ b0 þ b1 $CFs þ b2 $Q þ b3 $VC þ b4 $CFS $Q
þ b5 $CFS $VC þ b6 $Q $Vc þ b7 $CFS2 þ b8 $Q 2 X
o
gestimated ¼ gm þ ðgi  gm Þ (13)
þ b9 $Vc2 i¼1

Mathematical models were established between the responses
and the turning parameters using the experimental results by
substituting the values in Eqs. (9)e(11).
Flank wear model (R2 ¼ 99.69%):
VBmax ¼ 0:133  0:0036*CFs þ 0:0004*Q  0:0031*VC
 0:0003*CFS $Q þ 0:0017*CFS *VC  0:0076*CFS2
2
Notch wear model (R ¼ 99.77%):
VNmax ¼ 0:1776  0:0506*CFs þ 0:0005*Q  0:0025*VC
 0:0003*CFS *Q þ 0:0021*CFS $VC  0:0003*CFS2
2
Surface roughness model (R ¼ 98.77%):
Ra ¼ 4:12 þ 0:1266*CFs  0:0137*Q  0:076*VC
þ 0:0063*CFS $VC þ 0:0002*Q *Vc  0:0833*CFS2
Graphical and numerical methods were carried out to validate
the models in this study. A graphical method was used to charac-
terize the content of residuals of the models. By examining of re-
siduals, the sufficiency of models was investigated. The residuals
are the difference between the respective measured response and
the predicted response and they are analyzed using normal prob-
ability plots of the residuals for models. If the residuals plot
approximately along a straight line, then the normality assumption
is satisfied. In the present work, the normal probability plots of the
residuals for the responses are shown in Fig. 9(aec). In these
(8)
where gestimated is the grey relational grade to predict the optimal
machining parameters, gm is the total average grey relational grade,
gi is the average grey relational grade at the optimal level, and o is
the number of main design parameters that significantly affect the
quality characteristics.
Table 11 indicates the comparison between the estimated grey
relational grade (0.7756) which was calculated by Eq. (13) and the
experimental value (0.821) which was obtained from the experi-
(9) ment at optimal level. According to Table 11, it was determined that
there is a good agreement between estimated value and experi-
mental value. It was found out that the improvement of grey
relational grade from initial factor combination (CFs2-Q2-Vc3) to
the optimal factor combination (CFs3-Q3-Vc1) was 0.232 and the
percentage improvement in Grey relational grade with the multiple
(10) responses was 39.4% and is well in agreement with the results from
literature. Multi-response optimization was carried out using
Taguchi based GRA by Sahoo and Sahoo (2013). It was showed that
the improvement of grey relational grade from initial parameter
combination to the optimal parameter combination is found to be
(11) 54.5% (0.3093*100/0.5667). Ranganathan and Senthilvelan (2011)
were achieved that use of the optimal machining parameter com-
bination improves the grey relation of turning quality from 0.708 to
0.9184 by 29.7% (0.2104*100/0.708). Pawade and Joshi (2011)
enhanced the improvement as 4.11% in the weighted grey rela-
tional grade using Taguchi and GRA. Satyanarayana et al. (2013)
optimized the quality indicators in high speed turning of Inconel
718 using Taguchi based GRA. It was revealed that there is an
improvement in grey relational grade from the initial parametric
combination to optimal parametric combination by 11.5%
(0.084042*100/0.72865). Therefore, it may be said that the multiple
performance indicators (flank wear, notch wear and surface

Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
10 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11

Fig. 9. Normal probability plot of the residuals for responses a) VBmax b) VNmax c) Ra.

Table 11
important when environmental and health issues are
Results of the confirmation experiment.
considered.
Initial cutting conditions Optimal cutting conditions  The results presented that flank wear at the nose region, notch
Prediction Experiment wear at the depth of cut line and crater wear at the rake face
Level CFs2-Q2-Vc3 CFs3-Q3-Vc1 CFs3-Q3-Vc1 occur under MQL in machining of difficult-to-cut alloy Haynes
VNmax 0.145 0.08 25.
VBmax 0.125 0.065  The application of Taguchi based GRA directly combines the
Ra 0.95 1.4 multiple quality responses (VBmax, VNmax, and Ra) into a single
GRG 0.589 0.7756 0.821
performance characteristic called grey relational grade. From
The improvement in GRG ¼ 0.232. the multi-response optimization results, which were obtained
The percentage improvement in GRG ¼ 39.4%.
from the largest S/N ratio of GRG, it was found out that the best
combination values were vegetable base cutting fluid, fluid flow
roughness) are significantly improved in turning of difficult-to-cut rate of 180 mL/h and cutting speed of 30 m/min to minimize the
material Haynes 25 together by using Taguchi based GRA. responses. They are the recommended levels of the controllable
parameters as the minimization of the responses is concurrently
considered.
4. Conclusion  The improvement of grey relational grade from initial parameter
combination, which was CFs2-Q2-Vc3, to the optimal parameter
This paper focused on the use of the Taguchi based GRA to combination, which was CFs3-Q3-Vc1, is found as 0.232 and is
optimize the MQL process parameters such as cutting fluid; fluid improved through the approach of Taguchi based GRA to opti-
flow rate and cutting speed with the multiple-performance char- mize the process parameter for multiple responses (surface
acteristics like tool wear patterns and surface roughness. GRA and roughness, notch wear and flank wear).
Taguchi's signal to noise ratio were used for multi-response opti-  It was discovered that the percentage improvement in GRG with
mization. Analysis of variance (ANOVA) was utilized to determine the multiple responses is 39.4%. It was clearly shown that the
the effect of factors on GRG. Response surface models with inter- performance indicators (flank wear, notch wear and surface
action were developed to formulate the responses. The analytical roughness) are significantly improved in turning of difficult-to-
results are summarized as follows: cut material Haynes 25 using Taguchi based GRA. This
improvement is significant compared to literature review.
 MQL parameters like cutting speed, cutting fluid and flow are  According to the results of ANOVA for GRG, the contribution
the significant factors affecting tool wear and surface roughness. percentage of input parameters is the cutting fluid, fluid flow
In order to improve the cutting efficiency, MQL parameters must rate and cutting speed, respectively. Therefore, the cutting fluid
be taken into consideration to obtain maximum productivity in is the most significant controlled factor on GRG for the turning
turning operations. operation under MQL when the minimization of the responses is
 One of the main results of this study is to use the vegetable base concurrently considered.
cutting fluid. The vegetable base cutting fluid is a mineral oil free  Mathematical models were developed by using the response
and chlorine free product for the MQL. This result is very surface regression based methodology to formulate the input

Please cite this article in press as: Sarıkaya, M., Güllü, A., Multi-response optimization of MQL parameters using Taguchi-based GRA in turning of
difficult-to-cut alloy Haynes 25, Journal of Cleaner Production (2014), http://dx.doi.org/10.1016/j.jclepro.2014.12.020
 M. Sarıkaya, A. Güllü / Journal of Cleaner Production xxx (2014) 1e11
parameters like cutting fluid, fluid flow rate and cutting speed to
the output parameters like VBmax, VNmax and Ra. It was found
out that response surface models could be used to predict re-
sponses due to high R2 result. It demonstrates high relationship
between the test results and predicted results. Further, the
normal probability plot of residual for responses shows that the
residuals fall on a straight line implying that the errors are
distributed normally. It is evident that the developed models are
very reliable.
Minimum quantity lubrication is a good tool in order to increase
the cutting productivity and to decrease the negative effects on
health and environment in machining operations. However, in
machining of the materials some parameters of MQL method are
still uncertain in literature. Future works may deal with analyzing
the effects of some additional variables, such as the location and
dimensions of nozzle, number of nozzles, the distance of nozzle
from the cutting zone, geometry of the nozzle in MQL technique
and tool nose radius, cutting tool material and machined materials
on turning, milling, drilling and grinding to investigate the
machinability characteristics.
Acknowledgments
This research was supported by the Scientific and Technological
Research Council of Turkey (TUBITAK), Project no 112M029. Thanks
TUBITAK for financial support.
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