Parametric Optimization of Cutting Tool Temperature in Internal Turning

PARAMETRIC EVALUATION OF
CUTTING TOOL FOR INTERNAL

TURNING PROCESS
Dissertation submitted to
Shri Ramdeobaba College of Engineering & Management, Nagpur
In partial fulfillment of requirement for the award of
Degree of
Master of Technology
In
HEAT POWER ENGINEERING
By
Mahesh B. Patil
Guide
Prof. Pranjali Deole
Department of Mechanical Engineering

Shri Ramdeobaba College of Engineering & Management, Nagpur 440 013
(An Autonomous Institute affiliated to Rashtrasant Tukdoji Maharaj Nagpur University Nagpur)
June 2016
SHRI RAMDEOBABA COLLEGE OF ENGINEERING & MANAGEMENT, NAGPUR
(An Autonomous Institute affiliated to Rashtrasant Tukdoji Maharaj Nagpur University Nagpur)
Department of Mechanical Engineering
CERTIFICATE
This is to certify that the Thesis on “Parametric Evaluation of Cutting

Tool for Internal Turning Process” is a bonafide work of Mahesh B. Patil
submitted to the Rashtrasant Tukdoji Maharaj Nagpur University, Nagpur in
partial fulfillment of the award of a Degree of Master of Technology, Heat Power
Engineering. It has been carried out at the Department of M e c h a n i c a l
Engineering, Shri Ramdeobaba College of Engineering and Management,
Nagpur during the academic year 2015-2016.
Date:
Place: Nagpur
Prof. Pranjali Deole Dr. M.M. Gupta

Project Guide M. Tech Coordinator
.
Dr. K.N. Agrawal Dr. R.S. Pande

H.O.D Principal
Department of R.C.O.E.M, Nagpur
Mechanical Engineering .
ii
DECLARATION
I, hereby declare that the thesis titled “Parametric Evaluation of
Cutting Tool for Internal Turning Process” submitted herein, has been
carried out in the Department of M e c h a n i c a l Engineering of Shri
Ramdeobaba College of Engineering & Management, Nagpur. The work
is original and has not been submitted earlier as a whole or part for
the award of any degree / diploma at this or any other institution /
University.
Date:
Place: Nagpur
(Signature)
______________
Mahesh B. Patil
(Roll No. )
iii
Approval Sheet
This thesis/ dissertation/ report entitled “Parametric Evaluation of Cutting

Tool for Internal Turning Process” by Mahesh B. Patil is approved for the
degree of Master of Technology in Heat Power Engineering.
Prof. Pranjali Deole Name and signature of External Examiner (s)

Project Guide
Dr. K.N. Agrawal

H.O.D.
Department of
Mechanical Engineering
Date:
Place: Nagpur
iv
Acknowledgement
With a profound feeling of immense gratitude and affection, I would like to

thank my Project guide Prof. Pranjali Deole for their continuous support, motivation,
enthusiasm & guidance. Their encouragement, supervision with constructive criticism
and confidence enabled me to complete this project.
I also wish to extend my reverences to Dr. K. N. Agrawal, Head o f Mechanical
Engineering Department, for motivating me to put my best efforts in this project
work.
I express my deep gratitude towards Dr. R.S. Pande, Principal for constant
motivation and providing necessary infrastructure.
I express my admirations for Dr. M.M. Gupta (M. Tech Coordinator) for his
valuable advice and support throughout this venture.
Finally, graceful thanks to family, friends, colleagues and everyone who has
directly or indirectly contributed to make this project a success.
Mahesh B. Patil
v
ABSTRACT
Internal turning is a basic machining operation, yet it presents its own set of
complexities. Due to the high shear and friction energies dissipated during a machining
operation the temperature in the primary and secondary zones are usually very high,
hence affect the shear deformation and tool wear. The importance of knowledge on the
temperature gradient and its distribution with in cutting zones resulting from changes in
the cutting conditions is well recognized due to sever effects on the tool and work piece
material.
In this project, internal turning was done on lathe machine with three different
work piece materials and an attempt was made to obtain minimum tool tip temperature
during machining by selecting the best combination of cutting speed, feed, and depth of
cut. The temperature values of tool tip are determined for three different work piece
materials which are EN31, EN9 and EN8 type of steel. The temperature at the tool tip
was determined, generated during internal turning machining process. Different
temperature values are determined by varying cutting parameters values. In this project,
determination of optimal machining parameters to obtained minimum temperature at
tool tip by using GA which is a most widely used optimization method. IR pyrometer is
used for measuring temperature at tool tip temperature. In this project the temperature
distribution on cutting tool was determined for internal turning process with the help of
finite element analysis. FEA is carried out by using ANSYS workbench 15. After
simulation the results obtained from FEA was compared with the experimental results.
ANOVA was used to identify the significant factors and their contribution in machining
process. Regression equation is developed to calculate tool tip temperature at different
work piece materials and tool materials.
From ANOVA it is found that depth of cut and spindle speed was found to be
the most significant factors affecting to increase tool tip temperature and feed rate is
least significant factor. Finite element simulation of cutting tool insert was done in this
project for find out temperature distribution of cutting tool. After comparing FEA
results with experimental results it was found that the percentage difference is not more
than 10 %. The percentage difference between experimental tool temperature and tool
temperature obtained from regression equation is less than 4%, which shows good
agreement of both results.
vi
Outline of Thesis
Chapter 1: This chapter includes the basic idea of the machining operations and their
types and also introduction of the Internal Turning operation and their types.
Chapter 2: The detailed Literature review related to the project concept is done in this
chapter and also for the finite element analysis, ANOVA technique and for Genetic
Algorithm.
Chapter 3: Information regarding to experimental set up and instruments or materials
used in experimentation is discuss in this chapter.
Chapter 4: This chapter shows the methodology of project and experimental results of
the project.
Chapter 5: Introduction of ANOVA technique and their results obtained for this project
is discuss and suggest the most significant factors for increase tool temperature.
Chapter 6: Introduction to Finite Element Analysis and their results are discuss in this
chapter. FEA shows the temperature distribution on cutting tool during machining
process.
Chapter 7: Genetic Algorithm one of the best optimization technique is discuss in this
chapter, which is used for optimization of cutting tool temperature.
Chapter 8: The Regression analysis is performed in this chapter this chapter. A
generalized correlation is developed for calculating tool temperature for different
experimental conditions.
Chapter 9: encompasses the results obtained from the analysis, experimentation is
discussed in this chapter. Results of optimization techniques and FEA for this project
are included in this chapter.
Chapter 10: shows that the conclusions are drawn on the basis of result obtained from
the experimentation, graphs and the analysis. Future scope for the further progress is
also included in this chapter.
vii
CONTENTS
Chapter Topic Page No.

Chapter 1 Introduction 1
1.1 Introduction 1
1.2 Machining Processes 1
1.3 Internal Operations 3
1.4 Introduction To Internal Turning Process 4
1.5 Factors Characterizing Internal Turning Process 5
1.6 Control Of Internal Turning Process 7
1.7 Summary 8
Chapter 2 Literature Review 9
2.1 Need Of Project 15
2.2 Objective Of The Project 16
Chapter 3 Experimental Setup 17
3.1 Lathe Machine 17
3.2 Tool used in Lathe Machine 17
3.3 Work piece materials 20
3.4 IR Pyrometer 22
Chapter 4 Project Methodology and Observations 24
4.1 Project Methodology 24
4.2 Observations 25
Chapter 5 Analysis Of Variance (ANOVA) 26
5.1 Design Of Experiment 26
5.2 Steps In Taguchi Methodology 28
5.3 Selection Of An Orthogonal Array 30
5.4 ANOVA Terms, Notations And Development 34
5.5 ANOVA Calculations 37
ANOVA Calculations for Tool Tip Temperature
5.6 38
with work Piece Material EN31
5.7 41
5.8 44
Chapter 6 Finite Element Analysis 47
6.1 Thermal Analysis 48
6.2 Heat Generation In Machining 48
6.3 Analysis Technique 50
6.4 Heat Transfer In Machining 50
6.5 Heat Effects 50
6.6 Finite Element Method In Thermal Analysis 51
viii
6.7 Steps In Finite Element Analysis 52
6.8 FEA Results 55
Chapter 7 Genetic Algorithm 58
7.1 Introduction To GA 58
7.2 Basic Concept 59
7.3 Working Principle 59
7.4 Steps For GA 63
7.5 Procedure for GA 63
7.6 Results with work piece material EN 31 64
Chapter 8 Regression Analysis 69
8.1 Identification of Dependent/Independent Variables 69
8.2 Dimensional Analysis 71
8.3 Mathematical Modeling 73
Comparison of Regression Results with
8.4 79
Experimental Results
Chapter 9 Results and Discussion 81
Chapter 10 Conclusion and Future Scope 83
10.1 Conclusions 83
10.2 Future Scope 84
List of Publication 85
References 86
Appendix 88
ix
List of Figures:
Serial Figure Page
Title of Figure
No. No. No.
1 Lathe Machine 3.1 17
2 Turning Tool 3.2 18
3 Internal Turning tool 3.3 18
4 Insert Geometry 3.4 20
5 Inserts 3.5 20
6 Work piece 3.6 22
7 IR Pyrometer 3.7 23
8 Block diagram of an IR pyrometer 3.8 23
10 Steps 1, 2 for generating orthogonal array 5.1 33
11 Steps 3, 4 for generating orthogonal array 5.2 33
12 L9 Orthogonal Array 5.3 33
14 Interaction plots for tool tip temperature with EN31 5.4 39
15 Main effect plots for Tool Tip Temperature with EN31 5.5 40
16 Interaction plots for Tool Tip Temperature with EN9 5.6 42
18 Interaction plots for Tool Tip Temperature with EN 8 5.8 45
13 Regions of heat generation in turning 6.1 49
20 Insert Geometry exposed to natural convection 6.2 54
21 Meshing of Insert geometry 6.3 54
22 Insert geometry with heat flux 6.4 54
Temperature distribution on cutting insert with work piece material
23 6.5 55
EN 31
24 6.6 56
EN 9
25 6.7 57
EN 8
26 Fitness graph for set of parameters after cross over with EN31 7.1 65
27 Fitness graph for set of parameters after Mutation with EN31 7.2 65
x
32 Comparison of regression results with experimental results 8.1 80
xi
List of Tables:
Serial Table Page
Title of Table
No. No. No.
1 Notations 3.1 19
2 Specifications of tool 3.2 20
3 Chemical Composition of EN 8 3.3 20
6 Cutting Parameters levels 4.1 25
7 Experimental Results 4.2 25
9 Cutting Parameters and their levels 5.1 31
10 Allotment priority 5.2 32
11 ANOVA table for Tool Tip Temperature with EN31 5.3 38
11 ANOVA table for Tool Tip Temperature with EN9 5.4 41
12 ANOVA table for Tool Tip Temperature With EN8 5.5 44
13 Input values of the FEA model for the cutting tool 6.1 52
Convective Heat Transfer Coefficient Values for
14 6.2 53
Natural Convection
15 Heat Flux Values For Each Level of Parameters 6.3 53
Comparative results obtained for tool insert with work
16 6.4 55
piece material EN 31
17 6.5 56
piece material EN 9
18 6.6 57
piece material EN 8
Results obtained by GA after Cross over for tool tip
19 7.1 64
temperature with EN31
Results obtained by GA after Mutation for tool tip
20 7.2 65
21 7.3 66
Results obtained by GA after Mutation for tool tip
22 7.4 66
23 7.5 67
24 Results obtained by GA after Mutation for tool tip 7.6 68
xii
25 Results Obtained By Genetic Algorithm 7.7 68

26 Dependent and Independent variables 8.1 70
Comparative results for tool tip temperature by
27 8.2 80
regression equation
Appendix:
Coded Parameters Values with Work piece Material
28 A-1 88
EN8
Results After Cross Over with Work piece Material
29 A-2 88
EN8
Output of Genetic Algorithm with Work piece Material
30 A-3 89
EN8
31 A-4 90
EN9
32 A-5 90
EN9
33 A-6 91
EN9
34 A-7 92
EN31
35 A-8 92
EN31
36 A-9 93
EN31
Experimental Parameters for Internal Turning
37 B-1 94
Operation
Other Operating Parameters for Internal Turning
38 B-2 95
Operation
Calculations of Log of Pi (π) Terms for Internal
39 B-3 96
Turning
Calculations of the Multipliers of LHS and Log of Pi
40 B-4 97
(π) in Terms of Equation
Calculations of the Multipliers of LHS and RSH in
41 B-5 98
Terms of Equation
xiii
NOMENCLATURES:
T Cutting Tool temperature (⁰C)

V Spindle Speed (RPS)
Doc Depth of cut (m)
Fr Feed Rate (m/rev)
Diw/p Internal Diameter of work piece (m)
Ktool Thermal conductivity of tool material (w/m k)
Kw/p Thermal conductivity of work piece material (w/m k)
Cptool Specific heat of tool material (J/kg k)
Cpw/p Specific heat of work piece material (J/kg k)
ρtool Density of tool material (kg/m3)

ρw/p Density of work piece material (kg/m3)
hair Convective heat transfer coefficient (w/m2k)
xiv
CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
Material removal processes are a group of manufacturing process in which
excess material is removed from the starting work piece so that the resulting shape is the
desired geometry. The excess material is removed in the form of small fragments called
chips and the process is referred to as machining. The body which removes the excess
material through direct mechanical contact is called cutting tool and the machine which
provides the necessary motions between the work piece and the tool is called machine
tool. Since material is removed in the form of chips, therefore the machining of a finite
area requires a continuous movement of the uncut portion towards the cutting at a
suitable rate. The relative motion between the tool and the work responsible for the
cutting action is called primary or cutting motion, and that responsible for gradually
advancing the uncut portion is called secondary or feed motion. The line generated by
the cutting motion is called generatrix, and the line followed during the feed motion is
called directrix.
1.2 MACHINING PROCESSES
Depending on the nature of the two relative motions during machining, various
types of surfaces can be produced. A linear generatrix and linear directrix will generate
a plane surface, like in shaping. A circular generatrix with generatrix plane parallel to
the directrix would give a plane surface, such as in milling and grinding. But a circular
generatrix with generatrix plane perpendicular to the directrix would generate a
cylindrical surface, such as in drilling and turning. Milling and grinding can have
complex directrices and can give a variety of surfaces, for example a helical directrix
can give a cylindrical surface. A circular generatrix means that rotational motion is
being imparted to either the cutting tool or the work piece. Hence various kinds of
machining processes can be developed by different kinds of generatices and directrices.
Some of the major machining processes are as follows:
1. Drilling: This is used to make a hole in a solid body. The tool usually has two cutting
edges, and the cutting motion is obtained by the rotation of the tool and feeding motion
1
is obtained by linear motion of the tool along its axis. The surface generated is an
internal cylindrical surface. Operations similar to drilling include reaming (finishing an
existing hole), boring (enlarging an existing hole) and hole milling (improving hole
geometry).
2. Shaping and planning: This is used to generate a plane surface. A single point
cutting tool reciprocates to give cutting motion, and thus is is an intermittent cutting
operation. In shaping, the work piece is small and is thus advanced perpendicular to
cutting direction after every tool reciprocation to give feed motion. In planning, the
work piece is much larger and hence feed motion is given to the tool.
3. Milling: This is a very versatile process and uses a rotary tool with multiple cutting
edges to remove material. It can produce plane, contoured, axisymmetric or complex
surfaces based on the feed motion imparted to the cutting tool and the form of the
cutting tool itself. Various kinds of milling processes exist such as slab milling, end
milling, face milling, form milling, slot milling and thread milling.
4. Turning: This is widely used for producing external and internal axisymmetric
surfaces. This requires a special machine called a lathe in which the work piece is held
and rotated to give cutting motion and a single point cutting tool is moved against the
work piece to provide feed motion. Turning generally refers to machining of external
surfaces and includes many operations such as straight turning, taper turning, step
turning, form turning, thread turning, facing, grooving and parting off. The internal
surfaces machining counterpart to turning is called boring and includes straight boring,
taper boring, counter boring, thread boring
5. Facing: - A single-point turning tool moves radially, along the end of the work piece,
removing a thin layer of material to provide a smooth flat surface. The depth of the face,
typically very small, may be machined in a single pass or may be reached by machining
at a smaller axial depth of cut and making multiple passes.
6. Grooving: - A single-point turning tool moves radially, into the side of the work
piece, cutting a groove equal in width to the cutting tool. Multiple cuts can be made to
2
form grooves larger than the tool width and special form tools can be used to create
grooves of varying geometries.
1.3 INTERNAL OPERATIONS
1. Internal turning: - A Internal turning tool enters the work piece axially and cuts
along an internal surface to form different features, such as steps, tapers,
chamfers, and contours. The Internal turning tool is a single-point cutting tool,
which can be set to cut the desired diameter by using an adjustable Internal
turning head. Internal turning is commonly performed after drilling a hole in
order to enlarge the diameter or obtain more precise dimensions.
2. Reaming: - A reamer enters the work piece axially through the end and enlarges
an existing hole to the diameter of the tool. Reaming removes a minimal amount
of material and is often performed after drilling to obtain both a more accurate
diameter and a smoother internal finish.
3. Tapping: - A tap enters the work piece axially through the end and cuts internal
threads into an existing hole. The existing hole is typically drilled by the
required tap drill size that will accommodate the desired tap.
The family of turning operations seems most fascinating as it gives a wide
variety of products by using only a single point cutting tool. Today, various
techniques are being used in machining to improve the dimensional and
geometrical accuracy of products. For instance, tool balancing reduces chatter
and improves surface finish and dimensional accuracy considerably. But in case
of turning, it is the work piece which needs balancing and this increases the
complexity of machining even further.
Another point to note is the significance of boring operation. Boring is said to be
the internal machining counterpart to turning as it is almost similar to turning as
both employ same machine, same fixtures and same tool movements. However,
in boring, the cutting tool is surrounded by the work piece, and thus it is much
more challenging than turning. Therefore, control of boring operation would be
more complicated as compared to other machining operations.
3
1.4 INTRODUCTION TO INTERNAL TURNING PROCESS
Internal turning is one of the most important machining operations. In this, a
pre-drilled, cast or pierced hole is enlarged to required size by using a single point
cutting tool. Internal turning operation serves the following purposes:
1. A hole of any size can be obtained by an internal turning tool (such as micro-
adjustable internal turning tool).
On the other hand, drills and reamers have standard and fixed diameters.
2. A hole of any required surface finish can be obtained by an internal turning tool by
adjusting machining parameters. In contrast, a reamer is required to finish a drilled hole.
3. During drilling of comparatively long holes, the tool tends to deviate and „walk-off‟
from a straight line. Internal turning can straighten such holes.
4. In lathe, internal turning can make the hole at the work piece center concentric with
the outside diameter.
As much as the internal turning operation is beneficial, it suffers from certain
limitations too. Following are challenges faced during internal turning:
1. Maximum bore depth depends on the length of the internal turning tool.
2. Slender tooling‟s are susceptible to cantilever deflection.
3. Tool clearance angle needs to be increased so that the tool flank may clear the
machined surface, but this reduces tool rigidity.
4. Less cutting speed/spindle speed has to be used compared to other machining

processes.
5. Evacuating chips from the machined bore is very difficult.
6. Surface of machined bore gets deteriorated due to rubbing of accumulated chips.
7. Inspection of machined surface is very difficult.
With its own tips, tricks, challenges and body of expertise, internal turning in
lathes is considered as an area of machining practice in its own right separate from
turning. Internal turning process will thus be seen in more detail.
4
1.4.1 Types of Internal Turning Operation:
Internal turning operations are divided into following types:
1. Single-edge cuts
2. Multi-edge cuts
3. Step-Internal turning
Single-edge Internal turning is usually applied for finishing operations and for
roughing and finishing in materials where chip control is demanding. A single-edge
Internal turning tool may also be a solution when machine power is a limiting factor.
Multi-edge Internal turning, involving two or three cutting edges, is employed
for roughing operations where metal removal rate is the first priority. High productivity
levels can be maintained by allowing two or three inserts, set at the same axial height,
each to machine at the recommended feed per tooth. This results in a high feed per
revolution through the hole.
Step-Internal turning is performed in roughing by a Internal turning tool having

the inserts set at different axial heights and diameters. This also improves chip control
in demanding materials with the different depths of cut of up to 1.0 or 1.5 times the
cutting edge length. Depths of cut of 0.5 times the cutting edge length can be divided
into smaller cuts, providing smaller chips. Reaming is a light finishing operation
performed with a multi edge tool giving high-precision holes. Very good surface finish
and close dimensional tolerance are achieved at high penetration rates. The pre-
machined hole needs to be within close limits and the radial depth of cut is small.
1.5 FACTORS CHARACTERIZING INTERNAL TURNING

PROCESS
Various factors characterize an internal turning process and control its outcome.
Following are some of the factors that characterize an internal turning process.
1.5.1. Machine tool

Internal turning can be carried out in machine tools such as milling machines,
horizontal boring machines, vertical boring machines, jig borers and lathes. In lathes, jig
borers and vertical boring machines, a cylindrical work piece is rotated to enlarge a pre-
5
existing hole at the center of the work piece. In other machines, a rotating internal
turning tool is fed into a clamped work piece to enlarge the pre-existing hole.
1.5.2. Cutting tool

Boring bars of various designs are used for internal turning. Some of these are
solid bars, boring bars with fixed insert pockets and boring bars with adjustable insert
holders (or insert cartridges). The boring bar material may be steel, alloy steel or solid
carbide. The tool body may have an internal duct for supplying coolant to the cutting
edge. The boring bar slenderness (or length to diameter ratio) must be kept preferably
below 4 so that material removal rate does not get significantly impaired while trying to
reduce tool deflection. The bar diameter must be carefully selected to balance tool
deflection and ease of chip evacuation.
1.5.3. Tool geometry:

A large clearance angle is used in internal turning to prevent the tool flank from
rubbing on the machined surface. Increasing rake angle reduces tangential cutting
forces, and also reduces support material below the cutting edge thereby reducing tool
strength. A small lead angle results in smaller cutting force in radial direction and larger
cutting force in axial direction. Thus, more force gets directed along the boring bar, but
then cutting forces get distributed over a shorter section of the cutting edge leading to
abrupt loading when tool engages with work piece. Chip breakers on the tool are
required in internal turning, otherwise long chips would get jammed in the bore.
However, this requires more power and can increase tool vibration. Chip breaking is
dependent on lead angle, nose radius, cutting speed, speed and depth of cut.
1.5.4 Cutting parameters:

The cutting speed, speed and depth of cut directly influence material removal
rate. Generally reduced feed and increased cutting speed increase chip length. Also,
since the tool edge has less base material for support, cutting speeds have to be reduced
in order to reduce cutting forces and prevent tool breakage. Increased cutting speeds
will also lead to increase in .tangential cutting forces, tool shank torsion and uneven
cutting depth, thereby deteriorating the bore form and geometry. However, at too low
cutting speeds, the shearing of work material does not progress without fracturing the
sheared portion, thus causing intermittent ruptures leading to discontinuous chips and
6
rough surface. Increased feed and depth of cut can lead to buckling and deflection of the
tool and increase the surface roughness. However, at too low depths of cut, the tool
edge is not able to shear the material. It digs into the material, thereby crushing and
hardening it. At too high depths of cut, the sheared material tends to have higher
temperature and stick to the tool causing a built up edge. The built up edge changes the
tool geometry and when enough material has stuck to the tool, it breaks off and gets
embedded in the work material leading to a very rough work surface. Low feeds
improve surface finish and tool life, but reduce material removal rate significantly.
1.6 CONTROL OF INTERNAL TURNING PROCESS

The outcome of an internal turning process is a bore satisfying the required
dimensional and geometrical accuracy at the least cost. The measurable responses in an
internal turning process include
1. Bore diameter
2. Bore surface finish
3. Bore roundness
4. Bore straightness
5. Bore taper
6. Tool wear
7. Tool vibration
8. Tool temperature
9. Power consumption
10. Acoustic emission
Several process parameters need to be controlled in order to improve the responses.

These factors include:
1. Work piece material
2. Work piece physical properties
3. Work piece metallurgical properties
4. Tool cutting speed
5. Tool feed
6. Depth of cut
7. Tool geometry
7
8. Tool slenderness
9. Tool material
10. Coolant type
11. Coolant concentration
12. Coolant pressure
1.7 SUMMARY
A process improvement project would consist of selecting and adjusting a
number of process parameters for improving one response. In this project work, three
parameters or factors are considered for controlling internal turning process:
1. Spindle speed
2. Feed rate
3. Depth of cut
8
CHAPTER 2
LITERATURE REVIEW
STUDY OF PARAMETRIC EVALUATION OF CUTTING

PARAMETERS USING ANOVA
Satish Chinchanikar [1] present work performance of coated carbide tool was
investigated considering the effect of work material hardness and cutting parameters
during turning of hardened AISI 4340 steel at different levels of hardness. The
correlations between the cutting parameters and performance measures like cutting
forces, surface roughness and tool tip temperature, were established by multiple linear
regression models. The correlation coefficients found close to 0.9, showed that the
developed models are reliable and could be used effectively for predicting the responses
within the domain of the cutting parameters. Highly significant and optimized
parameters were determined by performing an Analysis of Variance (ANOVA).
S.R.Das [2] used optimization methods in turning process, considered being a vital role
for continual improvement of output quality in product and process include modeling of
input-output and in process parameters relationship and determination of optimal
cutting conditions. This paper presents an optimal method of the cutting parameters
(cutting speed, depth of cut and feed rate) in dry turning of AISI D2 steel to achieve
minimum tool wear and low work price surface temperature. The experimental layout
was designed based on Taguchi L9 orthogonal array technique and analysis of variance
(ANOVA) was performed to identify the effect of cutting parameters on the response
variable. The results show that depth of cut and cutting speed is the most important
parameter influencing the tool wear. Similarly low work piece surface temperature was
obtained. The relationship between factors and performance measure were developed by
using multiple regression analysis.
Achyut K. Panda [3] In this study, Taguchi method is used to identify the factors and
their interactions that may affect the thermo-catalytic degradation of waste
polypropylene to liquid fuel in a batch reactor. The yield of liquid fuel in this process
was greatly influenced by factors such as temperature, catalyst concentration and acidity
of catalyst. By using orthogonal experimental design and analysis technique, the
performance of this process can be analyzed with more objective conclusion through
9
only a small number of simulation experiments. Analysis of variance (ANOVA) was
carried out to identify the significant factors affecting the response and the best possible
factor level combination was determined through. Finally, a regression model for yield
of liquid fuel from catalytic degradation of waste polypropylene has been developed, as
a function of process parameters. It was found that yield of liquid fuel in this process
were highly dependent on temperature followed by acidity of catalyst and catalyst
concentration.
Ramanuj Kumar et al, [4] This paper works deals with the cutting forces and cutting
temperature during turning of titanium alloy Ti-6Al-4Vwith PVD Tin coated tungsten
carbide insert under dry environment. The first order mathematical models are
developed using multiple regression analysis and optimized the process parameters
using counter plots. The model present high determination coefficient (R2=0.964 and
0.989 explaining 96.4% and 98.9% of the variability in the cutting forces and cutting
temperature, which indicates the goodness of fit for the model and the high significance
of the model. The developed mathematical model correlates the relationship of the
cutting force and temperature with the process parameters with good degree of
approximation. Cutting speed is found to be the most significant parameter on cutting
forces followed by feed. Similarly, for cutting temperature, feed is found to be the most
influencing parameter followed by cutting speed.
Milenko Sekulic et al, [5] Determination of optimal machining parameters is continuous

engineering task which goals are to reduce the production costs and to achieve the
desired product quality. This paper discusses the use of Taguchi‟s method for
optimizing the cutting parameters in turning for minimizing the tool-chip interface
temperature. The cutting temperature is a key factor which directly affects cutting tool
wear, workpiece surface integrity and machining precision. In this research work the
tool-chip interface temperature is measured experimentally during turning of Č1730
(EN C60) steel with cemented carbide inserts using a tool-work thermocouple
technique. The study shows that the Taguchi method is suitable for optimizing the
cutting parameters with the minimum number of experiments. From the analysis using
Taguchi‟s method, results indicate that among the all-significant parameters, cutting
speed is the most significant parameter. Results obtained from Taguchi method closely
match with ANOVA.
10
Rahul Bhatti et al, [6] Hard Turning is a technique can be used in machining the steel
with hardness greater than 45 HRC (hardness on the Rockwell test c-scale). We
consider AISI H11 as work piece and Multi-coated carbide TH1500 (CVD) as cutting
tool. For this experiment, the L9 Taguchi method is used. The Taguchi method is an
Experimental design technique, which is useful in reducing the number of experiments
dramatically by using an orthogonal array and also tries to minimize effects out of
control. During an investigation the cutting conditions for an experiment are Speed =
100, 120 & 140 m/min, Feed = 0.1, O.2 & O.3 rev/min , D.O.C = 0.2, 0.4, & 0.6 mm . It
is observed that the tool wear (flank wear) is mainly effected by the cutting speed is
found to be the most contributing factor with percentage contribution of 89.83% while
in case of surface roughness also the cutting speed is found to be the most contribution
factor with 67.11%. The optimized machining condition for minimizing tool wear from
Taguchi Method are: cutting speed 100 m/min, feed 0.20 mm/rev, depth of cut 0.60 mm
with an estimated flank wear 130 μm. The optimized machining condition for
minimizing tool wear from Taguchi Method is: cutting speed 120 m/min, feed 0.20
mm/rev, D.O.C 0.25mm with an estimated surface roughness of 0.86 μm. Also, CVD
Multi-coated carbide cutting tool inserts employed in current investigation have been
observed to be an economical alternative to costly CBN, PCBN, Ceramic tools, for
continuous hard turning application over the range of parameters selected for this study.
In future, the effect of varying in work piece hardness may also be investigated. The
Chips forms using the same material with CVD Multi-coated Carbide cutting tool
inserts may be carried out to improve machining performance.
K. Someswara Rao et al, [7] Niobium based super alloys are an unusual class of
metallic materials with an exceptional combination of high temperature strength,
toughness, and resistance to degradation in corrosive or oxidizing environments. The
focus of present work was to study the effect of cutting parameters – speed, feed and
depth of cut on the machinability of Niobium C-103 under dry machining condition
using response surface methodology (RSM)1. In present study various machinability
models were developed. This machinability models defined a functional relationship
between cutting variables and response (Cutting Temperature). Cutting levels for
experimentation was selected based on the cutting insert manufacturer
11
recommendations. The analysis shows that Cutting speed is the most evident factor for
cutting temperature.
STUDY OF THERMAL ANALYSIS OF CUTTING TOOL USING

FINITE ELEMENT METHOD
S.H.Rathod [8] find out, temperature at tool-tip interface is determined, generated in
high-speed machining operations. Specially, three different analyses are comparing to
an experimental measurement of temperature in machining process at slow speed,
medium speed and at high speed. In addition, three analyses are done of a High Speed
Steel and a carbide tip tool machining process at three different cutting speeds, in order
to compare to experimental results produce as apart of this study. An investigation of
heat generation in cutting tool is performed by varying cutting parameters at the suitable
geometry. The experimental results reveal that the main factors are responsible for
increasing cutting temperature are cutting speed (v), feed rate (f), and depth of cut (d),
respectively. It is also determined that change in cutting g speed and depth of cut has the
maximum effect on increasing cutting temperature. Various researches have been
undertaken in measuring the temperature generated during cutting operations.
Investigators made attempt to measure these cutting temperatures with various
techniques during machining. By varying various cutting parameters the effect of those
on temperature are compared with the experimental results and FEA results. After
comparison nearly 4% variation is found in between the results.
Sana J. Yaseen [9] estimate the heat generation during metal cutting processes affects
materials properties and the tool wear. Knowledge of the ways in which the cutting
conditions effect the temperature distribution is essential for the study of thermal effects
on tool tip temperature. Analyses of three-dimensional transient temperature
distributions in a metal cutting process using a finite element code the Deform 3-D was
presented in this paper. The effects of the rake angle, cutting speed, feed rate, tool and
work piece materials on the temperature and heat flux are studied. The results show that
increase in cutting speed and feed rate increases the cutting temperature while
increasing rake angle reduces the cutting temperature. Results indicated that, as cutting
speed increased from 103.2 to 250 m/min an increased in temperature equal to 21.9%
occurred. With a reduction in rake angle from 5o to -5o, temperature increased by
12
12.3%. As the feed rate increases from 0.16 mm/rev to 0.25mm/rev, the temperature
increases in a 13.82%.
Satish Chinchanikar [10] present context of sustainable manufacturing, investigation of

cutting temperature during machining is extremely valuable to address metal cutting
issues such as dimensional accuracy, surface finish and tool tip temperature. In this
study, average chip-tool interface temperature was investigated considering the effect of
cutting parameters and the type of coating (coated tools), namely, PVD applied single-
layer TiAlN and CVD-applied multi-layer TiCN/Al2O3/TiN during turning of hardened
steel. Mathematical model which can predict the average chip-tool interface temperature
was developed based on experimental observations which were obtained in the wide
range of cutting conditions. A calibration set-up based on tool-work thermocouple
principle was developed to correlate the emf (electro motive force) and the interface
temperature. R-squared value for the developed model found 0.9693, indicate that the
developed model is reliable and could be used effectively for predicting the interface
temperature within the domain of the cutting parameters for the given tool and work
material pair. Experimental observations indicate that the interface temperature is higher
for CVD-coated multi-layer coated tool in comparison to single-layer TiAlN, which get
affected mostly by cutting speed followed by feed. However, depth of cut has negligible
influence on interface temperature when using both the coated carbide tools.
J. E. JAM et al, [11] In this paper thermal contact conductance of the tool-chip interface
in the metal cutting process is determined using an inverse procedure. An orthogonal
cutting of the AISI 1045 steel is simulated by LS-DYNA finite element code.
Numerical simulation results of the orthogonal cutting process consisting of temperature
in the tool-chip interface and cutting forces are shown and compared with experimental
data reported in literature. Also, in this paper three dimensional thermal analysis of the
cutting tool is performed.
Asmaa A. Kavi [12] Temperature behavior for four alloys steel during turning process.
Parameters such as cutting speed, feed rate were changed to explore their effect on
temperature behavior. All alloys have a sever increasing temperature with increasing
feed rate, while it looks less sharp with increasing cutting speed.
13
Mohd Andai [13] Determination of maximum temperature and research of the heat
generation along the rake face of cutting tool is particular importance due to its
controlling influence on tool life and also the quality of the machining parts. The point
which is located nearest to the contact phenomena between the tool, the chip and the
work piece give higher temperature value rather than the other point at the rake face of
insert cutting tool.
L.B. Abhang et al, [14] In this study, the temperature generated on the cutting tool and
experimental methods for the measurement of temperatures are reviewed. Special
attention has been paid to tool- work thermocouple method and an experimental setup
fabricated to measure the temperature on the cutting tool and work piece junction during
metal cutting is described. With this method, the average temperature at the tool-chip
interface is measured. The output of the thermocouple is in the mill volt range and
measured by a digital milli- voltmeter.
STUDY OF GENETIC ALGORITHM FOR PARAMETER

OPTIMIZATION
Abdelouahhab Jabri et al, [15] In this paper we present a multi-optimization technique
based on genetic algorithms to search optimal cuttings parameters such as cutting depth,
feed rate and cutting speed of multi-pass turning processes. This paper presents a multi-
objective optimization of turning process. Multi-pass turning operation is considered in
this study and the objective was to select cutting parameters of turning operation
(cutting speed, feed rate and depth of cut) which minimizes simultaneously cutting cost
and used tool life subject to practical constraints.
Mir Asif Iquebal, [16] Genetic Algorithm (GA) is a calculus free optimization technique
based on principles of natural selection for reproduction and various evolutionary
operations such as crossover, and mutation. Various steps involved in carrying out
optimization through GA are described. Three applications, viz. finding maximum of a
mathematical function, obtaining estimates for a multiple linear regression model, and
fitting a nonlinear statistical model through GA procedure, are discussed. Finally,
results are compared to those obtained from standard (calculus based) solution
techniques.
14
M.Sanjeev kumar, (IJMER) [17] In this paper an attempt is made to use of genetic
algorithm to minimize the surface roughness by optimizing the depth of cut, feed rate
and cutting speeds. Obtained a optimum values of cutting parameters to achieve a
minimum surface roughness of tool.
Dusan Petkovic et al, [18] Optimization methods of machining processes are tools for
improving product quality and reducing cost and production time. Modern optimization
methods, among which genetic algorithms (GA) have been, used a lot during last two
decades. This paper describes the optimization of machining processes by using genetic
algorithms. Optimal parameters of machining (cutting speed and feed) were determined.
Also, minimal cost for the turning process was achieved.
2.1 NEED OF THE PROJECT:

During metal cutting, the magnitude of the temperature on the cutting edge is a
function of the cutting parameters. This temperature directly affects production;
therefore, increased research on the role of cutting temperatures can lead to improved
machining operations. Heat generated during machining is affected by many events,
including tool life, chip formation, surface quality, cutting forces, tool wear etc.
Maximum heat occurs at the cutting edge. Thus, machinability can be improved
by monitoring the cutting temperature of the tool. A large amount of heat is generated in
machining processes as well as in other processes in which deformation of the material
occurs. Heat is a parameter that strongly influences the tool performance during these
processes. Thus, there is need to maintain minimum tool tip temperature during
machining by selecting optimum parameters levels. In this study, optimum parameters
levels obtained by Genetic Algorithm. By maintaining tool tip temperature minimum
we can increases the tool life, reduce tool wear and achieve good surface finish.
Temperature distribution on cutting too insert was determined by using Finite Element
Analysis.
15
2.2 OBJECTIVE OF THE PROJECT:
1. To determine the minimum tool tip temperature by selecting the optimized

parameters.
2. To determine the temperature distribution on cutting tool insert by using FEA in
ANSYS.
3. To determine the significant parameters which effects to increase the tool tip
temperature significantly.
16
CHAPTER 3
EXPERIMENTAL SETUP
3.1 LATHE MACHINE:

The lathe machine which was used for the experimentation purpose is given below:
Figure 3.1 Lathe Machine
3.2 TOOLS USED IN LATHE MACHINE:

a) Turning tool
Turning is a machining process in which a cutting tool, typically a non-rotary tool
bit, describes a helical tool path by moving more or less linearly while the work
piece rotates. The tool's axes of movement may be literally a straight line, or they may
be along some set of curves or angles, but they are essentially linear (in the
nonmathematical sense). Usually the term "turning" is reserved for the generation
of external surfaces by this cutting action, whereas this same essential cutting action
when applied to internal surfaces (that is, holes, of one kind or another) is called
"boring". Thus the phrase "turning and boring" categorizes the larger family of
(essentially similar) processes. The cutting of faces on the work piece (that is, surfaces
perpendicular to its rotating axis), whether with a turning or boring tool, is called
"facing", and may be lumped into either category as a subset.
17
Tool Holder
Insert
Shim Figure 3.2: Turning Tool
b) Internal Turning tool

A internal turning tool is usually a modular tool, consisting of a basic holder,
adaptor and a cutting unit in the form of a cartridge, slide or fine boring unit. A fine
boring head holds a boring bar which is easily adjustable and a reamer has a tool shank
with a close pitch head with brazed blades. The tools are adjustable within a specific
diameter range.
Boring Bar
Insert
Figure 3.3: Internal Turning Tool
Dimple Bars:
 The minimum cutting diameter is from Φ10. 5°, 7°, 11° positive inserts.
 Excellent vibration resistance due to a light dimple head.
 L/d is 3 to 5 times the diameter (Carbide shank is 7 to 8 times the diameter).
18
F Type Boring Bars:
 The minimum cutting diameter is from Φ5.8. 11° positive insert.
 Screw-on type and Clamp-on type.
 L/d is 3 to 5 times the diameter.
 FSWL type is 7°positive insert.
c) Inserts
The inserts are used for machining of the material. There are two types of inserts
we have used 1-Turning inserts, 2-Boring inserts. Turning inserts were used for initial
facing and turning of the raw material. Turning inserts are TNMG 16 04 08-PM 4325,
boring inserts are CNMG 12 04 08-PM 4325.
For example 1:- CNMG 432
Table 3.1: Notations
C N M G 4 3 2
Clearance Groove /
Shape Tolerance Size (IC) Thickness Radius
Angle Hole
For example: CNMG 130501WP
The meaning of different designation is given below:
C=Diamond shape
N= 00 angle
M=Tolerance (corner point=0.002-0.005",thikness=0.005",inscribed circle=0.002-

0.005")
G=Chip breaker (cylindrical and double sided)
Width=13
Thickness=05
Radius (corner) =01
19
Table 3.2: Specification of insert
di (mm) S (mm) r (mm)
13 5 1
Figure 3.4: Insert geometry
CNMG TNMG
Figure 3.5: Inserts
3.3 WORK PIECES MATERIALS:

i. The work pieces selected for the experiment are EN8, EN9 and EN31.
Table 3.3: Chemical Composition of EN 8

Carbon % 0.36 – 0.44
Silicon % 0.1 – 0.4
Manganese % 0.6 – 1
Sulphur % 0.05 max
Phosphorous % 0.05 max
Hardness – 74.5 HRB

Application: EN 8 finds its application in crank shafts, automobile axle beams,
connecting rods, lightly stressed gears. It is generally used for moderately
stressed parts of motor vehicles and general engineering works.
20
ii. EN 9 Table 3.4 – Chemical Composition of EN 9
Carbon % 0.5 – 0.6
Silicon % 0.5 - 0.8
Manganese % 0.05 – 0.35
Sulphur % 0.04 max
Phosphorous % 0.04 max
Hardness – 70 HRB
Application: EN 9 finds its application in crank shafts, cylinders, gears,
sprockets. It is mainly used in machine parts which require moderate wear
resistance.
Table 3.5 – Chemical Composition of EN 31

iii. EN 31
Carbon % 0.9 – 1.2
Silicon % 0.3 – 0.75
Manganese % 0.1 – 0.35
Sulphur % 0.04
Phosphorous % 0.04
Chromium % 1 – 1.6
Hardness – 82 HRB
Application: EN 31 finds its application in ball and roller Bearings, spinning
tools, beading rolls, punches and pies.
21
Specifications:
Type: Hollow Shaft

Outer diameter: 110 mm
Inner Diameter: 80 mm
Length: 140 mm
Figure 3.6: Work piece
3.4 IR PYROMETER:
The cutting speeds used in experimentation made response times of the
temperature measurement devices an important criterion. The temperature measurement
devices also had to be robust and have a wide measurement range. The Pyrometers is
technical advances have made it possible today to measure not only high temperatures
but also temperatures far below freezing point from a distance and without making
contact with the object to be measured.
3.4.1 Pyrometer Types:
• Spectral band pyrometers
• Total band pyrometers
• Ratio Pyrometers (2 colour pyrometers)
• Disappearing filament optical pyrometer (portable)
• Infrared pyrometer
• Laser pyrometer
We use Optical Infrared Pyrometer, which work on very sophisticated
mechanism. This thermal device detect temperature of an object by reckoning the
emitted, reflected and transmitted energy by means of optical sensors & detectors and
show temperature reading on display panel. The temperature Range is 0º to 550º C.
3.4.2 Specification of IR Pyrometer:
• The temperature range is -50 to 550⁰C
• Accuracy: ± 2⁰C / ± 2%
• Up to 96 cm long it gives accurate readings.
22
Figure 3.7: IR Pyrometer
3.4.3 Construction and Operation of the Infrared Pyrometer:

A block diagram showing the general construction of an infrared pyrometer can
be seen in Figure 3.8. By use of input optics, the emitted object radiation was focused
onto an infrared detector. The detector generates a corresponding electrical signal which
is then amplified and may be used for further processing. Digital signal processing
transforms the signal into an output value proportional to the object temperature. The
temperature result is shown on a display. Consequently, the temperature of the
measured object is mainly generated in three steps:
(1) Transformation of the received infrared radiation into an electrical signal;
(2) Compensation of background radiation from pyrometer and object; and
(3) Linearization and output of temperature information.
Figure 3.8 Block diagram of an IR pyrometer.
23
CHAPTER 4
PROJECT METHODOLOGY AND OBSERVATIOS
4.1 PROJECT METHODOLOGY
Selection of cutting parameters
Experimentation on Lathe machine
ANOVA Analysis for suggesting

significant cutting parameters
Developed Regression equation

used in GA as objective function
Genetic Algorithm to find out

optimized cutting parameters
Finite element anlysis to find out temperature

distribution on cutting tool
comparision of FEA results with

Experimental result
Figure 4.4 Flow Chart of Project Methodology
24
4.2 OBSERVATIONS
The observation table includes the input and output factors of the internal
turning operation. Input factors are spindle speed, depth of cut, feed, and work piece
material. Output factor is tool tip temperature. Three work pieces materials were used
for the experimentation which are EN 8, EN 9, and EN 31 respectively. Tool tip
temperature was obtained by using IR pyrometer which is a non-contact type
temperature measuring instrument.
Table 4.1: Cutting parameters and levels
SR.NO. Spindle Speed Depth of cut Feed rate
(RPM) (mm) (mm/rev)
1 160 0.5 0.04
2 230 0.75 0.08
3 380 1 0.16
Observation Table:
Table 4.2: Observation table for tool tip temperature with different work piece
materials
SR.NO. Spindle Depth of Feed rate Temp. Temp. Temp.

speed cut (mm) (mm/rev) for EN31 for EN9 for EN8
(RPM) (⁰C) (⁰C) (⁰C)
1 160 0.5 0.04 70 50 48
2 160 0.75 0.08 90 83 77
3 160 1 0.16 115 90 88
4 230 0.5 0.08 95 86 85
5 230 0.75 0.16 130 99 95
6 230 1 0.04 165 160 155
7 380 0.5 0.16 120 101 98
8 380 0.75 0.04 141 130 122
9 380 1 0.08 180 171 165
25
CHAPTER 5
ANALYSIS OF VARIANCE (ANOVA)
5.1 DESIGN OF EXPERIMENT

An effective way to improve performance is to optimize the engineering designs
of products or processes by experimental means. A structured and economical way to
study projects whose performance depends on many factors is to apply the experimental
method known as "Design of Experiments". Design of Experiments (DOE) is a
powerful statistical technique introduced by R. A. Fisher in England in the 1920's to
study the effect of multiple variables simultaneously. As a researcher in Electronic
Control Laboratory in Japan, Dr. Genechi Taguchi carried out significant research with
DOE techniques in the late 1940's. He spent considerable effort to make this
experimental technique more user-friendly (easy to apply) and applied it to improve the
quality of manufactured products. Dr. Taguchi's standardized version of DOE, popularly
known as the Taguchi method or Taguchi approach, was introduced in the USA in the
early 1980's. Today it is one of the most effective quality building tools used by
engineers in all types of manufacturing activities. The DOE using Taguchi approach can
economically satisfy the needs of problem solving and product/process design
optimization projects.
DOE can be highly effective when one wish to:
a) Optimize product and process designs, study the effects of multiple factors (i.e.
- variables, parameters, ingredients, etc.) on the performance, and solve
production problems by objectively laying out the investigative experiments.
(Overall application goals).
b) To study Influence of individual factors on the performance and determine
which factor has more influence, which ones have less. One can also find out
which factor should have tighter tolerance and which tolerance should be
relaxed.
Further, the experimental data will allow determining:
1. How to substitute a less expensive part to get the same performance
improvement proposed
2. How one can determine which factor is causing most variations in the result
26
3. How one can set up process such that it is insensitive to the uncontrollable
factors
4. Which factors have more influence on the mean performance
5. How the uncontrollable factors affect the performance
Every experimenter has to plan and conduct experiments to obtain enough and relevant
data so that he can infer the science behind the observed phenomenon. The various
methods available are:
i. Trial-and-error approach
Performing a series of experiments each of which gives some understanding

requires making measurements after every experiment so that analysis of observed data
will allow him to decide what to do next - "Which parameters should be varied and by
how much". Many a times such series DOEs not progress much as negative results may
discourage or will not allow a selection of parameters which ought to be changed in the
next experiment. Therefore, such experimentation usually ends well before the number
of experimental runs reaches a double digit. The data is insufficient to draw any
significant conclusions and the main problem (of understanding the science) still
remains unsolved.
ii. TAGUCHI approach
Dr. Taguchi of Nippon Telephones and Telegraph Company, Japan has

developed a method based on “ORTHOGONAL ARRAY” experiments which gives
much reduced “variance” for the experiment with “optimum settings “of control
parameters. Thus the marriage of Design of Experiment with optimization of control
parameters to obtain best results is achieved in the Taguchi Method. "Orthogonal
Arrays" (OA) provide a set of well balanced (minimum) experiments and Dr. Taguchi's
Signal-to-Noise ratios (S/N), which are log functions of desired output, serve as
objective functions for optimization, help in data analysis and prediction of optimum
results.
27
5.1.2 Advantages of DOE Using Taguchi Approach
The application of DOE requires careful planning, prudent layout of the experiment,
and expert analysis of results. Thus, DOE using the Taguchi approach has become a
much more attractive tool to practicing engineers and scientists. Based on years of
research and applications Dr. Genechi Taguchi has standardized the methods for each of
these DOE application steps described below.
1. Experiment planning and problem formulation - Experiment planning guidelines
are consistent with modern work disciplines of working as teams. Consensus
decisions about experimental objectives and factors make the projects more
successful.
2. Experiment layout -High emphasis is put on cost and size of experiments... Size
of the experiment for a given number of factors and levels is standardized.
Approach and priority for column assignments are established. Clear guidelines
are available to deal with factors and interactions (interaction tables).
Uncontrollable factors are formally treated to reduce variation. Discrete
prescriptions for setting up test conditions under uncontrollable factors are
described. Guidelines for carrying out the experiments and number of samples to
be tested are defined.
3. Data analysis -Steps for analysis are standardized. Standard practice for
determination of the optimum is recommended. Guidelines for test of
significance and pooling are defined.
4. Interpretation of results - Clear guidelines about meaning of error term. Discrete
indicator about confirmation of results (Confidence interval).
5. Overall advantage - DOE using Taguchi approach attempts to improve quality
which is defined as the consistency of performance. Consistency is achieved
when variation is reduced. The prime motivation behind the Taguchi experiment
design technique is to achieve reduced variation (also known as ROBUST
DESIGN). This technique, therefore, is focused to attain the desired quality
objectives in all steps. The classical DOE DOEs not specifically address quality.
5.2 STEPS IN TAGUCHI METHODOLOGY:

Taguchi method is a scientifically disciplined mechanism for evaluating and
implementing improvements in products, processes, materials, equipment, and facilities.
28
These improvements are aimed at improving the desired characteristics and
simultaneously reducing the number of defects by studying the key variables controlling
the process and optimizing the procedures or design to yield the best results.
The method is applicable over a wide range of engineering fields that include
processes that manufacture raw materials, sub systems, products for professional and
consumer markets. In fact, the method can be applied to any process be it engineering
fabrication, computer-aided-design, banking and service sectors etc. Taguchi method is
useful for 'tuning' a given process for 'best' results.
Taguchi proposed a standard 8-step procedure for applying his method for optimizing
any process,
5.2.1 STEPS IN TAGUCHI METHODOLOGY:
STEP-1: Identify the main function, side effects, and failure mode
STEP-2: Identify the noise factors, testing conditions, and quality characteristics
STEP-3: Identify the objective function to be optimized
STEP-4: Identify the control factors and their levels
STEP-5: Select the orthogonal array matrix experiment
STEP-6: Conduct the matrix experiment
STEP-7: Analyze the data; predict the optimum levels and performance
STEP-8: Perform the verification experiment and plan the future action
Taguchi has tabulated 18 basic orthogonal arrays which are called "Standard
Orthogonal Arrays". In this Experimentation, we are using L9 (34) orthogonal array. An
array's name, for example, L9 (34) indicates 9 number of rows, 4 columns and 3 number
of levels in each column. The number of columns of an array indicates the maximum
number of factors or parameters, which can be considered using that array. Number of
rows represents the number of experiments to be carried out. In order that an array is a
viable choice, the number of rows must be at least equal to the degree of freedom
29
required for the case study. The degree of freedom of a factor is equal to the number of
levels of a factor minus one and for an interaction among factors; it is equal to
multiplication of degree of freedom of individual factors. Usually, the smallest possible
orthogonal array that meets the requirement of the case study is selected for the
experiment i.e. L9.
Normally, most of the designs do not take into consideration the effect of
interaction among the parameters. However, in real life situations such as the boring,
consideration of interaction effects is essential. Taguchi's orthogonal arrays have the
advantage of considering the interaction effects.
Hence to reduce the number of experiments, to reduce cost and time involved in
the experimentation, to study the interaction effects between different parameters in the
present work, it was decided to do the experimentation systematically by using Taguchi
Orthogonal array.
5.3 SELECTION OF AN ORTHOGONAL ARRAY

Selection of an orthogonal array depends on the selection of the number of
factors, their operating levels and their interactions. These aspects may be discussed
before selecting an array.
5.3.1 Selection of Input and Output Factors

The input factors set for the boring operation are as follows:
a) Spindle speed - The rotational speed of the spindle and the work piece in
revolutions per minute (RPM). The spindle speed is equal to the cutting speed
divided by the circumference of the work piece where the cut is being made. In
order to maintain a constant cutting speed, the spindle speed must vary based on
the diameter of the cut. If the spindle speed is held constant, then the cutting
speed will vary.
b) Feed rate - The speed of the cutting tool's movement relative to the work piece
as the tool makes a cut. The feed rate is measured in mm per revolution.
c) Depth of cut - The depth of the tool along the radius of the work piece as it
makes a cut, as in a turning or boring operation. A large depth of cut will require
a low feed rate, or else it will result in a high load on the tool and reduce the tool
tip temperature. Therefore, a feature is often machined in several steps as the
tool moves over at the depth of cut.
30
d) Work piece material – The work piece material used for the internal turning
operation were EN31, EN 8 AND EN 9.
The output factors set for the internal turning operation are as follows:
a) Temperature of tool tip: Temperature of tool tip is measured by using IR
pyrometer during operation.
5.3.2 Selection of Levels of Factors:

The nature of variation of response with respect to a particular factor helps in
deciding the level of the factor. If the variation is linear, a factor with two levels is
chosen. However, the levels shall be decided carefully if the variation is non-linear in
nature. The nature of variation, linear or non-linear, is judged by the previous machining
experience. In the present case of internal turning experiments, the levels of the factors
are decided to be THREE for all the four factors.
5.3.3 Values of Factors at the Respective Levels

The range of values of the factors is decided based on the preliminary set of
experiments which satisfy the desired responses. For instance, a range of spindle speed
between 160rpm and 380rpm is chosen. Table 5.1 summarizes the levels assigned to
various factors for the different parameters used for internal turning operation.
Table 5.1 Cutting Parameters and their levels
Sr. Factor Factor Levels

No. name symbol / unit
1 2 3
1 Spindle s , rpm 160 230 380
2 Depth
speed of Cut d , mm 0.5 0.75 1
3 Feed f, mm/rev 0.04 0.08 0.16
4 W/p - EN3 EN 9 EN 8
material 1
5.3.4 Allotment of Priorities to the Factors
As per the general rules of Design of Experiments, the first priority goes to a
factor which is most important or exhibits maximum effect on the response, but if some
factor is difficult to change during conduct of experiments, first priority should be given
to such a factor.
31
The priority for the remaining factors can be assigned depending on their effect
on the response. Depth of cut is the most important factor from this point of view.
Hence it was given second priority. The factors with their respective priority are listed
below and henceforth shall be referred to by the numbers designated to them.
Table 5.2 Allotment priority
Factor number as Name of the factor

per priority
1 Spindle Speed
2 Depth of cut
3 Feed
4 Work piece material
5.3.5 Orthogonal Array Plan for Experiments

The array depicted by L9 (34) from Taguchi's Standard Orthogonal Array has been
chosen for internal turning process. The reasons for the choice of the array are listed in
the following:
1) The array gives minimum number of experiments to be performed with factor
level chosen as per the requirement.
2) It DOEs not have any mixed levels.
3) It considers the necessary interaction effects.
5.3.6 Generation of Final Orthogonal Array

The final orthogonal array is generated by allotting the factors to the columns.
The allotment is done considering factor priorities and their interaction. The array is
generated by using MINITAB software.
32
Fig 5.1 Steps 1, 2 for generating orthogonal array
Fig 5.2 Steps 3, 4 for generating orthogonal array
Fig 5.3 L9 Orthogonal array
33
5.4 ANOVA TERMS, NOTATIONS AND DEVELOPMENT
In the analysis of variance many quantities such as degrees of freedom, sums of
square, mean square etc. are computed and organized in a standard tabular format.
These quantities and their interrelationships are defined below and their mathematical
development is presented.
1. Total number of trials [n] : - It is the addition of all the experimental trials
performed at different levels to determine the effect of different factors on the
response.
n  n1  n2  ...  nt
2. Degrees of freedom [DOF, f] :- It is a measure of the amount of information
that can be uniquely determined from a given set of data. DOF for data
concerning a factor equals one less than the number of levels. Thus a 3 level
factor has 2 DOF. The concept of DOF can be extended to the experiment. An
experiment with n trial and r repetitions of each trial has n X r trial runs. The
total DOF becomes:
ft  n  r 1
Similarly, the DOF for a sum of squares term is equal to the number of terms
used to compute the sum of squares and the DOF of the error term is given by
fe  ft  f A  f B  fC
3. Sum of Squares [St]: - The sum of squares is a measure of the deviation of the
experimental data from the mean value of the data. Summing each squared
deviation emphasizes the total deviation. Thus
n
S t   (Yi  Y ) 2
i 1
where Y is the average value of Yi.

Y represents the response or output.
4. Variance [V]:- Variance measures the distribution of the data about the mean of
the data. Since the data is representative of only a part of all possible data. DOF
rather than the number of observations is used in the calculation. It is the ratio of
sum of squares to the degrees of freedom.
St
Variance =
f
34
5. Variance Ratio [F]:- The variance ratio commonly called the F statistic, is the
ratio of variance due to the effect of a factor and variance due to the error term.
It is named after Sir Ronald A. Fisher. This ratio is used to measure the
significance of the factor under investigation with respect to the variance of all
the factors included in the error term. The F value obtained in the analysis is
compared with a value from standard F-tables for a given statistical level of
significance. The tables for various significance levels and different degrees of
freedom are available in most handbooks of statistics. To use the tables enter the
DOF of the numerator to determine the column and the DOF of the denominator
for the row. The intersection is the F value. When the computed F value is less
than the value determined from the F tables at the selected level of significance,
the factor DOEs not contribute to the sum of the squares within the confidence
level.
V
F 
Ve
6. Pure sum of squares:- When the product of error variance and degrees of
freedom is subtracted from the sum of squares expression, the remainder is
called the pure sum of squares.
7. Percent Contribution [P]:- The percent contribution for any factor is obtained
by
dividing the pure sum of squares for that factor by St and multiplying the result
by 100.
8. Confidence Intervals (C.I.): - The calculations shown in the ANOVA table are
only estimates of the population parameters. These statistics are dependent upon
the size of the sample being investigated. In statistics, it is therefore customary
to represent the values of a statistical parameter as a range within which it is
likely to fall, for a given level of confidence. This range is termed as the
confidence interval (C.I.). If the estimate of the mean value of a set of
observations is denoted by E(m), then the CI for the mean is given by:
F ( f1 , f 2 )  Ve
CI (m)  E (m)  where,
ne
35
F ( f1 , f 2 ) = Variance ratio for DOF f1 and f 2 at the level of significance.
f1 = DOF of mean (which always equals 1)
f 2 = DOF of error term.
Ve = Variance of error term.
ne = number of equivalent replications and is given by:
(Number of trials)
=
[DOF of mean (always 1) + DOF of the factors used in the estimate]
9. Pooling: When the contribution of a factor is small, the sum of squares for that
factor is combined with the error Se. This process of disregarding the
contribution of a selected factor and subsequently adjusting the contributions of
the other factor is known as Pooling. Pooling is usually accomplished by starting
with the smallest sum of squares and continuing with the ones having
successively larger effects. Pooling is recommended when a factor is determined
to be insignificant by performing test of significance against the error term at a
desired confidence level. A general guideline for when to pool is obtained by
comparing error DOF with the total factor DOF. No matter the effect on the
results, insignificant factors should always be pooled. The larger DOF for the
error term as a result of pooling increases the confidence level of the significant
factors.
10. R-square: R-squared is a statistical measure of how close the data are to the
fitted regression line. It is also known as the coefficient of determination, or the
coefficient of multiple determinations for multiple regressions.
The definition of R-squared is fairly straight-forward; it is the percentage of

the response variable variation that is explained by a linear model. Or:
R-squared = Explained variation / Total variation
1. R-squared is always between 0 and 100%.0% indicates that the model explains
none of the variability of the response data around its mean.
2. 100% indicates that the model explains all the variability of the response data
around its mean.
36
In general, the higher the R-squared, the better the model provides a decent fit to the
data.
11. Residuals
Residuals of a observed value is the difference between the observed value and
estimated function value.
Residual=Observed value – Fitted value
12. Regression Equation

Linear regression calculates an equation that minimizes the distance between the fitted
line and all of the data points. Technically, ordinary least squares (OLS) regression
minimizes the sum of the squared residuals. In general, a model fits the data well if the
differences between the observed values and the model's predicted values are small and
unbiased.
5.5 ANOVA CALCULATIONS:
ANOVA TERMS
DOF – Degree of freedom

SS- Sum of Squares
MS- Mean Square
F, P- Statistical Parameters of ANOVA
Percent Contribution – It shows how a input factor contributes to the output factor
The experimental results were analyzed with analysis of variance (ANOVA),

which used for identifying the factors significantly affecting the performance measures.
The results of the ANOVA with tool tip temperature are shown in Tables 5.3, 5.4 and
5.5 for work piece materials EN31, EN9 and EN8 respectively. This analysis was
carried out for significance level of α=0.1 i.e. for a confidence level of 90%. The
sources with a P-value less than 0.1 are considered to have a statistically significant
contribution to the performance measures. The last column of the tables shows the
percent contribution of significant source of the total variation and indicating the degree
of influence on the result. Where, DOF= degree of freedom, SS= sum of square, MS=
mean square.
37
5.6 ANOVA CALCULATIONS FOR TOOL TIP TEMPERATURE WITH
WORK PIECE MATERIAL EN31:
Table 5.3 ANOVA table for Tool Tip Temperature with EN31
Source DF Seq SS Adj SS Adj MS F P C%
V 2 4820.2 4820.2 2410.1 30.08 0.032 47.53
D 2 5133.6 5133.6 2566.8 32.04 0.030 50.62
F 2 26.9 26.9 13.4 0.17 0.856 0.2652
Error 2 160.2 160.2 80.1 1.5797
Total 8 10140.9
S R-sq. R-sq.(adj)
8.95048 98.42% 93.68%
5.6.1 Regression Equation:
T = - 19.6 - (0.149*V) + (107*D) + (1180*F) + (0.49*V*D) - (0.61*V*F) -

(1260*D*F) (5.1)
T= Tool Tip Temperature.
In Table 5.3, column 1 represents variable sources such as spindle speed, feed,
and depth of cut. In next columns degree of freedom (DF), adjusted sum of square (Adj
SS), adjusted mean of square (Adj MS), distribution (F) and probability (P) are
calculated respectively. The standard deviation of errors in modelling, S=8.95048, R2
=98.42% which indicates that model is capable of predicting response with higher
accuracy.
Table 5.3 shows the results of ANOVA for tool tip temperature with work piece
material EN 31. It is observed from the ANOVA table, the depth of cut (50.62%) is the
most significant cutting parameter followed by spindle speed (47.53%). However, feed
has least effect (0.26%) in controlling the tool tip temperature which is not statistically
significant. From the analysis of the Table 5.3 shows that P-value of cutting speed
(0.032) and depth of cut (0.03) which are less than 0.1. It means that spindle speed and
depth of cut influence significantly on tool tip temperature, T. The error contribution is
1.57% for tool tip temperature. As the percent contribution due to error is very small it
signifies that neither any important factor was omitted nor any high measurement error
was involved.
38
There are three assumptions in ANOVA analysis: normality, constant variance,
and independence. The normality plot of the residuals is used to check the normality of
the treatment data. If the distribution of residuals is normal, the plot will resemble a
straight line. Here, since the distribution of residuals is about the straight line, it
confirms the normality of treatment data. The constant variance assumption is checked
by the plot of residuals versus fitted values. If the plot of residual vs. fitted values
(treatment) DOEs not show any pattern, the constant variance assumption is satisfied.
The residuals v/s fitted value plot confirms the second assumption of constant variance
as there is no specific pattern can be detected. If the plot of residual vs. run order (time
order of data collection) DOEs not reveal any pattern, the independence assumption is
satisfied. Here as there is no specific pattern detected, the assumption of independence
is satisfied.
Figure 5.4 Interaction plots for tool tip temperature with EN31
When the effect of one factor depends on the level of the other factor, one can
use an interaction plot to visualize possible interactions. Parallel lines in an interaction
plot indicate no interaction. The greater is the difference in slope between the lines, the
higher the degree of interaction. However, the interaction plot DOEsn't alert you if the
interaction is statistically significant.
Since the factors are more than two, the matrix for interaction plot is shown in
fig.5.4. In this figure, the first row shows the interaction plot between spindle speed vs
feed and spindle speed vs depth of cut. From this we can conclude that there is
interaction between spindle speed and feed, depth of cut for different levels. The second
39
row shows the interaction plot between feed vs depth of cut. As different lines have
steep slope and intersecting each other, there is significant interaction.
Figure 5.5 Main effect plots for Tool Tip Temperature with EN31
When the line is horizontal (parallel to the x-axis), then there is no main effect.
Each level of the factor affects the response in the same way, and the response mean is
the same across all factor levels. When the line is not horizontal, then there is a main
effect. Different levels of the factor affect the response differently. The steeper is the
slope of the line, the greater the magnitude of the main effect.
This plot is plotted against the data means for tool tip temperature and spindle
speed, feed, depth of cut, work piece material EN 31. From spindle speed 160 rpm to
380 rpm the tool tip temperature increases. For the feed rate of 0.16mm/rev the tool tip
temperature is low but it increases for feed rate 0.04 mm/rev and again decreases for a
feed rate 0.08 mm/rev. The tool tip temperature values increases as depth of cut
increases from 0.5mm to 1mm. The EN 31 work piece has the highest value for tool tip
temperature and EN 8 has the lowest tool tip temperature.
40
WORK PIECE MATERIAL EN 9:
Table 5.4 ANOVA table for Tool Tip Temperature

V 2 5574.9 5574.9 2787.4 22.64 0.042 46.13
D 2 5706.9 5706.9 2853.4 23.18 0.041 47.23
F 2 555.6 555.6 277.8 2.26 0.307 4.5
Error 2 246.2 246.2 123.1 2
Total 8 12083
S R-sq R-sq(adj) R-sq (pred)

11.095 97.96% 91.85% 0.00%
T = - 81.9 - (0.018*V) + (183*D) + (1479*F) + (0.332*V*D) - (1.05*V*F) –

(1712*D*F) (5.2)
T= Tool Tip Temperature

In Table 5.4 column 1 represents variable sources such as spindle speed, feed,
=97.96% which indicates that model is capable of predicting response with higher
accuracy.
has least effect (4.5%) in controlling the tool tip temperature which is not statistically
2% for tool tip temperature. As the percent contribution due to error is very small it
was involved.
41
is satisfied.
Figure 5.6 Interaction plots for Tool Tip Temperature with EN9
the graph. In this graph, the first row shows the interaction plot between spindle speed
42
vs feed and spindle speed vs depth of cut. From this we can conclude that there is
interaction between spindle speed and feed, depth of cut for different levels.
The second row shows the interaction plot between feed vs depth of cut. As different
lines have steep slope and intersecting each other, there is significant interaction.
Figure 5.7 Main effect plots for Tool Tip Temperature with EN9
speed, feed, depth of cut, work piece material EN 9. From spindle speed 160 rpm to 380
rpm the tool tip temperature increases. For the feed rate of 0.16mm/rev the tool tip
increases from 0.5mm to 1mm. The EN 9 work piece has the highest value for tool tip
temperature than EN8 and EN 8 has the lowest tool tip temperature.
43
WORK PIECE MATERIAL EN 8:
Table 5.5 ANOVA table for Tool Tip Temperature

V 2 5218.7 5218.7 2609.3 25.01 0.038 46.41
D 2 5366.0 5366 2683 25.72 0.037 47.72
F 2 450.7 450.7 225.3 2.16 0.316 4
Error 2 208.7 208.7 104.3 1.85
Total 8 11244
S R-sq R-sq(Adj) R-sq(pred)

10.2144 98.14% 92.580% 0.00%
T = - 73.8 - (0.036*V) + (174.1*D) + (1346*F) + (0.32*V*D) - (0.8*V*F) -

(1599*D*F) (6.3)
T= Tool Tip Temperature
In Table 5.5, column 1 represents variable sources such as spindle speed, feed,
=98.14% which indicates that model is capable of predicting response with medium
accuracy.
has least effect (4%) in controlling the tool tip temperature which is not statistically
1.85% for tool tip temperature. As the percent contribution due to error is very small it
was involved.
44
is satisfied.
Figure 5.8 Interaction plots for tool tip temperature with EN8
the graph. In this graph, the first row shows the interaction plot between spindle speed
vs feed and spindle speed vs depth of cut. From this we can conclude that there is
interaction between spindle speed and feed, depth of cut for different levels.
45
The second row shows the interaction plot between feed vs depth of cut. As
different lines have steep slope and intersecting each other, there is significant
interaction.
Figure 5.9 Main effect plots for tool tip temperature with EN8
speed, feed, depth of cut, work piece material EN 8. From spindle speed 160 rpm to 380
rpm the tool tip temperature increases. For the feed rate of 0.16mm/rev the tool tip
increases from 0.5mm to 1mm. EN 8 has the lowest tool tip temperature.
46
CHAPTER 6
FINITE ELEMENT ANALYSIS
Finite element analysis (FEA) is the most useful and accurate approach for the
determination of field variables. This method is made possible by advancements in
computing and computer processing powers and thus it has been used for almost all
computer aided design methodologies in recent years. Applications range from
deformation and stress analysis to field analysis of heat flux, fluid flow, magnetic flux,
seepage and other flow problems. In this method of analysis, a complex region defining
a continuum is disassembled into simple geometric shapes called finite elements. In this
work, the application of FEA for thermal analysis of a single-point cutting tool in a
turning operation is presented. Once the model for the determination of the temperature
field for the single-point cutting tool was developed and verified using the experimental
results, it was used to observe the effects of various parameters including the cutting
parameters, the tool geometry, the tool material, the distance of the sensors from the
cutting region and the rate of heat dissipation.
The heat generation during metal cutting processes affects materials properties
and the tool wear. Knowledge of the ways in which the cutting conditions effect the
temperature distribution is essential for the study of thermal effects on tool tip
temperature. Analyses of three-dimensional transient temperature distributions in a
metal cutting process using a finite element code the Deform 3-D was presented in this
project. The effects of the spindle speed, feed rate, tool and work piece materials on the
temperature and heat flux are studied.
During a cutting process, the mechanical energy resulting from the plastic
deformation developed at the primary shear plane and at the chip–tool interface is
converted into heat. Studies have shown that the chip and the environment dissipate a
great deal of this heat while the reminiscent is conducted both into the work piece and
into the cutting tool. However, this small quantity of heat conducted into the tool (8–
10% of the total heat rate) is enough to create high temperatures near the cutting edges.
It is clear that the determination of the exact temperature rise in the tool has been
recognized as an important factor in achieving the best cutting performance. That is the
reason why several researchers have become interested in determining the temperature
histories on the rake face of cutting tools. Many of temperature measurement techniques
47
have been developed over the years, to determine the temperature distribution of the
tool chip interface, rake face, cutting tool, work piece, chip surface, etc. The methods
commonly adopted by the researchers are the metallographic method, i.e., micro
hardness and microstructure analysis, embedded and tool chip thermocouples, thermal
radiation, thermo sensitive paints, powders of constant melting point, thermocouple
techniques. Thermocouple-insert techniques, hybrid technique and heat source methods.
etc. However, direct measurements of temperatures at the tool–work piece interfaces are
very difficult due to the cutting movement and the small contact areas involved. Due to
these experimental difficulties many analytical and numerical methods solution have
been employed to predict machining temperature the moving heat source method, the
image sources method, the finite difference method, the semi-analytical methods and
the finite element method.
6.1 THERMAL ANALYSIS:

In machining operations, mechanical work is converted to heat through the
plastic deformation involved in chip formation and through friction between the tool
and work piece. Some of this heat conducts into cutting tool, resulting in high tool
temperatures near cutting edge. Elevated tool temperatures have negative impact on a
tool tip temperature. The temperature of the tool plays an important role in the thermal
distortion and the, machined part‟s dimensional accuracy, as well as in the tool tip
temperature in machining. Tools become softer and wear more rapidly by abrasion as
temperatures are increased, and in many cases constituents of the tool tip temperature
may diffuse into the chip or react chemically with the work piece or cutting fluid.
6.2 HEAT GENERATION IN MACHINING:

Heat generation while machining has significant influence on machining. It can
increases tool wear and thereby reducing tool tip temperature. It gives rise to thermal
softening of cutting tool. It is commonly accepted that both the wear and failure
mechanisms which develop in cutting tools are predominantly influenced by
temperature and it also results in modification to the properties of work piece and tool
material such as hardness. In order to predict the wear and failure characteristics of a
tool, it is necessary to quantify the temperatures which develop during the cutting
operation. In machining operations, mechanical work is converted to heat through the
48
plastic deformation involved in chip formation and through friction between the tool
and work piece. Figure 6.1 shows three regions of heat generation in turning; which are,
the shear zone, the chip-tool interface and the tool-work piece interface zone:
1. The shear zone: The shear zone, where the main plastic deformation takes place due
shear energy. This heat raises the temperature of the chip. Part of this heat is carried
away by the chip when it moves upward along the tool. Considering a continuous type
chip, as the cutting speed increases for a given rate of feed, the chip thickness decreases
and less shear energy is required for chip deformation so the chip is heated less from
this deformation. About 80-85% of the heat generated in shear zone.
2. The chip-tool interface zone: The chip-tool interface zone, where secondary plastic
deformation due to friction between the heated chip and tool takes place. This causes a
further rise in the temperature of the chip. This chip-tool interface contributes 15-20%
of heat generated.
Figure 6.1 Regions of heat generation in turning
3. The tool-work piece interface zone: The work-tool interface zone 3, at flanks where
frictional rubbing occurs. This area contributes 1-3% of heat generated. As the portion
of heat that flows into the tool cause very high temperature in vicinity of tool tip which
in turn decrease the hardness of the tool material and in extreme case may even cause
melting. The wear rate of tool therefore increases, resulting in a decrease in useful life
of the tool. It is increasingly important to understand how machining temperature are
49
affected by the process variable involved which are cutting speed, feed rate, and tool
geometry.
6.3 ANALYSIS TECHNIQUES:

Several methods have been used for measuring the temperatures generated
during metal cutting operations. In this project, instrument used to measure too tip
temperature is IR pyrometer which is a non-contact type temperature measuring
instrument. The main techniques used to evaluate the temperature during machining are
as following:
Experiment Retrospection: Many experimental methods have been devised to
measure the tool, chip or work piece temperature and their distribution, these are:
1. Tool-Chip Thermocouple Technique
2. Embedded Thermocouple Technique
3. Infrared Radiation Technique
4. Metal Microstructure and Micro-hardness Variation Measurement
5. Thermo-sensitive Painting Technique
6. Temper Colour Technique
6.4 HEAT TRANSFER IN MACHINING:

Heat is transferred across boundaries by conduction, convection and radiation
because of the temperature gradient, and air present at ambient temperature
• Heat transfer inside the chip and work piece, the tool and tool-holder is by conduction.
• Heat transfer between coolant/air and the chip/tool/work piece is by convection.
• Radiation is rarely investigated in traditional machining operations.
6.5 HEAT EFFECTS:

In metal cutting, severe deformations take place in the vicinity of the cutting
edge of the tool because of the high temperatures resulting from machining operation.
These elevated temperatures have a negative impact on tool tip temperature, and quality
of surface.
50
Following are some of the effects of heat on various cutting parameters:
• Heat Influences on Cutting Forces: The heat influence on the cutting forces is mainly
because of the following reasons-the friction co-efficient is tightly dependent upon
temperature, and the properties of cut material also depend on temperature.
• Heat Effects on Tool tip temperature
• Heat Influences on Surface Toughness
• Heat Influences on Thermal Deformation in Lathe.
6.6 FINITE ELEMENT ANALYSIS IN INTERNAL TURNING:

Finite element analysis is a most useful and accurate approach for the
determination of field variables that is made possible by advancements in computational
and processing power of computers and thus it is almost used for all the computer aided
design methodologies in recent years. Applications range from deformation and stress
analysis to field analysis of heat flux, fluid flow, magnetic flux, seepage and other flow
problem. In this method of analysis, a complex region defining a continuum is
discredited into simple geometric shapes called finite elements. The Present work is also
based on the application of finite element for thermal analysis of single point cutting
tool for internal turning operation. Once the model developed for determination of
temperature field for single point cutting tool, it can also be implemented for other
multipoint processes like drilling, milling or grinding also.
In this project, the temperature distribution on cutting tool during internal
turning process find out with the help of finite element analysis. FEA is carried out by
using ANSYS workbench 15.
FEA is the most useful and accurate approach for the determination of field
variable. In this study application of FEA for thermal analysis of single point cutting
tool in a internal turning process is shown. The comparison was done of FEA results
and experimental results. The FEA results were verified with experimental results. FEA
was used to observe the effects of various cutting parameters, the tool geometry, the
tool material and rate of heat dissipation.
51
Table 6.1 Input values of the FEA model for the cutting tool
Thermal conductivity of the tool 84 W/m⁰C
K (W/m⁰C)
Ambient temperature T∞ (⁰C) 25 ⁰C
Convection heat transfer coefficient 25 W/m2 ⁰C
h (W/m2 ⁰C)
Density (kg/m3) 15800 kg/m3
Yang modulus of elasticity (MPa) 686 MPa
Poisson‟s ratio 0.22
Specific Heat (J/kg⁰C) 292 J/kg⁰C
Compressive ultimate strength (MPa) 6833 MPa
Tensile ultimate strength (MPa) 530 MPa
Bulk modulus (MPa) 408 MPa
6.7 STEPS IN FINITE ELEMENT ANALYSIS:

1. Add material properties in library of engineering materials in ANSYS
2. Create geometry
3. Meshing
4. Boundary Conditions
5. Results
In this finite element analysis, selected the insert geometry for finite element
simulation and to find out the temperature distribution along the surface of insert
geometry. In ANSYS first add insert material properties in library of engineering
materials. After that, create the geometry of insert according to the insert dimensions.
Then, mesh the whole geometry of insert in ANSYS.
After meshing, give the boundary conditions to the insert geometry. Boundary
conditions given at the time of simulation is given below.
1. Ambient temperature
2. Initial temperature of insert
3. Consider the natural convection for heat transfer from insert to surrounding
4. Give the heat flux to that portion of insert which is in contact with work piece
material.
5. Heat losses due to radiation are very small and it is neglected.
Here, the ambient temperature is taken as 25⁰C and initial temperature of insert is taken
as 22⁰C. Convective heat transfer coefficient value for natural convection for air is
taken as according to temperature difference of insert and surrounding.
52
The convective heat transfer coefficient is calculated from given relation as follows.
h = 1.32 (∆T/L)0.25 [19] (6.1)
h = Convective heat transfer coefficient (W/m2K), ∆T = Temperature difference (⁰C)
ble 6.2 Convective Heat Transfer Coefficient Values for Natural Convection
S.R. NO. h (EN 31) h (EN 9) h (EN 8)

1 19.53 17.075 16.7616
2 21.3157 20.744 20.2145
3 23.05 21.3157 21.1573
4 21.69 20.99 20.9126
5 23.92 21.9885 21.6972
6 25.66 25.4415 25.2079
7 23.355 22.13 21.9168
8 24.5166 23.9292 23.4733
9 26.3171 25.934 25.6689
The heat flux is given to that area of insert which is in contact with the work
piece material at the time of machining process. The convective heat transfer coefficient
for the top surface of the cutting tool insert was set as value obtained from the above
relation, where the heating zone on the corner was held constant: A = π × 1 mm2/4 =
0.78 × 10-6m2.
Heat flux is calculated from following formula
[9] (6.2)
Table 6.3 Heat Flux Values for Each Level of Parameters
Temp. of Heat Heat Heat

S.R. Temp. of Temp. of
EN31 Flux Flux Flux
NO. EN9 (⁰C) EN8 (⁰C)
(⁰C) (MW) (MW) (MW)
1 70 3.7 50 2 48 1.9
2 90 5.4 83 4.8 77 4.4
3 123 8.1 90 5.4 88 5.2
4 95 5.8 86 5 85 5
5 120 7.8 99 6.2 95 5.8
6 165 11.7 160 11.3 155 10.6
7 130 8.8 101 6.3 98 6
8 141 9.7 130 8.8 122 8.1
9 180 13 171 12.2 165 11.7
53
Figure 6.2 Insert Geometry exposed to natural convection`
Figure 6.3 Meshing of Insert geometry
Figure 6.4 Insert geometry with heat flux
54
6.8 FEA RESULTS:
Table 6.4 Comparative results obtained for tool insert with work piece material
EN 31
SR.NO. Spindle Depth Feed Experimental FEA %
speed of cut rate Temp. (⁰C) Temp. Difference
(RPM) (mm) (mm/rev) (⁰C)
1 160 0.5 0.04 70 73 7.1

2 160 0.75 0.08 90 97 7.7
3 160 1 0.16 123 130 5.6
4 230 0.5 0.08 95 103 8.4
5 230 0.75 0.16 120 127 5.83
6 230 1 0.04 165 176 6.7
7 380 0.5 0.16 130 141 8.46
8 380 0.75 0.04 141 150 6.38
9 380 1 0.08 180 188 4.4
Following Parameters level result shown in figure 6.5:

 Spindle speed 160 RPM
 Depth of cut 1 mm
 Feed rate 0.16 mm/rev
Figure 6.5 Temperature distribution on cutting insert with work piece material EN
31
55
EN 9
SR.NO. Spindle Depth Feed Experimental FEA %

speed of cut rate Temp. (⁰C) Temp. Difference
(RPM) (mm) (mm/rev) (⁰C)
1 160 0.5 0.04 50 52 4

2 160 0.75 0.08 83 89 7.2
3 160 1 0.16 90 97 7.7
4 230 0.5 0.08 86 93 8.1
5 230 0.75 0.16 99 108 9
6 230 1 0.04 160 171 6.8
7 380 0.5 0.16 101 109 7.9
8 380 0.75 0.04 130 140 7.6
9 380 1 0.08 171 183 7.01
Following Parameters level results shown in figure 6.6:

 Depth of cut 0.5 mm
Figure 6.6 Temperature distribution on cutting insert with work piece material EN
9
56
EN 8
FEA
Spindle Depth Feed Experimental
Temp. %
SR.NO. speed of cut rate Temp. (⁰C)
(⁰C) Difference
(RPM) (mm) (mm/rev)
1 160 0.5 0.04 48 52 8.3
2 160 0.75 0.08 77 84 9.09
3 160 1 0.16 88 95 7.9
4 230 0.5 0.08 85 92 8.2
5 230 0.75 0.16 95 103 8.4
6 230 1 0.04 155 166 7
7 380 0.5 0.16 98 107 9.1
8 380 0.75 0.04 122 134 9.8
9 380 1 0.08 165 178 7.3
Following Parameters level results shown in figure 6.7:

 Depth of cut 0.5 mm
Figure 6.7 Temperature distribution on cutting insert with work piece material
EN8
57
CHAPTER 7
GENETIC ALGORITHM
7.1 INTRODUCTION TO GA:

A genetic algorithm (GA) is a search and optimization method which works by
mimicking the evolutionary principles and chromosomal processing in natural genetics.
Genetic algorithm is an optimization technique based on natural selection for
reproduction and various operations such as crossover, mutation. A GA begins its
search with a random set of solutions usually coded in binary strings. Every solution is
assigned a fitness which is directly related to the objective function of the search and
optimization problem. Thereafter, the population of solutions is modified to a new
population by applying three operators similar to to natural genetic operators-
reproduction, crossover, and mutation. It works iteratively by successively applying
these three operators in each generation till a termination criterion is satisfied. Over the
past decade and more, GAs have been successfully applied to a wide variety of
problems, because of their simplicity, global perspective, and inherent parallel
processing.
Classical search and optimization methods demonstrate a number of difficulties
when faced with complex problems. The major difficulty arises when one algorithm is
applied to solve a number of different problems. This is because each classical method
is designed to solve only a particular class of problems efficiently. Thus, these methods
do not have the breadth to solve different types of problems often faced by designers
and practitioners. Moreover, most of the classical methods do not have the global
perspective and often get converged to a locally optimum solution. Another difficulty is
their inability to be used in a parallel computing environment efficiently.
7.1.1 Basics of Genetic Algorithms:

The basic concept of GAs is designed to simulate processes in natural system
necessary for evolution, specifically those that follow the principles first laid down by
Charles Darwin of survival of the fittest. GAs have been widely studied, experimented
and applied in many fields of sciences. Not only does GAs provide an alternative
method to solving problem, it consistently outperforms other traditional methods in
58
most of the problems. Many of the real world problems involved finding optimal
parameters, which might prove difficult for traditional methods but ideal for GAs.
The idea of evolutionary computing was introduced in 1960 by Rechenberg in
his work “Evolutionary strategies”. GAs is computerized search and optimization
algorithms based on mechanics of natural genetics and natural selection.
7.2 BASIC CONCEPTS:

GA is good at taking larger, potentially huge, search spaces and navigating them
looking for optimal combinations of things and solutions which we might not find in a
life time.
GA is very different from most of the traditional optimization methods. Genetic
algorithms need design space to be converted into genetic space. So, Genetic algorithms
work with a coding of variables. The advantage of working with a coding of variable
space is that coding discretizes the search space even though the function may be
continuous. A more striking difference between GAs and most of the traditional
optimization method is that GA uses a population of points at one time in contrast to the
single point approach by traditional optimization methods. This means that GA
processes a number of designs at the same time.
7.3 WORKING PRINCIPLE:

The GA is an iterative optimization procedure. Instead of working with a single
solution in each iteration, a GA works with a number of solutions (collectively known
as population) in each iteration. In the absence of any knowledge of the problem
domain, a GA begins its search from a random population of solutions. Now notice how
a GA processes strings in an iteration. If a termination criterion is not satisfied, three
different operators – reproduction, crossover and mutation – are applied to update the
population of strings. One iteration of these three operators is known as a generation in
the parlance of GAs. Since the representation of a solution in a GA is similar to a
natural chromosome and GA operators are similar to genetic operators, the above
procedure is called a genetic algorithm.
Genetic Algorithms provide a powerful tool to solve optimization problems.
With an appropriate selection of their operators and parameters they can potentially
explore the entire solution space and reach the global optimum. The concept of elite
59
selection makes the employed algorithm a versatile tool for solving continuous
optimization problems. Here, the set-up of the Genetic Algorithm operators and
parameters is addressed, providing method to tune them to improve performance of
condition monitoring technique.
Genetic algorithms are stochastic search algorithms based on the mechanics of
biological evolution and natural genetics, which is designed to efficiently search large,
non-linear, discrete and poorly understood search space, where expert knowledge is
scarce or difficult to model and where traditional optimization techniques fail. Genetic
Algorithms are good at taking large, potentially huge search spaces and navigating
them, looking for optimal combinations of things, solutions one might not otherwise
find with conventional available methods. As an effective global search method, genetic
algorithm has obvious advantages. But it usually has problems of premature
convergence and local optimum in practical application. Through the simulation and
experimentation, the improved algorithm shows its faster convergence and better
stability. It is validated that this improvement can not only avoid local optimum but also
enhance the accuracy and probability of convergence. Optimization of geometric and
machining parameters is a non-linear optimization with constrains, so it is difficult for
the conventional optimization algorithms to solve this problem because of problems of
convergence speed or accuracy. The new approach which ensures efficient and fast
selection of the optimum cutting conditions and processing of available technological
data are the Genetic algorithm (GA). The genetic algorithm is used for optimization of
parameters and experimental results show an improved performance. In this study a GA
is used to estimate the tool tip temperature, the inputs to our optimization system are
four ranges of parameters (Spindle Speed, feed rate and depth of cut). Identification of
the tool tip temperature formulated as an optimization problem, and the genetic
algorithm is used to find the theoretical fitness function which is based geometric and
machining parameters. The goal is finding the exact parameters for which the fitness.
Conventional optimization techniques have difficulty in finding the global maximum
unless the starting point is in the immediate vicinity of it.
7.3.1 Steps for Genetic Algorithm:

Step 1: Generate random possible combination as per population size of four parameters
values Spindle speed, feed rate and depth of cut.
60
Step 2: Convert each combination into a single binary string.
Step 3: The algorithm then creates a sequence of new population.
At each step, the algorithm uses individuals in current generation to create the next
population. To create the new population, the algorithm performs the following steps:
a. Scores each member of the current population by computing fitness i.e. minimizing.
b. Select members, called parents, based on their fitness.
c. Some of the individuals in the current population that have lesser fitness are chosen
as elite. These elite individuals are considered to the next population
d. Produces offspring from the parents. Offspring are produced either by combining the
vector entries of a pair of parents crossover or by making random changes to a single
parent mutation.
e. Replaces the current population with the children to form the next generation.
Step 4: The algorithm stops after running specified number of generations which is
considered as stopping limit.
Step 5: The final optimum solution in binary string, given by G.A. is decode in to
decimal number values.
Step 6: Repeat the above five steps for each possible parameter.
7.3.2 Problem Encoding:

Traditionally, GA has used bit strings as their chromosome representation, with
each gene either being one or zero. In our problem, the candidate solution be searched is
the geometric and machining parameters. They are all numerical parameters. So, we can
directly use bit strings to encode the candidate solution, and the representation of the
solution or the approximation for finding the tool tip temperature is a bit string of which
each substring represents one parameter. The length of each substring is determined by
the solution accuracy and the interval of the solution.
1. Initialization:
Initially many individual solutions are randomly generated to form an initial
population. The population size depends on the nature of the problem, but typically
contains several hundreds or thousands of possible solutions. Traditionally, the
population is generated randomly, covering the entire range of possible solutions (the
search space). Population size says how many chromosomes are in population (in one
generation). If there are too few chromosomes, GA has a few possibilities to perform
61
crossover and only a small part of search space is explored. On the other hand, if there
are too many chromosomes, GA slows down. Research shows that after some limit
(which depends mainly on encoding and the problem) it is not useful to increase
population size, because it does not make solving the problem faster.
2. Fitness Evaluation:
In GAs, to improve the solution, each individual is evaluated using some
measure of fitness. A fitness value is computed for each individual in the population and
the objective is to find the individual that has the highest fitness for the considered
problem. Objective function used in the present study is based on the changes in
experimental tool tip temperature and calculated tool tip temperature. The main reason
to use this is that tool tip temperature is rather easy to determine with a relatively high
level of accuracy.
The fitness function is based on tool tip temperature calculated experimentally
and theoretically by optimizing the geometric and machining parameters. This includes
methods such as roulette-wheel selection and stochastic universal selection. In roulette-
wheel selection, each individual in the population is assigned a roulette wheel slot sized
in proportion to its fitness. That is, in the biased roulette wheel, good solutions have a
larger slot size than the less fit solutions. The roulette wheel is spun to obtain a
reproduction candidate.
3. Input GA Parameter:
Genetic algorithm is an adaptive search and optimization algorithm that mimics
the principles of natural genetics. GA‟s are very different from traditional search and
optimization methods used in engineering design problems. Because of their simplicity,
easy of operations minimum requirements and global perspective, GA‟s has been
successfully used in a wide variety of problem domains. GA work through three
operators, namely reproduction, cross over and mutation. In this work an attempt is
made to use of genetic algorithm to minimize the tool tip temperature by optimizing the
depth of cut, feed rate and spindle speeds.
4. Fitness Function:
Genetic Algorithm mimics the survival of the fittest principle of nature to make
search procedure. The fitness function f(x) is first derived from the objective function
and used in successive genetic potation. For, minimization problem, the fitness function
is equivalent maximization problem such that the optimum point remains unchanged.
Fitness function f (x) = T.L. (x)
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7.4 STEPS IN GENETIC ALGORITHM:
1. Coding
Parameters values are coded in to binary numbers.
2. Parent selection
The parents are selected according to their fitness, with those chromosomes having
higher fitness value being selected more often.
3. Crossover
Before cross over after crossover
String 1: 1001|10010 new string 1: 100100110
String 2: 1101|00110 new string 2: 110110010
4. Mutation
In mutation changing 0 to1 or vice versa on a bit by bit basis and with a small mutation
probability to 0.01 to 0.05
String 1: 100110010 new string 1: 100100010
String 2: 110100010 new string 2: 110110010
7.5 PROCEDURE FOR GA:
In genetic algorithm objective function is needed for the optimization, without

objective function we cannot go for optimization. Objective function is mathematical
relation between input and output parameters. In coding all the parameters value are
first to be coded into binary digits. All binary numbers are to be of same bit, here all
binary numbers of 9 bit. After coding of parameters values calculate their fitness values
and reject those parameters values which have very less fitness value. Those parameters
values have higher fitness value which is select twice for further process for cross over.
IP is said to be initial population after coding into binary numbers. NP is said to be new
population, new population set of values obtained after the cross over step. For cross
over first make mating pool, which tells about which population is make cross over to
another population. Cross over sites and mating pool selection is a randomly selected in
GA. Cross over sites also selected randomly i.e. shift the binary numbers after 3 digit of
one population to another population and vice versa. We can select rather than after 3
digit also because cross over sites selected randomly.
After gating cross over results the next and important step is mutation. In
mutation changing 0 to1 or vice versa on a bit by bit basis and with a small mutation
63
probability to 0.01 to 0.05. Here for one parameter there is 81 bits from that we can only
change less than 4 bits 0 to 1 or vice versa with less than mutation probability 0.05.
After doing mutation we obtained new set of population by using this new population
we gate new tool tip temperature values. From this new set of population calculate their
fitness values and which have higher fitness value that parameters values are the
optimized parameters values.
7.5.1 OBJECTIVE FUNCTIONS:

For work piece material EN31
T = - 19.6 - (0.149*V) + (107*D) + (1180*F) + (0.49*V*D) - (0.61*V*F) -
(1260*D*F) .
T = - 81.9 - (0.018*V) + (183*D) + (1479*F) + (0.332*V*D) - (1.05*V*F) -
(1712*D*F)
T= - 73.8 - (0.036*V) + (174.1*D) + (1346*F) + (0.32*V*D) - (0.8*V*F) -
(1599*D*F)
7.10 RESULTS WITH WORK PIECE MATERIAL EN 31:

Table 7.1 Results obtained by GA after Cross over for tool tip temperature with
EN31
NP NP SUM
NP V DOE FR V D F T' TM' TM' FITNES
100100000 110010 00100 288 0.5 0.04 76.52 123.48 793.74 0.15557
11100000 1110010 00100 224 1.14 0.04 178.4 21.591 793.74 0.0272
11100000 101011 01000 224 0.43 0.08 80.36 119.64 793.74 0.15073
11100000 1011 01000 224 0.11 0.08 43.25 156.75 793.74 0.19748
10100000 100100 10000 160 0.36 0.16 123.9 76.088 793.74 0.09586
10100110 1110010 01000 166 1.14 0.08 141.8 58.239 793.74 0.07337
10100110 1010010 01000 166 0.82 0.08 113.7 86.252 793.74 0.10866
10100110 1011 10000 166 0.11 0.16 126.8 73.194 793.74 0.09221
11111100 110010 10000 252 0.5 0.16 121.5 78.503 793.74 0.0989
64
0.25 FITNESS
0.2
0.15
FITNES
Fitness 0.1
0.05
0
0 2 Sr.4No. 6 8 10
Figure 7.1 Fitness graph for set of parameters after cross over with EN31
Table 7.2 Results obtained by GA after Mutation for tool tip temperature with
EN31
Sr. M SUM
No. M NP V M NP D NP F F' V' D'' T' TM' TM' FITNESS
1 100010000 110010 01000 0.08 272 0.5 90 109 822 0.132811
2 11100000 1100010 00100 0.04 224 0.98 151 48 822 0.058599
3 11110000 101011 00100 0.04 240 0.43 60 139 822 0.169093
4 11101000 1001011 01000 0.08 232 0.75 118 81 822 0.098676
5 10100000 100100 01000 0.08 160 0.36 73 126 822 0.153633
6 10100110 1110000 01000 0.08 166 1.12 140 59 822 0.07292
7 11100100 1010010 01000 0.08 228 0.82 126 73 822 0.089468
8 10100110 1011 10000 0.16 166 0.11 126 73 822 0.08897
9 11100100 110110 01000 0.08 228 0.54 93 106 822 0.129602
FITNESS
0.2
0.15
Fitness
0.1
0.05
FITNESS
0
0 2 Sr. No. 4 6 8 10
Figure 7.2 Fitness graph for set of parameters after Mutation with EN31
65
EN9
NP NP SUM
NP V DOE FR V D F T' TM' TM' FITNESS'
101100000 110010 00100 352 0.5 0.04 108 71 840 0.08484
10100000 1110010 00100 160 1.14 0.04 139 40 840 0.04813
11100000 111011 01000 224 0.59 0.08 81 98 840 0.11661
11100000 101011 01000 224 0.43 0.08 62 117 840 0.13996
101100000 100100 10000 352 0.36 0.16 73 106 840 0.12655
10100110 1010010 01000 166 0.82 0.08 95 84 840 0.10016
10100110 1000010 01000 166 0.66 0.08 76 103 840 0.12352
11100110 1001011 10000 230 0.75 0.16 91 88 840 0.10566
10111100 110010 10000 188 0.5 0.16 50 129 840 0.15456
FITNESS
0.2
0.15
Fitness
0.1
FITNESS'
0.05
0
0 2 4 6 8 10
Sr. No.
EN9
M NP SUM
M NP V M NPD F V' D'' F'' T' TM'' TM'' FITNES
10110000
0 110010 1000 352 0.5 0.08 81 98 822 0.119217
10100000 1110001 100 160 1.13 0.04 157 22 822 0.027857
11100000 110011 100 224 0.51 0.04 60 119 822 0.145746
11100100 101010 1000 228 0.42 0.08 64 115 822 0.140711
10110010
0 100110 1000 356 0.38 0.08 62 117 822 0.142872
10100110 1010010 1000 166 0.82 0.08 102 77 822 0.09433
10100110 1000010 1000 166 0.66 0.08 86 93 822 0.114012
11100100 1001011 10000 228 0.75 0.16 100 79 822 0.096177
10111000 110110 1000 184 0.54 0.08 75 104 822 0.127081
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0.2 FITNESS
0.15
Fitness
0.1
FITNES
0.05
0
0 2 Sr.
4 No. 6 8 10

EN8
Sr. NP V NP NP FR V D F T' TM SUM FITNESS
No. DOE TM
1 11100000 110010 000100 224 0.5 0.04 74.2 100 954 0.10
2 10100000 110010 000100 160 0.5 0.04 58.8 116 954 0.12
3 10100000 111011 001000 160 0.59 0.08 62.6 112 954 0.11
4 10100000 1101011 001000 160 1.07 0.08 115 59 954 0.06
5 11100000 100100 010000 224 0.36 0.16 40.8 134 954 0.14
6 10100000 1000100 001000 160 0.68 0.08 72.4 102 954 0.10
7 10100000 1000010 001000 160 0.66 0.08 70.2 104 954 0.10
8 11100110 1001011 010000 230 0.75 0.16 84.9 90 954 0.09
9 10100110 110010 010000 166 0.5 0.16 42.1 132 954 0.13
FITNESS
0.2
0.15
Fitness
0.1
FITNESS
0.05
0
0 2 4 6 8 10
Sr. No.
67
EN8
Sr. M NP D NP F M NP V D' F' T TM SUM FITNES
No. F TM
1 110010 100 1000 224 0.5 0.08 70 104 816 0.128146
2 110110 100 10000 224 0.54 0.16 99 75 816 0.092637
3 1101001 1000 100 168 1.05 0.04 140 34 816 0.042012
4 1101011 1000 1000 160 1.07 0.08 122 52 816 0.064843
5 1100100 10000 10000 224 1 0.16 94 80 816 0.098307
6 1000100 1000 1000 160 0.68 0.08 84 90 816 0.111375
7 1000010 1000 1000 160 0.66 0.08 82 92 816 0.113761
8 1001010 10000 10000 228 0.74 0.16 97 77 816 0.094746
9 110110 10000 1000 164 0.54 0.08 70 104 816 0.127722
FITNESS
0.14
0.12
0.1
0.08
Fitness
0.06
FITNES
0.04
0.02
0
0 2 4 6 8 10
Sr. No.
Table 7.7 Results Obtained By Genetic Algorithm

Work Piece Spindle Speed Depth Of Cut Feed Rate Temperature
Material (RPM) (mm) (mm/rev) (⁰C)
EN 31 240 0.43 0.04 60.89
EN 9 224 0.51 0.04 60.15
EN 8 224 0.5 0.08 70.41
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CHAPTER 8
REGRESSION ANALYSIS
In this study, regression equations for tool tip temperature is developed for
calculate temperature at different conditions or levels of input parameters. This equation
gives the tool tip temperature values for different tool material, work piece material and
cutting parameters. Tool tip temperature is an output parameter.
8.1 Identification of Dependent/Independent Variables

The term variables are used in a very general sense to apply any physical
quantity that undergoes change. If a physical quantity can be changed independent of
the other quantities, then it is an independent variable. If a physical quantity changes in
response to the variation of one or more number of variables, then it is termed as
dependent or response variable. If a physical quantity that affects our test is changing in
random and uncontrolled manner, then it is called an extraneous variable. The variables
affecting the cutting tool temperature phenomenon under consideration are
1. Spindle Speed (RPS)
2. Depth of cut (m)
3. Feed Rate (m/rev)
4. Internal Diameter of work piece (m)
5. Thermal conductivity of tool material (w/m k)
6. Thermal conductivity of work piece material (w/m k)
7. Specific heat of tool material (J/kg k)
8. Specific heat of work piece material (J/kg k)
9. Density of tool material (kg/m3)
The dependency and the independency of the variables along with their units and
fundamental dimensions are shown in table 8.1.
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Table 8.1 Dependent and Independent variables
Dependent/ Variable/
Symbol
Variables Units MLTθ Independen Constant
s
t
Cutting Tool Variable
T °C [θ1] Dependent
Temperature
Convective Heat
Transfer h W/m2°C [MT-3θ-1] Independent Variable
Coefficient
Spindle Speed V rpm [LT-1] Independent Variable
Depth of Cut Doc m [L] Independent Variable
Feed Rate Fr m/rev [LT] Independent Variable
Internal
Diameter of Diw/p m [L] Independent Variable
work piece
Thermal
conductivity of Ktool W/m K [MLT-3 θ-1] Independent Variable
tool material
Thermal
conductivity of Variable
Kw/p (w/m k) [MLT-3 θ-1] Independent
work piecel
material
Specific heat of Constant
Cptool KJ/Kg.K [L2T-2 θ-1] Independent
tool material
Specific heat of
work piece Cpw/p KJ/Kg.K [L2T-2θ-1] Independent Constant
material
Density of tool Constant
ρtool Kg/m3 [ML-1T-1] Independent
material
Density of work Constant
ρw/p Kg/m3 [ML] Independent
piece material
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8.2 Dimensional Analysis:
Dimensional analysis is a method by which the information is deduce about a

phenomenon from the single premise that the phenomenon can be described by a
dimensionally correct equation among certain variables. The generality of the method is
both its weakness and strength. With little effort, a partial effort a partial solution to
nearly all problems is obtained.
This method is used for determining cutting tool tip temperature for empirical
equations obtained by correlating experimental data with the aid of dimensional
analysis. In the past dimensional analysis was primarily used as an experimental tool
whereby several experimental variables could be combined to form one. The field of
fluid mechanics and heat transfer were greatly benefited from the application of this
tool. Almost every major experiment in this area was planned with its help. Using this
principle modern experiments can substantially improve their working techniques and
be made shorter requiring less time without loss of control. Deducing the dimensional
equation for a phenomenon reduces the number of independent variables in the
experiments. The exact mathematical form of this dimensional equation is the targeted
model. This is achieved by applying Buckingham‟s π theorem. When we apply this
theorem to a system involving n independent variables, (n minus number of primary
dimensions viz. M, L, T, θ i.e. (n-4) numbers of π terms are formed. When n is large,
even by applying this theorem number of π terms will not be reduced significantly than
number of all independent variables. Thus much reduction in number of variables is not
achieved. It is evident that, if we take the product of the terms it will also be
dimensionless number and hence a π term. This property is used to achieve further
reduction of the number of variables.
Cutting tool tip temperature is a function of all following parameters,
( )
T ……..Cutting Tool tip temperature (⁰C)

V……....Spindle Speed (RPS)
…… Depth of cut (m)
………Feed Rate (m/rev)
……Internal Diameter of work piece (m)
……Thermal conductivity of tool material (w/m k)
71
…… Thermal conductivity of work piece material (w/m k)
…… Specific heat of tool material (J/kg k)
…… Specific heat of work piece material (J/kg k)
…… Density of tool material (kg/m3)
…… Density of work piece material (kg/m3)
……..Convective heat transfer coefficient (w/m2k)
Total number of variables = 12
Number of fundamental dimensions = 4
Number of π terms = Total number of variables - Number of fundamental dimensions
= 12 – 4 = 8
Repeating Variables:
1. Internal Diameter of work piece (m)
2. Thermal conductivity of tool material (w/m k)
3. Specific heat of tool material (J/kg k)
4. Density of tool material (kg/m3)
ƒ (π1, π2, π3, π4, π5, π6, π7, π8) = 0

The values different constants, repeating variables and non-repeating variables are
clubbed together to form the equations in the terms of π
π1 = (Diw/p)a1×(Ktool)b1×(Cptool)c1×(ρtool)d1×(T)
π2 = (Diw/p)a2×(Ktool)b2×(Cptool)c2×(ρtool)d2×(kw/p)
π3 = (Diw/p)a3×(Ktool)b3×(Cptool)c3×(ρtool)d3×(Cpw/p)
π4 = (Diw/p)a4×(Ktool)b4×(Cptool)c4×(ρtool)d4×(ρw/p)
π5 = (Diw/p)a5×(Ktool)b5×(Cptool)c5×(ρtool)d5×(V)
π6 = (Diw/p)a6×(Ktool)b6×(Cptool)c6×(ρtool)d6×(Doc)
π7= (Diw/p)a7×(Ktool)b7×(Cptool)c7×(ρtool)d7×(Fr)
π8 = (Diw/p)a8×(Ktool)b8×(Cptool)c8×(ρtool)d8×(hair)
After calculating values of a, b, c and d the π terms are follows:
π1 = (Diw/p)2×(Ktool)-2×(Cptool)3×(ρtool)2×(T)
π2 = (Ktool)-1× (kw/p)
π3 = (Cptool)-1× (Cpw/p)
π4 = (ρtool)-1× (ρw/p)
π5 = (Diw/p) × (Ktool)-1× (Cptool) × (ρtool) × (V)
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π6 = (Diw/p)-1× (Doc)
π7= (Diw/p)-3× (Ktool) × (Cptool)-1× (ρtool)-1× (Fr)
π8 = (Diw/p)× (Ktool)-1× (hair)
(Diw/p )2 ×(Cptool)3 ×(ρtool )2 Kw/p Cpw/p ρw/p

ƒ( 2 , ,
(Ktool ) Ktool Cptool ρtool
Diw/p ×Cptool ×ρtool ×V Doc Ktool ×Fr hair ×Diw/p

3 , )=0
Ktool Diw/p Cp ×ρ ×(Diw/p ) Ktool
tool tool
b
(Ktool )2 Kw/p a Cpw/p ρw/p c
= C× ×[ ] ×[ ] ×[ ]
(Diw/p )2 ×(Cptool )3 ×(ρtool )2 Ktool Cptool ρtool
f
Diw/p ×Cptool ×ρtool ×V d e
Doc Ktool ×Fr
×[ ] ×[ ] ×[ 3]
Ktool Diw/p Cp ×ρtool ×(Diw/p )
tool
g
hair ×Diw/p
×[ ]
Ktool
All the dependent and independent variables are clubbed together and formed a
dimension less correlation. Based on the correlations obtained using dimensional
analysis and the calculated values the analysis of data is done further.
8.3 MATHEMATICAL MODELLING

8.3.1 Development of a Mathematical Model
A mathematical model is defined as a representation of the essential aspects of
an existing system (or a system to be constructed) which presents knowledge of that
system in usable form. A mathematical model can take many forms, including but not
limited to dynamic systems, statistical models, differential equations, or game
theoretical models. These and other types of models can overlap, with a given model
involving a variety of abstract structures. Often when engineers analyse a system to be
controlled or optimized, they use a mathematical model. A mathematical model is a
description of the behaviour of the system using mathematical language. The process of
developing a mathematical model is termed as mathematical modelling (also written as
modelling). Mathematical models are extensively used in the natural sciences (such as
economics, psychology, sociology and political science) and also by physicists,
engineers, statisticians, operations research analysts and economists. In analysis,
engineers can build a descriptive model of the system as a hypothesis of how the system
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could work. Similarly, in control of a system, engineers can try out different control
approaches in simulation.
Actual model is the set of functions that describe the relations between the
different variables. A mathematical model usually describes a system by set of variables
and a set of equations that establish relationships between the variables. The values of
the variables can be practically anything; real or integer numbers. The Theory of
Experimentation as suggested by Hilbert Schenck is a good approach of representing
the response of any phenomenon in terms of proper interaction of various inputs of the
phenomenon. This approach finally establishes an experimental data based models for
any phenomenon. There are many phenomenon which are very complex and it is very
difficult to fabricate large number of experimental set-ups to gather data in a planned
way. The concept of Least Square Multiple Regression curves has been used to develop
the models, hereafter referred as mathematical model.
The objective of any researcher, experimenter or designer of any machine or
manufacturer or entrepreneur is to arrange the optimized inputs to get targeted response.
The objective is only achievable by formulation of such models.
8.3.2 Formulation of Model

To formulate the mathematical model there are various technique available. In
present experimental work Buckingham‟s pi theorem is used for model development.
The dependent and the independent variables are reduced and clubbed in a single
dimension less mathematical equation in which both the sides of equation is balanced.
The Eq.8.1 shows the dimensionless mathematical equation. Dimensional equations so
obtained can be formulated into model using multiple regression analysis. Multiple
Regression analysis is a statistical tool that utilizes the relation between two or more
quantitative variables so that one variable can be predicted from another. The variable to
be predicated is called the output or response/dependent variable. The variable
predicting is called the input or independent variable.
With the use of this procedure the different dimensional equations and models
can be formulated for the different outputs. The formulated models can be evaluated on
the basis of Correlation and Root Mean Square Error between the computed values and
the estimated values.
A mathematical model is the representation of the selected phenomenon of the
system of interest. A model is similar to but simpler than the phenomenon it simulates.
74
One purpose of a model is to enable the analyst to predict the effect of changes to the
phenomena. On one hand, a model has to be a close approximation to the real system
and incorporates most of its salient features. On the other hand, it should not be so
complex that it is impossible to understand and experiment with it.
8.3.3 Formulation of Experimental Data Based Model
In the mathematical equation 8.1, there are seven independent pi terms (π02, π03, π04, π05,
π06, π07, π08) and one dependent pi terms (π 01).
Independent π term = (π02, π03, π04, π05, π06, π07, π08)
Dependent π term = (π01)
The dependent π term is the function of independent π terms,
Cutting tool tip temperature =(π02, π03, π04, π05, π06, π07, π08)
A probable exact mathematical form for this phenomenon could be the empirical
relationships in between dependent dimensionless ratio and independent dimensionless
Ratios are assumed to be exponential.
T = K × (π02) a × (π03) b × (π04) c × (π05) d× (π06) e× (π07) f× (π08) g
The values of exponential a, b, c, d are established, considering exponential
relationship between dependent pi term T and Independent π terms π02, π03, π04, π05, π06,
π07, π08 independently taken one at a time, on the basis of data collected through classical
experimentation.
There are eight unknown values K, a, b, c, d, e, f and g. The curve fitting is
required, for those five sets of values of (π02, π03, π04, π05, π06, π07, π08) required. In the
experimental work all 27 readings were taken. All 27 readings are included in this
model formulation.
8.3.4 Establishment of Relationship for π Term

T (π01) = K × (π02) a × (π03) b × (π04) c × (π05) d× (π06) e× (π07) f× (π08) g
Taking log on both the side of equation for π04, getting five unknown terms in the
equation.
Log (π01) = Log (C) × Log (π02) a × Log (π03) b × Log (π04) c × Log (π05) d × Log (π06) e ×
Log (π07) f × Log (π08) g
Log (π01) = Log (C) + aLog (π02) + bLog (π03) + cLog (π04) + dLog (π05) + eLog (π06) +
fLog (π07) + gLog (π08) (8.2)
Now,
75
Take Log (π01) = Y, Log C = K, Log (π02) = A, Log (π03) = B, Log (π04) = C, Log (π05) =
D, Log (π06) = E, Log (π07) = F, Log (π08) = G
Putting the values in Eq.8.2 becomes
Y = K + a×A + b×B + c×C + d ×D + e×E + f×F +g×G (8.3)
Eq.8.3 is a regression equation of „Y‟ on A, B, C, D, E, F and G in an n dimensional co-
ordinate system. This represents a regression hyper plane.
To determine the regression hyper plane, determining a, b, c, d, e, f and g in Eq.8.3 so
that,
(8.4)
(8.5)
(8.6)
(8.7)
(8.8)
(8.9)
(8.10)
(8.11)
(8.12)
In the above set of equations the values of the multipliers of K, a, b, c, d, e, f and g are
substituted to compute the values of the unknowns (viz. K, a, b, c, d, e, f and g). The
values of the terms on LHS and the multipliers of K, a, b, c, d, e, f and g in the set of
equations are calculated and tabulated in the Table B-3 to B-8 (Appendix B). After
substituting these values will get a set of 8 equations, which are to be solved
simultaneously to get the values of K, a, b, c, d, e, f and g. The above equations can be
verified in the matrix form and further values of K, a, b, c, d, e, f and g can be obtained
by using matrix analysis.
[Y]=[A][X]
The matrix method of solving these equations using „MATLAB‟ is given below.
A = 8 x 8 matrix of the multipliers of K, a, b, c and b
Y = 8 x 1 matrix of the terms on LHS and
X = 8 x 1 matrix of solutions of values of K, a, b, c, d, e, f and g.
76
= ×
[ ] [ ] [ ]
[X] = [Y] [A]-1

[X] = [A] \[Y]
After putting all the values in the above matrix, it becomes
[ ] [ ] [ ]
Using MATLAB, [ X ] = [ A ] \ [ Y ], after solving X matrix with K and indices a, b, c,

d, e, f and g are as follows
[ ] [ ]
In the above matrix value of K is log C, for the value of C, take Antilog (K),
Therefore C = 1
Regression equation for tool tip temperature is given below:
-9.079
(Ktool )2 Kw/p -0.0091 Cpw/p ρw/p -57.2414
= ×[ ] ×[ ] ×[ ]
(Diw/p )2 ×(Cptool )3 ×(ρtool )2 Ktool Cptool ρtool
-0.0212
Diw/p ×Cptool ×ρtool ×V 0.1556 Doc
0.0909
Ktool ×Fr
×[ ] ×[ ] ×[ 3]
Ktool Diw/p Cp ×ρtool ×(Diw/p )
tool
hair ×Diw/p 2.7272

×[ ] (8.13)
Ktool
77
The regression equation is very useful for calculating tool tip
temperature at different cutting conditions and at different process variables. These
regression equation is developed for calculating tool tip temperature at different
conditions or levels of input parameters. This equation gives the cutting tool tip
temperature values for different tool material, work piece material, cutting parameters
and different ambient conditions. Tool tip temperature is an output parameter.
78
8.4 COMPARISON OF REGRESSION RESULTS WITH
EXPERIMENTAL RESULTS:
Percentage difference for above regression equation from experimental results:
Table 8.2 Comparative results for tool tip temperature by regression equation
Temperature
Experimental
w/p T (⁰C) From %
Temperature
material Regression Difference
T (⁰C)
equation
EN-31 70 71.195 1.7
EN-31 90 92.142 2.3
EN-31 115 114.643 0.3
EN-31 95 95.063 0.06
EN-31 130 127.277 2.09
EN-31 165 162.411 1.5
EN-31 120 118.651 1.12
EN-31 141 144.193 2.26
EN-31 180 176.499 1.94
EN-9 50 48.513 2.97
EN-9 83 84.553 1.87
EN-9 90 90.872 0.96
EN-9 86 85.764 0.27
EN-9 99 98.93 0.07
EN-9 160 156.922 1.92
EN-9 101 100.769 0.22
EN-9 130 133.234 2.48
EN-9 171 167.621 1.97
EN-8 48 46.13 3.89
EN-8 77 78.683 2.186
EN-8 88 89.059 1.2
EN-8 85 84.956 0.05
EN-8 95 95.33 0.356
EN-8 155 152.879 1.36
EN-8 98 98.124 0.1272
EN-8 122 126.142 3.39
EN-8 165 162.768 1.35
79
200
180
160
140
120
100 T
80
T'
60
40
20
0
200
180
160
140
120
100 T
80 T'
60
40
20
0
Figure 8.1 Comparison of regression results with experimental results
T – Experimental tool tip temperature (⁰C)

T‟–Tool tip temperature from regression equation (⁰C)
The percentage difference between experimental tool tip temperature and tool
temperature obtained from regression equation is less than 4%, which shows good
agreement of both results.
80
CHAPTER 9
RESULTS AND DISCUSSION
1. The factors that affect to increase tool tip temperature with work piece material
EN 31 are spindle speed, depth of cut and feed rate with their percent
contribution as 47.53%, 50.62% and 0.26% during machining. Percentage
contribution is calculated by ANOVA.
EN 9 are spindle speed, depth of cut and feed rate with their percent contribution
as 46.13%, 47.23% and 4.5% during machining.
EN 8 are spindle speed, depth of cut feed rate and with their percent contribution
as 46.41%, 47.71% and 4% during machining.
4. From main effective plots obtained by ANOVA shows minimum tool tip
temperature at parameters values are spindle speed (160 RPM), depth of cut (0.5
mm) and feed rate (0.16 mm/rev) with three work piece materials.
5. Optimized parameters values obtained by GA for tool tip temperature with work
piece material EN 31 are spindle speed (240 RPM), depth of cut (0.43 mm) and
feed rate (0.04 mm/rev). From this values minimum tool tip temperature
60.89⁰C is obtained.
8. Temperature distribution on cutting tool was determined for internal turning
process by using FEA.
9. From the comparison of experimental and FEA results for tool tip temperature,
difference is not greater than 10 %.
81
10. The regression equation is very useful for calculating tool tip temperature at
different cutting conditions and at different process variables.
11. The percentage difference of tool tip temperature obtained by experimentation
and from regression equation is less than 4%, which shows good agreement of
both results.
82
CHAPTER 10
CONCLUSION AND FUTURE SCOPE
10.1 Conclusion:
1. From the results obtained by experimentation and FEA, percentage difference
for tool tip temperature is not more than 10%.
2. Finite element method is found to be a successful technique to perform trend

analysis to estimate cutting tool tip temperatures in metal cutting with respect to
various combinations of design variables (metal spindle speed speed, feed rate
and depth of cut).
3. In finite element analysis by developing 3-D model of cutting tool insert to
estimate tool tip temperature in metal cutting with respect to various
combinations of cutting parameters. Hence FEA is found to be a successful
technique to estimate cutting tool tiptemperature.
4. From Analysis of Variance it is found that depth of cut and spindle speed are the
most significant factors for increase tool tip temperature. Feed rate is a least
significant factor for tool tip temperature than depth of cut and spindle speed.
5. The spindle speed and depth of cut has the major contribution in increasing the
tool tip temperature during machining along with feed rate.
6. Thus, finally it can be observed that we must select the cutting parameters,
which are cutting speed, feed rate, and depth of cut, in such a way so as to have
the optimum temperature at the tool tip because of the heat generated, so that the
minimum tool wear is encountered, and thus we could have the longest tool life
and better machining economy.
83
10.2 Future Scope:
1. In this study IR pyrometers is used for measuring tool tip temperature, instead of
this we can use another method of method of temperature measurement such
tool-work thermocouple for better experimental results.
2. In this study machining is done in dry condition, by using coolant during
machining process we can maintain minimum tool temperature.
3. Prediction of the tool tip temperature in metal cutting simulations will be
improved using the actual thermal contact conductance.
4. With coated cutting tool minimum tool tip temperature is achieve than uncoated
cutting tool. Hence at higher levels of cutting parameters is easy to maintain
minimum tool tip temperature.
84
LIST OF PUBLICATIONS
1. Mahesh Patil, Prof. Pranjali Deole, “Finite Element Analysis of Cutting Tool and
Regression Analysis for Internal Turning Process”, International Advanced
Research Journal in Science, Engineering and Technology”, Accepted.(DOI No.
10.17148)
2. Mahesh Patil, Prof. Pranjali Deole,” Cutting Parameters Optimization for Internal
Turning operation Using GA and ANOVA”, Ready to send.
85
REFRENCES
[1]. Satish Chinchanikar, “Effect of work material hardness and cutting parameters on
performance of coated carbide tool when turning hardened steel: An optimization
approach”, ELSEVIER, 2013, pp.1572-1584.
[2]. S.R.Das, S.P.Nayak, “Optimization of cutting parameters on tool wear and work
piece surface temp. in turning of AISI D2 steel”, International journal of lean
thinking, 2012, volume 3, issue 2, pp.141-156.
[3]. Achyut K. Panda, “Optimization of process parameters by Taguchi method:
Catalytic degradation of polypropylene to liquid fuel”, International Journal of
Multidisciplinary and Current, 20132, pp.2321-3124.
[4]. Ramanuj Kumar et al, “Some Studies on Cutting Forces and Temperature in
Machining Ti-6Al-4V Alloy using Regression Analysis and ANOVA”, 2013,
International Journal of Industrial Engineering Computations, pp.427-436.
[5]. Milenko Sekulic, “Optimization Of Cutting Parameters Based On Tool chip
Interface Temperature In Turning Process UsingTaguchi‟s Method”, 15th
International Research/Expert Conference, Trends in the Development of Machinery
and Associated Technology, 2011, pp.69-72.
[6]. Rahul Bhatti, “Optimization of Cutting Parameters on AISI H11 Steel using Multi-
Coated Carbide Tool by Taguchi Method”, International Journal of Current
Engineering and Technology, 2015, Vol.5, pp.2418-2424.
[7]. K. Someswara Rao et al, “Optimization of Machining Parameters for cutting
temperature on turning of Niobium alloy C-103by using RSM”, 2015, Vol.4, pp.13-
17.
[8]. S.H. Rathod, Mohd. Razik, “finite element analysis of single point cutting tool“,
International journal of modern engineering research, 2014, Vol.4, pp.2249-664.
[9]. Sana J. Yaseen, “Theoretical study of temperature distribution and heat flux
variation in aturning process”, Al-Qadisiya journal for engineering science, 2012,
Vol., No.3, pp.299-313.
[10]. Satish Chinchanikar, ”Evaluation of tool-chip interface temperature: Effect of
coating and cutting parameters during turning hardened AISI4340 steel”,
ELSEVIER, 2014, pp.996-1005.
[11]. J.E. Jam, V.N. Fard, ”A noval method is to determine tool-chip interface thermal
contact conductance in machining”, IJEST, 2011, pp.0975-5462.
86
[12]. Asmaa A. kawi, ” Temperature Behavior of some alloy steels in turning process
under different operating conditions “, Al-Qadisiya Journal For Engineering
Sciences, 2011, Vol.4.
[13]. Mohd Andai, “ Analysis of maximum temperature and heat generation of cutting
Tool during machining”, 2007, Thesis.
[14]. L.B. Abhang, M Hameemdullah,” The Measurement of chip-tool interface
Temperature in the Turning of steel”, International journal of computer
Communication and information system, 2010, Vol.2, pp.0976-1349.
[15]. Abdelouahhab Jabri, “Multi-Objective Optimization Using Genetic Algorithms of
Multi-Pass Turning Process”, www.scirp.org/journal/eng, 2013, Vol. 5, No. 3, 601
610.
[16]. Mir Asif Iquebal, “Genetic Algorithms And Their Applications: An Overview”,
I.A.S.R.I., Library Avenue.
[17]. M.Sanjeev kumar ,” Machining Parameter Optimization of Poly Tetra Fluoro
Ethylene (PTFE) Using Genetic Algorithm ”,IJMER, Vol.2, Issue.1, pp-143-149 .
[18]. Dusan Petkovic et al, “Using Genetic Algorithms for Optimization of Turning
Machining Process”, Journal of Engineering Studies and Research, 2013, Vol.19,
pp.47-55.
[19]. C. P. Kodandaraman, ”Heat and Mass Transfer Data Book”.
87
APPENDIX A- GENETIC ALGORITHM
Table A-1 Coded Parameters Values with Work piece Material EN8
IP OF SUM
Sr.No. SP(V) DOC FR T IP OF V IP OF FR TM FITNESS COUNT
DOE TM
1 160 0.5 0.04 48 010100000 000110010 000000100 127 642 0.1918 2
2 160 0.8 0.08 77 010100000 001001011 000001000 98 642 0.1550 2
3 160 1 0.16 88 010100000 001100100 000010000 87 642 0.1335 2
4 230 0.5 0.08 85 011100110 000110010 000001000 90 642 0.1459 1
5 230 0.8 0.16 95 011100110 001001011 000010000 80 642 0.1284 1
6 230 1 0.04 155 011100110 001100100 000000100 20 642 0.0377 0
7 380 0.5 0.16 98 101111100 000110010 000010000 77 642 0.1163 1
8 380 0.8 0.04 122 101111100 001001011 000000100 53 642 0.0861 0
9 380 1 0.08 165 101111100 001100100 000001000 10 642 0.0151 0
Table A-2 Results After Cross Over with Work piece Material EN8
MT MT CROSS NP SUM FITN
MT V MATE NP V NP FR V D F T' TM
DOE FR OVER DOE TM ESS
10100000 0110010 000100 9 4 11100000 110010 000100 224 0.5 0.04 74.2 100 954 0.10
10100000 0110010 000100 8 2 10100000 110010 000100 160 0.5 0.04 58.8 116 954 0.12
10100000 1001011 001000 7 5 10100000 111011 001000 160 0.59 0.08 62.6 112 954 0.11
10100000 1001011 001000 6 4 10100000 1101011 001000 160 1.07 0.08 115 59 954 0.06
10100000 1100100 010000 9 4 11100000 100100 010000 224 0.36 0.16 40.8 134 954 0.14
10100000 1100100 010000 4 4 10100000 1000100 001000 160 0.68 0.08 72.4 102 954 0.10
10100000 0110010 001000 3 5 10100000 1000010 001000 160 0.66 0.08 70.2 104 954 0.10
11100110 1001011 010000 2 2 11100110 1001011 010000 230 0.75 0.16 84.9 90 954 0.09
11100110 0110010 010000 1 4 10100110 110010 010000 166 0.5 0.16 42.1 132 954 0.13
88
Table A-3 Output of Genetic Algorithm with Work piece Material EN8
S.R. NP M SUM
NP V M NP V M NP D NP F V D' F' T TM FITNES
No. DOC NP F TM
1 11100000 11100000 110010 110010 100 1000 224 0.5 0.08 70 104 816 0.128146
2 10100000 11100000 110010 110110 100 10000 224 0.54 0.16 99 75 816 0.092637
3 10100000 10101000 111011 1101001 1000 100 168 1.05 0.04 140 34 816 0.042012
4 10100000 10100000 1101011 1101011 1000 1000 160 1.07 0.08 122 52 816 0.064843
5 11100000 11100000 100100 1100100 10000 10000 224 1 0.16 94 80 816 0.098307
6 10100000 10100000 1000100 1000100 1000 1000 160 0.68 0.08 84 90 816 0.111375
7 10100000 10100000 1000010 1000010 1000 1000 160 0.66 0.08 82 92 816 0.113761
8 11100110 11100100 1001011 1001010 10000 10000 228 0.74 0.16 97 77 816 0.094746
9 10100110 10100100 110010 110110 10000 1000 164 0.54 0.08 70 104 816 0.127722
89
IP
Sr. SP IP OF SUM FITN MT MT
DOC FR T IP OF V OF TM COUNT MT V
No. (V) DOE TM ESS DOE FR
FR
1 160 0.5 0.04 50 010100000 0110010 00100 130 650 0.2 2 010100000 0110010 00100
2 160 0.75 0.08 83 010100000 1001011 01000 97 650 0.14 2 010100000 0110010 00100
3 160 1 0.16 90 010100000 1100100 10000 90 650 0.13 1 010100000 1001011 01000
4 230 0.5 0.08 86 011100110 0110010 01000 94 650 0.14 2 010100000 1001011 01000
5 230 0.75 0.16 99 011100110 1001011 10000 81 650 0.12 1 010100000 1100100 10000
6 230 1 0.04 160 011100110 1100100 00100 20 650 0.03 0 011100110 0110010 01000
7 380 0.5 0.16 101 101111100 0110010 10000 79 650 0.12 1 011100110 0110010 01000
8 380 0.75 0.04 130 101111100 1001011 00100 50 650 0.07 0 011100110 1001011 10000
9 380 1 0.08 171 101111100 1100100 01000 9 650 0.01 0 101111100 0110010 10000
Table A-5 Results After Cross Over with Work piece Material EN9
SUM
MATE CROSS NP V NP DOE NP FR V D F T' TM' FITNESS'
TM'
9 4 101100000 110010 000000100 352 0.5 0.04 108.692 71.3084 840.5 0.08484
8 2 10100000 1110010 000000100 160 1.14 0.04 139.546 40.454 840.5 0.04813
7 5 11100000 111011 000001000 224 0.59 0.08 81.9922 98.0078 840.5 0.11661
6 4 11100000 101011 000001000 224 0.43 0.08 62.3602 117.64 840.5 0.13996
9 4 101100000 100100 000010000 352 0.36 0.16 73.6336 106.366 840.5 0.12655
4 4 10100110 1010010 000001000 166 0.82 0.08 95.8118 84.1882 840.5 0.10016
3 5 10100110 1000010 000001000 166 0.66 0.08 76.1798 103.82 840.5 0.12352
2 2 11100110 1001011 000010000 230 0.75 0.16 91.194 88.806 840.5 0.10566
1 4 10111100 110010 000010000 188 0.5 0.16 50.0904 129.91 840.5 0.15456
90
S.R. M NP SUM
NP V NP D NP F M NP V M NPD V' D'' F'' T' TM'' FITNES
No. F TM''
1 101100000 0110010 00100 101100000 110010 1000 352 0.5 0.08 81 98 822 0.119217
2 010100000 1110001 00100 10100000 1110001 100 160 1.13 0.04 157 22 822 0.027857
3 011100000 0111011 01000 11100000 110011 100 224 0.51 0.04 60 119 822 0.145746
4 011100000 0101011 01000 11100100 101010 1000 228 0.42 0.08 64 115 822 0.140711
5 101100000 0100100 10000 101100100 100110 1000 356 0.38 0.08 62 117 822 0.142872
6 010100110 1010010 01000 10100110 1010010 1000 166 0.82 0.08 102 77 822 0.09433
7 010100110 1000010 01000 10100110 1000010 1000 166 0.66 0.08 86 93 822 0.114012
8 011100110 1001011 10000 11100100 1001011 10000 228 0.75 0.16 100 79 822 0.096177
9 010111100 0110010 10000 10111000 110110 1000 184 0.54 0.08 75 104 822 0.127081
91
Sr. SP IP IP OF IP OF SUM FITN MT MT

DOC FR T TM COUNT MT V
No. (V) OF V DOE FR TM ESS DOE FR
1 160 0.5 0.04 70 010100000 0110010 00100 130 684 0.19 2 010100000 110010 00100
2 160 0.8 0.08 90 010100000 1001011 01000 110 684 0.16 2 010100000 110010 00100
3 160 1 0.16 115 010100000 1100100 10000 85 684 0.12 1 010100000 1001011 01000
4 230 0.5 0.08 95 011100110 0110010 01000 105 684 0.15 2 010100000 1001011 01000
5 230 0.8 0.16 130 011100110 1001011 10000 70 684 0.10 1 010100000 1100100 10000
6 230 1 0.04 165 011100110 1100100 00100 35 684 0.05 0 011100110 110010 01000
7 380 0.5 0.16 120 101111100 0110010 10000 80 684 0.11 1 011100110 110010 01000
8 380 0.8 0.04 141 101111100 1001011 00100 59 684 0.08 0 011100110 1001011 10000
9 380 1 0.08 180 101111100 1100100 01000 20 684 0.02 0 101111100 110010 10000
Table A-8 After Cross Over with Work piece Material EN31
CROSS SUM
MATE NP V NP DOE NP FR V D F T' TM' FITNES
OVER TM'
9 2 100100000 110010 000000100 288 0.5 0.04 76.52 123.48 793.74 0.15557
8 3 11100000 1110010 000000100 224 1.14 0.04 178.4 21.591 793.74 0.0272
7 4 11100000 101011 000001000 224 0.43 0.08 80.36 119.64 793.74 0.15073
6 3 11100000 1011 000001000 224 0.11 0.08 43.25 156.75 793.74 0.19748
2 4 10100000 100100 000010000 160 0.36 0.16 123.9 76.088 793.74 0.09586
4 3 10100110 1110010 000001000 166 1.14 0.08 141.8 58.239 793.74 0.07337
3 4 10100110 1010010 000001000 166 0.82 0.08 113.7 86.252 793.74 0.10866
2 3 10100110 1011 000010000 166 0.11 0.16 126.8 73.194 793.74 0.09221
1 2 11111100 110010 000010000 252 0.5 0.16 121.5 78.503 793.74 0.0989
92
S.R. SUM
M NP V M NP D M NP F F' V' D' D'' T' TM' FITNESS
No. TM'
1 100010000 110010 000001000 0.08 272 50 0.5 90.7384 109.2616 822.686 0.132811
2 11100000 1100010 000000100 0.04 224 98 0.98 151.7912 48.2088 822.686 0.058599
3 11110000 101011 000000100 0.04 240 43 0.43 60.89 139.11 822.686 0.169093
4 11101000 1001011 000001000 0.08 232 75 0.75 118.8204 81.1796 822.686 0.098676
5 10100000 100100 000001000 0.08 160 36 0.36 73.608 126.392 822.686 0.153633
6 10100110 1110000 000001000 0.08 166 112 1.12 140.01 59.99 822.686 0.07292
7 11100100 1010010 000001000 0.08 228 82 0.82 126.396 73.604 822.686 0.089468
8 10100110 1011 000010000 0.16 166 11 0.11 126.8058 73.1942 822.686 0.08897
9 11100100 110110 000001000 0.08 228 54 0.54 93.3784 106.6216 822.686 0.129602
93
APPENDIX-B
CORRELATIONS AND REGRESSION ANALYSIS
Table B-1 Experimental Parameters for Internal Turning Operation
Sr. V Doc Fr w/p Diw/p

T
No. (rpm) (mm) (mm/rev) material (mm)
1 160 0.5 0.04 EN-31 70 80
2 160 0.75 0.08 EN-31 90 79
3 160 1 0.16 EN-31 115 77.5
4 230 0.5 0.08 EN-31 95 75.5
5 230 0.75 0.16 EN-31 130 74.5
6 230 1 0.04 EN-31 165 73
7 380 0.5 0.16 EN-31 120 71
8 380 0.75 0.04 EN-31 141 70
9 380 1 0.08 EN-31 180 68.5
10 160 0.5 0.04 EN-9 50 80
11 160 0.75 0.08 EN-9 83 79
12 160 1 0.16 EN-9 90 77.5
13 230 0.5 0.08 EN-9 86 75.5
14 230 0.75 0.16 EN-9 99 74.5
15 230 1 0.04 EN-9 160 73
16 380 0.5 0.16 EN-9 101 71
17 380 0.75 0.04 EN-9 130 70
18 380 1 0.08 EN-9 171 68.5
19 160 0.5 0.04 EN-8 48 80
20 160 0.75 0.08 EN-8 77 79
21 160 1 0.16 EN-8 88 77.5
22 230 0.5 0.08 EN-8 85 75.5
23 230 0.75 0.16 EN-8 95 74.5
24 230 1 0.04 EN-8 155 73
25 380 0.5 0.16 EN-8 98 71
26 380 0.75 0.04 EN-8 122 70
27 380 1 0.08 EN-8 165 68.5
94
Table B-2 Other Operating Parameters for Internal Turning Operation
Sr. Density Density

T hair Ktool Kw/p Cptool Cpw/p
No. of tool of w/p
1 70 19.53 81.8571 53.5526 292 460 15800 7800
2 90 21.3157 81.8929 53.5789 292 460 15800 7800
3 115 23.0512 81.9464 53.6184 292 460 15800 7800
4 95 21.6972 82.0179 53.6711 292 460 15800 7800
5 130 23.9293 82.0536 53.6974 292 460 15800 7800
6 165 25.6689 82.1071 53.7368 292 460 15800 7800
7 120 23.355 82.1786 53.7895 292 460 15800 7800
8 141 24.5166 82.2143 53.8158 292 460 15800 7800
9 180 26.3171 82.2679 53.8553 292 460 15800 7800
10 50 17.075 81.8571 19.1667 292 500 15800 7700
11 83 20.744 81.8929 19.2 292 500 15800 7700
12 90 21.3158 81.9464 19.25 292 500 15800 7700
13 86 20.99 82.0179 19.3167 292 500 15800 7700
14 99 21.9885 82.0536 19.35 292 500 15800 7700
15 160 25.4415 82.1071 19.4 292 500 15800 7700
16 101 22.13 82.1786 19.4667 292 500 15800 7700
17 130 23.9292 82.2143 19.5 292 500 15800 7700
18 171 25.934 82.2679 19.55 292 500 15800 7700
19 48 16.7616 81.8571 17.1667 292 500 15800 7700
20 77 20.2145 81.8929 17.2 292 500 15800 7700
21 88 21.1573 81.9464 17.25 292 500 15800 7700
22 85 20.9126 82.0179 17.3167 292 500 15800 7700
23 95 21.6972 82.0536 17.35 292 500 15800 7700
24 155 25.2079 82.1071 17.4 292 500 15800 7700
25 98 21.9168 82.1786 17.4667 292 500 15800 7700
26 122 23.4733 82.2143 17.5 292 500 15800 7700
27 165 25.6689 82.2679 17.55 292 500 15800 7700
95
Table B-3 Calculations of Log of Pi (π) Terms for Internal Turning
Sr. logπ logπ1 logπ2 logπ3 logπ4 logπ5 logπ6 logπ7

No. (y) (A) (B) (C) (D) (E) (F) (G)
1 11.61 -0.18404 0.19 -0.306 4.078151 -2.20 -5.8563 -1.72116
2 11.72 -0.18452 0.19 -0.306 4.076478 -2.02 -5.54267 -1.68483
3 11.82 -0.18513 0.19 -0.306 4.072937 -1.88 -5.22145 -1.65438
4 11.70 -0.18464 0.19 -0.306 4.215358 -2.17 -5.48459 -1.69585
5 11.84 -0.1855 0.19 -0.306 4.216295 -1.99 -5.17291 -1.65239
6 11.94 -0.18639 0.19 -0.306 4.214295 -1.86 -5.7553 -1.62391
7 11.76 -0.18525 0.19 -0.306 4.41152 -2.15 -5.10828 -1.68577
8 11.83 -0.18578 0.19 -0.306 4.409429 -1.97 -5.69593 -1.66678
9 11.93 -0.18679 0.19 -0.306 4.40768 -1.83 -5.37434 -1.63775
10 11.46 -0.61407 0.23 -0.312 4.074394 -2.20 -5.85255 -1.78325
11 11.68 -0.63221 0.23 -0.312 4.075148 -2.02 -5.54134 -1.69797
12 11.71 -0.63623 0.23 -0.312 4.068153 -1.88 -5.21667 -1.69315
13 11.66 -0.63393 0.23 -0.312 4.213645 -2.17 -5.48287 -1.71196
14 11.73 -0.64149 0.23 -0.312 4.210331 -1.99 -5.16695 -1.69509
15 11.92 -0.68014 0.23 -0.312 4.213312 -1.86 -5.75432 -1.62876
16 11.68 -0.64267 0.23 -0.312 4.407872 -2.15 -5.10464 -1.71282
17 11.79 -0.66044 0.23 -0.312 4.407293 -1.97 -5.6938 -1.67945
18 11.90 -0.68774 0.23 -0.312 4.405901 -1.83 -5.37256 -1.6459
19 11.44 -0.65821 0.23 -0.312 4.074021 -2.20 -5.85217 -1.79167
20 11.64 -0.67642 0.23 -0.312 4.074011 -2.02 -5.54021 -1.71033
21 11.69 -0.68365 0.23 -0.312 4.067772 -1.88 -5.21629 -1.69678
22 11.65 -0.68166 0.23 -0.312 4.213455 -2.17 -5.48268 -1.71375
23 11.69 -0.68836 0.23 -0.312 4.209568 -1.99 -5.16618 -1.70165
24 11.91 -0.73228 0.23 -0.312 4.212332 -1.86 -5.75334 -1.63375
25 11.66 -0.6904 0.23 -0.312 4.407298 -2.15 -5.10406 -1.7176
26 11.75 -0.70728 0.23 -0.312 4.405746 -1.97 -5.69225 -1.68935
27 11.88 -0.7403 0.23 -0.312 4.404719 -1.83 -5.37138 -1.65155
Avg.
11.74 -0.5095 0.22 -0.310 4.23137 -2.01 -5.4658 -1.6881
Values
96
Table B-4 Calculations of the Multipliers of LHS and Log of Pi (π) in Terms of
Equation
Sr. No. YA YB YC YD YE YF YG
1 -2.1376 2.29248 -3.5607 47.3671 -25.601 -68.02 -19.991
2 -2.1626 2.31336 -3.5931 47.779 -23.706 -64.964 -19.747
3 -2.1882 2.33298 -3.6236 48.1422 -22.332 -61.718 -19.555
4 -2.1615 2.3106 -3.5888 49.3478 -25.509 -64.206 -19.853
5 -2.1972 2.33786 -3.6312 49.941 -23.655 -61.272 -19.572
6 -2.2263 2.35751 -3.6617 50.3368 -22.256 -68.743 -19.397
7 -2.1794 2.32199 -3.6065 51.8986 -25.32 -60.096 -19.832
8 -2.1978 2.33498 -3.6267 52.1644 -23.306 -67.384 -19.718
9 -2.2289 2.35523 -3.6581 52.5958 -21.905 -64.131 -19.543
10 -7.038 2.67719 -3.5778 46.6975 -25.262 -67.077 -20.438
11 -7.386 2.72896 -3.647 47.6092 -23.629 -64.739 -19.837
12 -7.4464 2.7339 -3.6536 47.6136 -22.112 -61.056 -19.817
13 -7.3916 2.72363 -3.6399 49.1312 -25.407 -63.93 -19.961
14 -7.5147 2.73636 -3.6569 49.322 -23.395 -60.528 -19.857
15 -8.1134 2.78646 -3.7238 50.2605 -22.228 -68.643 -19.429
16 -7.5078 2.72881 -3.6468 51.4936 -25.143 -59.633 -20.009
17 -7.787 2.75414 -3.6806 51.9648 -23.228 -67.134 -19.802
18 -8.1888 2.7813 -3.7169 52.4607 -21.857 -63.971 -19.598
19 -7.5317 2.67287 -3.572 46.6179 -25.221 -66.965 -20.502
20 -7.8789 2.72081 -3.6361 47.4539 -23.559 -64.532 -19.922
21 -7.9943 2.73144 -3.6503 47.5664 -22.092 -60.997 -19.841
22 -7.9444 2.72236 -3.6382 49.106 -25.395 -63.898 -19.973
23 -8.0504 2.73182 -3.6508 49.2313 -23.356 -60.419 -19.901
24 -8.7238 2.78278 -3.7189 50.1825 -22.198 -68.541 -19.463
25 -8.0555 2.72548 -3.6423 51.4241 -25.113 -59.554 -20.041
26 -8.3176 2.74698 -3.6711 51.8114 -23.168 -66.941 -19.867
27 -8.8014 2.77713 -3.7114 52.3679 -21.825 -63.861 -19.635
Avg.
-5.976 2.60072 -3.6439 49.6995 -23.621 -64.183 -19.819
Values
97
Table B-5 Calculations of the Multipliers of LHS and RSH in Terms of Equation
Sr. No. AA AB AC AD AE AF AG
1 0.03387 -0.03632 0.056419 -0.75053 0.405641 1.07778 0.316757
2 0.034046 -0.03642 0.056566 -0.75218 0.373196 1.022713 0.310879
3 0.034272 -0.03654 0.056753 -0.75401 0.349761 0.966632 0.30627
4 0.034091 -0.03644 0.056603 -0.77831 0.40232 1.012659 0.313118
5 0.03441 -0.03661 0.056868 -0.78213 0.370462 0.959578 0.30652
6 0.034742 -0.03679 0.057141 -0.78552 0.347311 1.07275 0.302687
7 0.034318 -0.03656 0.056791 -0.81724 0.398714 0.946315 0.312291
8 0.034513 -0.03667 0.056953 -0.81917 0.365989 1.058179 0.309652
9 0.034889 -0.03687 0.057261 -0.82329 0.34288 1.003847 0.305908
10 0.377082 -0.14344 0.191692 -2.50196 1.353484 3.593873 1.095043
11 0.399693 -0.14768 0.197356 -2.57636 1.278692 3.503309 1.073478
12 0.404789 -0.14862 0.19861 -2.58828 1.202031 3.319003 1.077237
13 0.401864 -0.14808 0.197891 -2.67114 1.381313 3.475742 1.085257
14 0.411507 -0.14984 0.200251 -2.70088 1.281112 3.314534 1.087379
15 0.462595 -0.15887 0.212318 -2.86566 1.267326 3.913762 1.107791
16 0.413025 -0.15012 0.20062 -2.83281 1.383212 3.280599 1.100779
17 0.43618 -0.15427 0.206167 -2.91075 1.30109 3.760408 1.109176
18 0.472983 -0.16065 0.214689 -3.03011 1.262474 3.694913 1.131949
19 0.433243 -0.15375 0.205472 -2.68157 1.450778 3.85197 1.1793
20 0.457539 -0.158 0.211154 -2.75573 1.368096 3.747485 1.156898
21 0.467379 -0.15969 0.213413 -2.78094 1.291624 3.566122 1.160003
22 0.464659 -0.15923 0.212791 -2.87214 1.48532 3.737321 1.168196
23 0.473834 -0.16079 0.214882 -2.89768 1.374713 3.556175 1.171338
24 0.536228 -0.17105 0.228592 -3.08459 1.364467 4.213035 1.196355
25 0.476648 -0.16127 0.215519 -3.04279 1.485934 3.523831 1.185824
26 0.500252 -0.16521 0.22079 -3.11612 1.393377 4.02604 1.194853
27 0.54804 -0.17292 0.231096 -3.2608 1.358956 3.976415 1.222635
Avg.
Values 0.312841 -0.11677 0.158691 -2.15677 1.023714 2.784259 0.862503
98
Sr. No. BB BC BD BE BF BG
1 0.038957 -0.06051 0.804925 -0.43504 -1.15589 -0.33971
2 0.038957 -0.06051 0.804595 -0.3992 -1.09399 -0.33254
3 0.038957 -0.06051 0.803896 -0.3729 -1.03058 -0.32653
4 0.038957 -0.06051 0.832006 -0.43008 -1.08252 -0.33472
5 0.038957 -0.06051 0.832191 -0.39418 -1.021 -0.32614
6 0.038957 -0.06051 0.831796 -0.36777 -1.13595 -0.32052
7 0.038957 -0.06051 0.870724 -0.42481 -1.00825 -0.33273
8 0.038957 -0.06051 0.870311 -0.38884 -1.12423 -0.32898
9 0.038957 -0.06051 0.869966 -0.36232 -1.06076 -0.32325
10 0.054563 -0.07292 0.951726 -0.51485 -1.36708 -0.41655
11 0.054563 -0.07292 0.951902 -0.47245 -1.29439 -0.39662
12 0.054563 -0.07292 0.950268 -0.44132 -1.21855 -0.3955
13 0.054563 -0.07292 0.984253 -0.50898 -1.28073 -0.39989
14 0.054563 -0.07292 0.983479 -0.4665 -1.20693 -0.39595
15 0.054563 -0.07292 0.984176 -0.43525 -1.34414 -0.38046
16 0.054563 -0.07292 1.029622 -0.50275 -1.19238 -0.40009
17 0.054563 -0.07292 1.029487 -0.46018 -1.33 -0.3923
18 0.054563 -0.07292 1.029162 -0.42879 -1.25496 -0.38446
19 0.054563 -0.07292 0.951639 -0.51485 -1.36699 -0.41851
20 0.054563 -0.07292 0.951637 -0.47245 -1.29412 -0.39951
21 0.054563 -0.07292 0.950179 -0.44132 -1.21846 -0.39635
22 0.054563 -0.07292 0.984209 -0.50898 -1.28068 -0.40031
23 0.054563 -0.07292 0.983301 -0.4665 -1.20675 -0.39748
24 0.054563 -0.07292 0.983947 -0.43525 -1.34391 -0.38162
25 0.054563 -0.07292 1.029488 -0.50275 -1.19224 -0.40121
26 0.054563 -0.07292 1.029126 -0.46018 -1.32964 -0.39461
27 0.054563 -0.07292 1.028886 -0.42879 -1.25468 -0.38578
Avg.
0.049361 -0.06878 0.937292 -0.44582 -1.21073 -0.37416
Values
99
Sr. No. CC CD CE CF CG DD DE DF DG
1 0.093981 -1.25021 0.6757 1.795323 0.527642 16.63132 -8.98873 -23.8829 -7.01913
2 0.093981 -1.2497 0.620043 1.699176 0.516506 16.61767 -8.24495 -22.5946 -6.86818
3 0.093981 -1.24861 0.579189 1.600701 0.50717 16.58881 -7.69501 -21.2666 -6.73818
4 0.093981 -1.29227 0.667993 1.681368 0.519885 17.76925 -9.18517 -23.1195 -7.14863
5 0.093981 -1.29256 0.612234 1.585821 0.506561 17.77715 -8.42034 -21.8105 -6.96697
6 0.093981 -1.29194 0.571225 1.76436 0.497831 17.76028 -7.85259 -24.2546 -6.84365
7 0.093981 -1.35241 0.659811 1.566008 0.516794 19.46151 -9.49486 -22.5353 -7.43682
8 0.093981 -1.35177 0.603939 1.746159 0.510973 19.44306 -8.68674 -25.1158 -7.34956
9 0.093981 -1.35123 0.562754 1.647571 0.502074 19.42765 -8.09114 -23.6884 -7.2187
10 0.097448 -1.27189 0.688052 1.826968 0.556672 16.60069 -8.98045 -23.8456 -7.26568
11 0.097448 -1.27212 0.631377 1.729821 0.530049 16.60683 -8.24226 -22.5818 -6.91947
12 0.097448 -1.26994 0.589776 1.628468 0.528546 16.54987 -7.68597 -21.2222 -6.88801
13 0.097448 -1.31536 0.680203 1.711568 0.534416 17.75481 -9.18144 -23.1029 -7.21359
14 0.097448 -1.31432 0.623426 1.612947 0.52915 17.72689 -8.40843 -21.7546 -7.13689
15 0.097448 -1.31525 0.581667 1.796306 0.508445 17.752 -7.85076 -24.2448 -6.86248
16 0.097448 -1.37599 0.671872 1.593496 0.534685 19.42933 -9.48701 -22.5006 -7.54989
17 0.097448 -1.37581 0.614979 1.777412 0.524268 19.42423 -8.68253 -25.0942 -7.40183
18 0.097448 -1.37537 0.573041 1.677132 0.513795 19.41196 -8.08787 -23.671 -7.25168
19 0.097448 -1.27177 0.688052 1.826851 0.5593 16.59764 -8.97963 -23.8419 -7.29931
20 0.097448 -1.27177 0.631377 1.729466 0.533909 16.59757 -8.23996 -22.5709 -6.96792
21 0.097448 -1.26982 0.589776 1.628349 0.529676 16.54677 -7.68525 -21.2187 -6.9021
22 0.097448 -1.3153 0.680203 1.711509 0.534976 17.75321 -9.18102 -23.101 -7.22082
23 0.097448 -1.31409 0.623426 1.612709 0.531196 17.72046 -8.40691 -21.7474 -7.16319
24 0.097448 -1.31495 0.581667 1.795999 0.510001 17.74374 -7.84893 -24.235 -6.88189
25 0.097448 -1.37581 0.671872 1.593317 0.536176 19.42428 -9.48578 -22.4951 -7.56996
26 0.097448 -1.37533 0.614979 1.776929 0.527359 19.4106 -8.67948 -25.0786 -7.44286
27 0.097448 -1.375 0.573041 1.676763 0.515557 19.40155 -8.0857 -23.6594 -7.2746
Avg.
Values 0.096292 -1.31298 0.624506 1.696018 0.523838 17.9233 -8.51329 -23.1198 -7.14081
100
Sr. No. EE EF EG FF FG GG
1 4.858145 12.90799 3.793632 34.29628 10.0796 2.962375
2 4.090773 11.21042 3.407681 30.72123 9.338468 2.838655
3 3.569461 9.864897 3.12562 27.26356 8.638256 2.736968
4 4.747941 11.95079 3.695228 30.08068 9.301059 2.875922
5 3.988388 10.3308 3.299982 26.75901 8.547674 2.730397
6 3.471972 10.72399 3.025876 33.12353 9.34612 2.637097
7 4.632345 10.9945 3.628268 26.09457 8.611404 2.841828
8 3.881045 11.2212 3.283624 32.44365 9.493885 2.778166
9 3.36976 9.865624 3.006409 28.88352 8.801845 2.682238
10 4.858145 12.89971 3.930505 34.25229 10.43657 3.179993
11 4.090773 11.20773 3.434252 30.70649 9.409025 2.883096
12 3.569461 9.855859 3.19888 27.21362 8.832626 2.866773
13 4.747941 11.94705 3.730319 30.06189 9.386452 2.930803
14 3.988388 10.31888 3.385255 26.69735 8.758438 2.873329
15 3.471972 10.72216 3.034909 33.11222 9.372417 2.652864
16 4.632345 10.98665 3.686481 26.05731 8.743319 2.93375
17 3.881045 11.21699 3.308581 32.41932 9.562454 2.820557
18 3.36976 9.862357 3.021367 28.8644 8.842706 2.708993
19 4.858145 12.89889 3.949061 34.24791 10.48518 3.210091
20 4.090773 11.20543 3.459264 30.69389 9.475607 2.925244
21 3.569461 9.85514 3.205722 27.20965 8.850871 2.879049
22 4.747941 11.94664 3.734229 30.05981 9.395965 2.93695
23 3.988388 10.31736 3.398347 26.68945 8.791011 2.895596
24 3.471972 10.72033 3.0442 33.10093 9.39951 2.669133
25 4.632345 10.98541 3.696764 26.05145 8.766722 2.950139
26 3.881045 11.21394 3.328086 32.40171 9.616215 2.853911
27 3.36976 9.860187 3.031728 28.85169 8.871079 2.727606
Avg.
Values 4.067759 11.00337 3.40164 29.93916 9.227944 2.851168
101

Parametric Optimization of Cutting Tool Temperature in Internal Turning

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Parametric Optimization of Cutting Tool Temperature in Internal Turning

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PARAMETRIC EVALUATION OF

CUTTING TOOL FOR INTERNAL

HEAT POWER ENGINEERING

Department of Mechanical Engineering

Department of Mechanical Engineering

This is to certify that the Thesis on “Parametric Evaluation of Cutting

Prof. Pranjali Deole Dr. M.M. Gupta

Dr. K.N. Agrawal Dr. R.S. Pande

I, hereby declare that the thesis titled “Parametric Evaluation of

carried out in the Department of M e c h a n i c a l Engineering of Shri

Ramdeobaba College of Engineering & Management, Nagpur. The work

the award of any degree / diploma at this or any other institution /

This thesis/ dissertation/ report entitled “Parametric Evaluation of Cutting

Prof. Pranjali Deole Name and signature of External Examiner (s)

Dr. K.N. Agrawal

With a profound feeling of immense gratitude and affection, I would like to

Chapter Topic Page No.

25 Results Obtained By Genetic Algorithm 7.7 68

T Cutting Tool temperature (⁰C)

Kw/p Thermal conductivity of work piece material (w/m k)

Cptool Specific heat of tool material (J/kg k)

Cpw/p Specific heat of work piece material (J/kg k)

ρtool Density of tool material (kg/m3)

1.2 MACHINING PROCESSES

1.3 INTERNAL OPERATIONS

2. Slender tooling‟s are susceptible to cantilever deflection.

4. Less cutting speed/spindle speed has to be used compared to other machining

5. Evacuating chips from the machined bore is very difficult.

6. Surface of machined bore gets deteriorated due to rubbing of accumulated chips.

7. Inspection of machined surface is very difficult.

Step-Internal turning is performed in roughing by a Internal turning tool having

1.5 FACTORS CHARACTERIZING INTERNAL TURNING

1.5.1. Machine tool

1.5.2. Cutting tool

1.5.3. Tool geometry:

1.5.4 Cutting parameters:

1.6 CONTROL OF INTERNAL TURNING PROCESS

Several process parameters need to be controlled in order to improve the responses.

STUDY OF PARAMETRIC EVALUATION OF CUTTING

Milenko Sekulic et al, [5] Determination of optimal machining parameters is continuous

STUDY OF THERMAL ANALYSIS OF CUTTING TOOL USING

Satish Chinchanikar [10] present context of sustainable manufacturing, investigation of

STUDY OF GENETIC ALGORITHM FOR PARAMETER

2.1 NEED OF THE PROJECT:

1. To determine the minimum tool tip temperature by selecting the optimized

3.1 LATHE MACHINE:

Figure 3.1 Lathe Machine

3.2 TOOLS USED IN LATHE MACHINE:

Shim Figure 3.2: Turning Tool

b) Internal Turning tool

For example: CNMG 130501WP

The meaning of different designation is given below:

M=Tolerance (corner point=0.002-0.005",thikness=0.005",inscribed circle=0.002-

G=Chip breaker (cylindrical and double sided)

Radius (corner) =01

Figure 3.4: Insert geometry

3.3 WORK PIECES MATERIALS:

Table 3.3: Chemical Composition of EN 8

Silicon % 0.1 – 0.4

Sulphur % 0.05 max

Phosphorous % 0.05 max

Hardness – 74.5 HRB

T = - 19.6 - (0.149V) + (107D) + (1180F) + (0.49V*D) - (0.61VF) -

T = - 81.9 - (0.018V) + (183D) + (1479F) + (0.332V*D) - (1.05VF) –

T = - 73.8 - (0.036V) + (174.1D) + (1346F) + (0.32V*D) - (0.8VF) -