International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October 2014)

Optimization of Process Parameters in Turning Operation

Using Response Surface Methodology: A Review
Ranganath M S1, Vipin2, Harshit3
1
Associate Professor, 2Professor, 3Student
1, 2
Production and Industrial Engineering, 3Mechanical Engineering, Delhi Technological University, Delhi, India
Abstract— The parameters affecting the roughness of This causes high manufacturing cost and low product
surfaces produced in the turning process for various materials quality .Surface roughness is mainly a result of process
have been studied by many researchers. Design of parameters such as tool geometry (i.e. nose radius, edge
experiments were conducted for the analysis of the influence geometry, rake angle) and cutting conditions (feed rate,
of the turning parameters such as cutting speed, feed rate and
cutting speed, depth of cut) [8].Surface roughness is harder
depth of cut on the surface roughness. The results of the
machining experiments were used to characterize the main to attain and track than physical dimensions are, because
factors affecting surface roughness by the DOE techniques relatively many factors affect surface roughness. Some of
like Taguchi, Full factorial, Response Surface Methodology these factors can be controlled and some cannot.
and other methods. The key element for achieving high Controllable process parameters include feed, cutting
quality at low cost is Design of Experiments (DOE). Response speed, tool geometry, and tool setup. Other factors, such as
surface methodology (RSM) is an effective tool for robust tool, work piece and machine vibration, tool wear and
design, it offers a simple and systematic qualitative optimal degradation, and work piece and tool material variability
design to a relatively low cost. In this paper RSM, an cannot be controlled as easily [13]. The important cutting
approach of DOE used by various researchers to analyze the
parameters considered for discussion here are cutting
effect of process parameters like cutting speed, feed, and
depth of cut on Surface Roughness of work material while speed, feed and depth of cut. It is found in most of the cases
machining with various tools and to obtain an optimal setting surface roughness decreases with increase in cutting speed
of these parameters that may result in good surface finish and decrease in feed and depth of cut. Since these cutting
have been discussed. parameters will decide about the type of chips which we
expect at the time of machining of a single constant
Keywords—DOE, Response surface methodology, ANOVA, material thus we have to analyze them for no such built-up
Surface Roughness, Turning. edge chips formation.
I. INTRODUCTION Response Surface Methodology
The need for selecting and implementing optimal RSM is a collection of mathematical and statistical
machining conditions and most suitable cutting tools has techniques that are useful for modeling and analysis of
been felt very important over few decades.Surface problems in which a response of interest is influenced by
roughness has become the most significant technical several variables and the objective is to optimize this
requirement and it is an index of product quality. In order response [10].RSM can be defined as a statistical method
to develop a surface roughness model and optimize, it is that uses quantitative data from appropriate experiments to
essential to understand the current status of work in this determine and simultaneously solve multi-variable
area. A good surface finish is desired in order to improve equations correlating the dependent parameters(response)
the properties, fatigue strength, corrosion resistance and such as cutting force, power consumption, surface
aesthetic appeal of the product. The manufacturing roughness, tool life with independent parameters (input
industries specially are focusing their attention on variables). cutting speed, feed rate and depth of cut, in a
dimensional accuracy and surface finish. In order to obtain turning process. The graphical representations of these
optimal cutting parameters to achieve the best possible equations are called response surfaces, which can be used
surface finish, manufacturing industries have resorted to to describe the individual and cumulative effect of the input
the use of handbook based information and operators variables on the response and to determine the mutual
experience. This traditional practice leads to improper interactions between the input variables and their
surface finish and decrease in the productivity due to sub- subsequent effect on the response.
optimal use of machining capability.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October 2014)
The work which initially generated interest in the
package of technique was by box and Wilson in 1951.RSM
can be used in the following ways [20]:
1) To determine the factor levels that will
simultaneously satisfy a set of desired specifications,
2) To determine the optimum combination of factors that
yields a desired response and describes the response
near the optimum,
3) To determine how a specific response is affected by
changes in the level of the factors over the Specified
levels of interest,
4) To achieve a quantitative understanding of the system
behavior over the region tested,
5) To predict product properties throughout the region,
even for a factor combinations not actually run,
6) To find the conditions necessary for process stability
(insensitive spot).
To generate contour surface [5]
Response surface methodology, or RSM, is a collection
of mathematical and statistical techniques in which a
response of interest is influenced by several variables and
the objective is to optimize this response. For example,
suppose that a chemical engineer wishes to find the levels
of temperature (x1) and pressure (x2) that maximize the
yield (y) of a process. The process yield is a function of the
levels of temperature and pressure, y = f (x1, x2) +e
Where e represents the noise or error observed in the
response y. Then the surface represented by h= f (x1, x2),
which is called a Response surface. We usually represent
the response surface graphically, where h is plotted versus
the levels of x1 and x2. To help visualize the shape of a
response surface, we often plot the contours of the response
Figure 1.Steps in Response Surface Methodology (RSM).
surface as well. In the contour plot, lines of constant
In design optimization using RSM, the first task is to response are drawn in the x1, x2 planes. Each contour
determine the optimization model, such as the corresponds to a particular height of the response surface.
identification of the interested system measures and the Objective is to optimize the response. In RSM, polynomial
selection of the factors that influence the system measures equations, which explain the relations between input
significantly. To do this, an understanding of the physical variables and response variables, are constructed from
meaning of the problem and some experience are both experiments or simulations and the equations are used to
useful. After this, the important issues are the design of find optimal conditions of input variables in order to
experiments and how to improve the fitting accuracy of the improve response variables. For the design of RSM, many
response surface models. DOE techniques are employed researchers have used central composite design (CCD) for
before, during, and after the regression analysis to evaluate their experiments. CCD is widely used for fitting a second-
the accuracy of the model.RSM also quantifies order response surface. CCD consists of cube point runs,
relationships among one or more measured responses and plus center point runs, and plus axial point runs.
the vital input factors.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October 2014)
Depending on the capacity of the machine, an augment
length of ±1 was chosen. The augment points consist of
three levels for each of the independent variables denoted
by -1, 0, 1. These six experiments were repeated twice to
develop the second-order model. The resulting 12 or 24
experiments form the central composite design with 23
designs. Regression analysis was successfully used to
develop the surface roughness model. The surface
roughness equation showed that the feed is the main
influencing factor on the surface roughness, followed by
cutting speed and depth of cut in the operation model.
32 Increasing any of these three cutting variables increases the
surface roughness. Dual-response contours provided useful
Fig2: To generate contour surface
information about the maximum attainable surface
The three factors speed, feed rate, depth of cut, selected roughness for a given metal removal rate as a function of
in the screening experiment, will be used in CCD. The all three independent cutting variables.
process can be studied with a standard RSM design called a
Central composite design (CCD). The factorial portion is a
full factorial design with all factors at three levels, the star
points are at the face of the cube portion on the design
which correspond to value of -1. This is commonly referred
to as a face centered CCD. The center points, as implied by
the name, are points with all levels set to coded level 0, the
midpoint of each factor range, and this is repeated six
times. Twenty experiments to be performed. For each
experimental trial, a new cutting edge to be used. The latest
version of the Minitab or Design Expert may be used to
develop the experimental plan for response surface
methodology. The same software can also be used to
analyze the data collected. Fig3: Representation of a CCD

Alexandru STANIMIR.et.al.,[22] have presented a paper

II. LITERATURE REVIEW where in order to find out a mathematical relation of
Vipin and Harish Kumar [24] used Response surface polynomial second degree type which describe, in finish
methodology for their investigations. The surface turning of hardened 205 Cr115 steel, the roughness
roughness models were developed for turning leaded gun parameter Ra dependence on cutting edge wear, depth of
metal under dry conditions. The models were developed in cut, feed rate and cutting speed, a factorial design
terms of cutting speed, feed rate and depth of cut obtained methodology was used. The experimental tests were done
experimentally. The effects of cutting variables (cutting according to a composed, central, four-factor five-level
speed, feed and depth of cut) on surface roughness had factorial program. The established second degree
been investigated by Central composite Design. The first- polynomial relationship for the Ra calculus as a function of
order model was developed by an experimental design the cutting conditions and the flank wear approximate in a
consisting of 12 experiments. Twelve experiments satisfactory way the studied phenomena. The main
constitute Eight experiments (23 factorial designs) and influence on the surface roughness was exerted by the feed
Four experiments (an added centre point repeated four rate and flank wear.The interactions of some parameters as
times) as shown in Fig.2. This was done to predict the ‗b‘ feed rate and flank wear had a great influence on the
parameters as used in the Equation. The blocks provide the roughness values of the machined surface. Karin
confidence interval of the parameters and help in the Kandananond [7] used Design of Experiment for the
analysis of variance. A second-order model was developed determination of Empirical Model for Surface Roughness
by adding six augment points to the factorial design. in Turning Process.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October 2014)
This process was performed in the final assembly The developed models were used to determine the
department at a manufacturing company which supplies optimum machining parameters. These optimized
fluid dynamic bearing (FDB) spindle motors for hard disk machining parameters were validated experimentally, and it
drives (HDDs). The work pieces used were the sleeves of was observed that the response values were in reasonable
FDB motors made of ferritic stainless steel, grade AISI agreement with the predicted values. The experiment was
12L14. A 2k factorial experiment was used to characterize performed by using a PMT –TNS-25 CNC lathe. Inconel
the effects of machining factors, depth of cut, spindle speed 718 cylindrical rod is considered as the work piece
and feed rate on the surface roughness of the sleeve. The material. Titanium carbide based cermet inserts
results show that the surface roughness was minimized (Triangular) were used as the cutting tool. The
when the spindle speed and feed rate were set to the highest consequences of the experimental data is used for
levels while the depth of cut was set to the lowest level. predicting the outcome of assorted input machining
Even though the results from this research were process parameters such as cutting speed, feed and depth of cut on
specific, the methodology deployed can be readily applied the surface roughness when machining Inconel 718 using
to different turning processes. As a result, practitioners cermet inserts. A non-linear regression equation was
have guidelines for achieving the highest possible developed and projected. Cutting speed has the strongest
performance potential. The purpose of this research is to effect on the surface roughness among the selected
quantify the effect of depth of cut, spindle speed and feed parameters; it was inversely proportional to the response. It
rate on surface roughness of the FDB sleeve in HDD. The was found that the surface roughness could be controlled in
factorial design was utilized to obtain the best cutting the design stage which was the most effective and
condition which leads to the minimization of the surface inexpensive way.
roughness. The half normal plot and ANOVA indicate that Y. Sahin, A.R. Motorcu [17] presented a paper in which
the feed rate (C) is the most significant factor followed by the surface roughness model was developed in terms of
spindle speed (B) and feed rate (A). Moreover, it was main cutting parameters such as cutting speed, feed rate
interesting to note that there are interactions among these and depth of cut, using response surface methodology.
three factors with the highest order term, ABC. Regarding Machining tests were carried out in turning AISI 1050
the model validation, the regression model developed hardened steels by cubic boron nitride (CBN) cutting tools
proves accuracy and has the capability to predict the value under different conditions. The model predicting equations
of response within the limits of factors investigated. After for surface roughness of Ra, Rz and Rmax were developed
the optimal cutting condition is implemented, the surface using an experimental data when machining steels. The
roughness was significantly reduced about 8 percent. In results indicate that the feed rate was found out to be
addition to the factorial design experiment, the RSM and dominant factor on the surface roughness, but it decreased
Taguchi design were proved to be potential methodologies with decreasing cutting speed, feed rate, and depth of cut
to develop an empirical model and optimize the surface for these tools. In addition, average surface finish of Ra
roughness of the metal work pieces. value produced by CBN cutting tool was about 0.823 µm
M. Aruna and V. Dhanalaksmi [3] used Inconel 718, a when machining hardened steels. However, the Ra value
nickel based super-alloy accounting for about 50% by decreased about 0.55 µm in terms of trial conditions.
weight of materials used in an aerospace engine, mainly in Moreover, a good agreement between the predicted and
the gas turbine compartment. This is owing to their experimental surface roughness was observed within
outstanding strength and oxidation resistance at elevated reasonable limit. To develop a second-order model, a
temperatures in excess of 5500 C. machiningis a requisite design consisting of 18 experiments was conducted. Eight
operation in the aircraft industries for the manufacture of experiments constitute 23 factorial designs with an added
the components especially for gas turbines. This paper is center point repeated four times, the added center point
concerned with optimization of the surface roughness when being used to estimate pure error. An augment length of 2
turning Inconel 718 with cermet inserts. Optimization of was chosen depending on the capacity of the center lathe.
turning operation is very useful to reduce cost and time for The augments point consists of three levels for each of the
machining. The approach was based on Response Surface independent variables denoted by -2,-1, 0, +1, +2. The
Method (RSM). In their work, second-order quadratic following conclusions were drawn from the cutting
models were developed for surface roughness, considering conditions in machining hardened AISI 1050 steels using
the cutting speed, feed rate and depth of cut as the cutting CBN/TiC cutting tools.
parameters, using central composite design.
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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October 2014)
The result clearly showed that feed rate was the most LB Abhang and M Hameedullah [1] have published a
powerful factor on surface roughness for all tools. In paper in which experimental investigations had been
general, surface roughness of Ra, Rz and Rmax parameters conducted to determine the effect of the tool geometry
decreased with decreasing main cutting parameters of V (effective tool nose radius) and metal cutting conditions
(cutting speed), f (feed rate), d (depth of cut) for CBN (cutting speed, feed rate and depth of cut) on surface finish
cutting tools. Furthermore, the average surface finish during the turning of EN-31 steel. First and second order
values of Ra produced by CBN/TiC cutting tools was about mathematical models were developed in terms of
0.823 µm for machining the hardened carbon steel. machining parameters by using the response surface
However, this Ra value even reduced about 0.55 µm methodology on the basis of the experimental results. The
depending upon cutting parameters. Moreover, the surface roughness prediction model had been optimized to
regression model showed that the predicted values had obtain the surface roughness values by using LINGO solver
been very close to experimental values of surface programs. LINGO is a mathematical modeling language
roughness when machining hardened steels. which is used in linear and nonlinear optimization to
M. Naga PhaniSastry and. K. Devaki Devi [17] have formulate large problems concisely, solve them, and
presented a paper which was concerned with the effect of analyze the solution in engineering sciences, operation
turning process parameters (cutting speed, feed rate, and research. It gives minimum values of surface roughness and
depth of cut) on the metal removal rate and surface their respective optimal conditions. The factorial design
roughness as responses or output parameters. Response with eight added centre points (24 + 8) used in this work is
surface methodology (R.S.M), determine and present the a composite design. A reliable surface roughness model for
cause and effect of the relationship between true mean steel turning was developed using RSM and incorporated
response and input control variables influencing the cutting speed, feed rate, depth of cut, and the tool nose
response as a two or three dimensional surface. R.S.M had radius. The study was optimized by the LINGO-solver
been used for designing a three factor with three level approach, which is a global optimization technique. This
central composite factors design in order to construct has resulted in a fairly useful method of obtaining process
statistical models capable of accurate prediction of parameters in order to attain the required surface quality.
responses. The results obtained shows that the application The optimal parameter combination of the turning process
of R.S.M can predict the effect of machining parameters on corresponded to a cutting speed of 189 m/minute, a feed
MRR and surface roughness. A case of straight CNC rate of 0.06 mm/revolution, a depth of cut of 0.2 mm, and a
turning of aluminum bar using HSS tool was being tool nose radius of 1.2 mm by the Lingo-solver approach.
considered. The predicted optimal setting ensured This had validated the trends available in the literature and
minimization of surface roughness and maximization of extended the data range to the present operating conditions,
MRR (Material Removal Rate). Optimal result was verified apart from improving the accuracy and modeling by
through confirmatory test. The roughness is measured by involving the most recent modeling method. The
surface roughness meter (Stylus Type) and the force is application of LINGO-solver optimization to obtain
measured by dynamometer .The results were then recorded optimal machining conditions will be quite useful at the
to analyze the effect of different parameters and their levels computational planning stage in the production of high
on surface roughness and MRR. The model for three quality goods with tight tolerances by a variety of
different parameters namely speed, feed and depth of cut machining operations, and in the adaptive control of
for turning process in CNC LATHE on aluminium material automated machine tools.
were developed using response surface method(RSM).The Srinivasan, A. et al [21] published a paper in which an
second order models had been validated with the analysis attempt has been made to model the machinability
of variance. It was found that the feed and depth of cut had evaluation through the response surface methodology in
more significant effect while speed had less significant machining of homogenized 10% micron Al2O3 LM25 Al
effect on MRR and feed and depth of cut had equal MMC manufactured through stir casting method. Results:
significance on surface roughness (Ra).

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October 2014)
The combined effects of three machining parameters Response surface methodology and Taguchi techniques
including cutting speed (s), feed rate (f) and depth of cut were used to accomplish the objective of the experimental
(d) on the basis of three performance characteristics of tool study. L27 orthogonal array design was used for
wear (VB), surface Roughness (Ra) and cutting Force (Fz) conducting the experiments. RSM as well as Taguchi‘s
were investigated. The contour plots were generated to techniques revealed that Feed is the most significant factor
study the effect of process parameters as well as their in minimizing surface roughness followed by speed and
interactions. The process parameters were optimized using depth of cut. RSM technique predicted results better than
desirability-based approach response surface methodology. the Taguchi‘s technique.
RSM model have been developed for predicting tool life,
surface roughness and cutting force. The optimized cutting Contour Plot of Ra vs C, B
1.0
condition that gives lower surface finish and cutting force Ra
< 0.50
when machining micron MMCs had been identified: 0.50 – 0.75

Cutting speed ‗V‘ 100 m/min, Feed ‗f‘ 0.1 mm/rev and
0.75 – 1.00
0.5 1.00 – 1.25
–
Depth of cut ‗a‘ 0.10 mm. The surface roughness improves
1.25 1.50
1.50 – 1.75
1.75 – 2.00
with increase of the cutting speed whilst increasing feed > 2.00
0.0

C
Hold Values
adversely affects the surface roughness. The tool wear A 0

increases with increase of the cutting speed, the feed and

the depth of cut. Among the machining parameters cutting -0.5

speed had the most dominant effect on tool wear. The

cutting force almost linearly varies with feed. At low -1.0
cutting speed the cutting force was higher and the -1.0 -0.5 0.0 0.5 1.0
B
interactions of cutting speed with feed and depth of cut
with feed dominantly affects the cutting forces. The Figure 4: Contour Plot of Ra vs C, B [16]
machining parameters for turning process were optimized
using Taguchi‘s technique for minimizing the tool wear,
surface roughness and cutting force. The developed model
had been validated experimentally and exhibit low values
of error.
Ranganath. M. S. et al. [16], presented the findings of an
experimental investigation into the effects of speed, feed
rate and depth of cut on surface roughness in CNC turning
of Aluminium (KS 1275).
Table 1:
Design Table [16]
Run Blk A B C
1 1 0 0 0
2 1 0 0 -1
3 1 -1 1 1
4 1 0 0 0 Figure 5: Optimization Plot [16]
5 1 0 1 0
6 1 -1 -1 1 Young Kug Hwang and Choon Man Lee [6] paper
7 1 -1 -1 -1
8 1 0 0 0 presents an investigation into the MQL (minimum quantity
9 1 -1 1 -1 lubrication) and wet turning processes of AISI 1045 work
10 1 1 1 1
11 1 0 0 1 material with the objective of suggesting the experimental
12 1 1 1 -1 model in order to predict the cutting force and surface
13 1 -1 0 0
14 1 0 0 0
roughness, to select the optimal cutting parameters, and to
15 1 0 -1 0 analyze the effects of cutting parameters on machinability.
16 1 1 -1 -1 Fractional factorial design and central composite design
17 1 0 0 0
18 1 1 -1 1 were used for the experiment plan.
19 1 1 0 0
20 1 0 0 0

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 International Journal of Emerging Technology and Advanced Engineering
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Cutting force and surface roughness according to cutting If we consider only surface roughness and cutting force,
parameters were measured through the external cylindrical MQL turning has more advantages than wet turning.
turning based on the experiment plan. The measured data Ali riza motorcu [11] uses the response surface
were analyzed by regression analysis and verification methodology to investigate the effects of main cutting
experiments were conducted to confirm the results. From parameters such as cutting speed, feed rate, and depth of
the experimental results and regression analysis, this cut on the surface roughness when turning AISI 1050
research project suggested the experimental equations, carbon steel. Machining tests were carried out with
proposed the optimal cutting parameters, and analyzed the uncoated ceramic (KY1615) and coated ceramic cutting
effects of cutting parameters on surface roughness and tools (KY4400). Optimal machining conditions for the
cutting force in the MQL and wet turning processes., a desired surface finish were determined. The adequacy of
number of experiments should be done to confirm results. the second order developed model was analyzed by using
A two-level fractional factorial design with resolution V, analysis of variance. The experimental results indicated
was used for screening experiments. The reason for the that the feed rate was the dominant factor, followed by the
usage of resolution V was to analyze the main effect and depth of cut. The cutting speed showed the minimal effect
two-factor interactions. Generally, in resolution V,the main on the surface roughness. It could be seen that the KY1615
effects are confounded with four-factor interactions, and tool produced a better surface roughness than the KY4400
two-factor interactions are confounded with three-factor tool. It was shown that average surface roughness‘ of Ra
interactions. If interactions higher than three-factor values were about 2.515 μm, 2.984 μm for the KY1615,
interactions can be ignored, the main effect and two-factor KY4400 cutting tools, respectively. Furthermore, the
interactions can be analyzed. In this paper, in order to analysis of variance for the second-order model indicated
select the optimal cutting parameters and to analyze the that squares terms were significant on the roughness, but
effect of cutting parameters on surface roughness and interaction terms of cutting parameters were insignificant
cutting force, experimental equations were suggested. for both cutting tools. To develop a second-order model, a
Within the range of cutting parameters used in this study, design consisting of 18 experiments was conducted. Details
we were able to draw the following conclusions. Using of the model and design are given elsewhere (Sahin and
fractional factorial design, nozzle diameter, cutting speed, Motorcu, 2004; Motorcu, 2006). 18 experiments constitute
feed rate, and depth of cut were found as the parameters 23 factorial designs with an added center point repeated
affecting the surface roughness of the MQL turning. four times, the added center point being used to estimate
Experimental equations, which can estimate the surface pure error. An augment length of 2 was chosen depending
roughness and cutting force in the MQL and wet turning on the capacity of the center lathe. The augments point
processes of AISI 1045 work material, were suggested with consists of three levels for each of the independent
RSM. From the verification experiment, the cutting force variables denoted by -2, -1, 0, +1, +2. The RSM was
equations confirmed the validity in the MQL and wet adopted to investigate the effects of machining factors such
turning processes, but the surface roughness equations were as cutting speed, feed rate, and depth of cut on the surface
not appropriate for accurate prediction. When considering roughness when turning the AISI 1050 carbon steel. The
surface roughness and cutting force at the same time in the feed rate was the dominant factor, followed by the depth of
MQL turning process, the optimal combination of cutting cut. The cutting speed showed the minimum effect on the
parameters to maximize the machinability was as follows: surface roughness. Furthermore, it could be seen that the
nozzle diameter of 6mm, cutting velocity of 361m/min, KY1615 cutting tool produced a better surface roughness
feed rate of 0.01mm/rev, and depth of cut of 0.1mm. In the than that of the KY4400 tool. The average surface
case of the wet turning process, the optimal combination of roughness, Ra values were about 2.515 μm, 2.984 μm for
cutting parameters consisted of nozzle diameter of 6mm, the KY1615, KY4400 cutting tools, respectively. It was
cutting speed of 394m/min, feed rate of 0.02mm/rev, and found that it was appropriate when machining the mild
depth of cut of 0.1mm. According to the experiment steel with ceramic based cutting tools under high speed
results, cutting speed and depth of cut showed opposite conditions. Moreover, the ANOVA showed that the
effects on cutting force and surface roughness. Therefore, quadratic effects were significant on the roughness while
cutting conditions should be set under a clear standard the interactions terms of cutting parameters were
because the optimal combination of cutting conditions statistically insignificant for both cutting tools.
could be different depending on machinability.

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Alagarsamy S.V, Rajakumar N.[2] used an effective The Design-Expert software had been used to investigate
approach for the optimization of turning parameters based the effects of the Machining process parameters and
on the Taguchi‘s method with Response surface subsequently to predict sets of optimal parameters for
methodology (RSM) .The paper discusses the use of optimum quality characteristics. The response surface
Taguchi‘s technique for minimizing required surface methodology (RSM) in conjunction with second order
roughness and maximizing the material removal rate in central composite rotatable design had been used to
machining Aluminium Alloy 7075 using TNMG 115 100 develop the empirical models for response characteristics.
tungsten carbide tool. Experiments were conducted based Desirability functions had been used for simultaneous
on the established Taguchi‘s technique L27orthogonal optimization of performance measure. Confirmation
array and Minitab-16 statistical software was used to experiments was further conducted to validate the results.
generate the array. Three machining parameters were Conclusion: Quadratic model was fitted for surface
chosen as process parameters: Cutting Speed, Feed rate and roughness. The results show that the surface roughness did
Depth of Cut. The orthogonal array, signal to noise ratio not vary much with experimental depth of cut in the range
and analysis of variance were employed to study the of 0.1 to 0.15 mm. Feed rate was the dominant contributor,
performance characteristics in CNC turning operation. accounting for 69.06% of the variation in surface roughness
Optimal values of process parameters for desired whereas cutting speed accounts for 3.30% and depth of cut
performance characteristics were obtained by Taguchi 2.41%. Secondary contributions of interaction effect
design of experiment. A second order mathematical model between speed and depth of cut (3.90%), second order
in terms of cutting parameters was also developed using (quadratic) effect of cutting speed (17.11%) and feed (4.2
response surface model. the Taguchi method and Response %). The values of feed, speed, depth of cut had been found
surface methodology was applied for analysing to get a for best surface finish (lowest surface roughness). These
minimum surface roughness and maximum material were 0.14 mm/rev .76.10 m/min and 0.102 mm
removal rate for turning process of Aluminium Alloy 7075 respectively. The value of surface roughness at these
using CNC machine via considering three influencing input setting is predicted as 0.626558 μm.
parameters- Speed, Feed and Depth of Cut. The optimize Basha N.Z.,Vivek S.[4] presented a paper that
results for Surface Roughness indicate that the input investigates the effect of process parameter in turning
parameter feed had most influencing to the quality operation to predict surface roughness of Aluminium 6061,
characteristics of surface roughness. Best parameters found by optimizing the input parameters such as spindle speed,
for surface finish machining were-Cutting Speed: 500 feed rate and depth of cut by using coated carbide tool. A
m/min; Feed: 0.10 mm/rev; Depth of Cut: 0.3mm. For second order mathematical model was developed using
depth of cut being most affecting parameter .Whenever the regression technique and optimization was carried out
MRR increases feed and depth of cut were gradually using Box-Behnken of response surface methodology. The
increases. Finally found the best parameters of MRR were- application of response surface methodology for optimizing
Cutting Speed: 1500 m/min; Feed: 0.20 mm/rev; Depth of the input parameters such as spindle speed (rpm), feed rate
Cut: 0.8mm. The equations obtained from Response (mm/min) and depth of cut (mm), the output parameter
Surface Methodology for Surface Roughness, MRR were surface roughness can also be optimized for economical
having R-sq. values as 98.85%, and 97.56% respectively. production. Therefore, this study attempts the application
Predicted response values were calculated from Taguchi of response surface methodology to find the optimal
Analysis and Response Surface Methodology were very solution of the cutting conditions for giving the minimum
similar. value of surface roughness using design- expert 8.0
Wasif G. M. & Safiulla M. [25] have presented a paper software. The confirmatory test was conducted and found
to find the effects of the various machining (turning) that the percentage of error within ±1.5%. Conclusions
process parameters on the machining quality of obtained from experimental data were used to predict the
NICROFER C263 ALLOY and to obtain the optimal sets surface roughness 'Ra' by developing the regression model
of process parameters so that the quality of machined parts using DoE. A good surface roughness was obtained at the
can be optimized. The working ranges and levels of the feed rate (0.04-0.05 mm/min) and spindle speed (1700-
machining process (turning) parameters were found using 2000 rpm). The change in feed rate (0.04-0.08 mm/min)
three factors. Cutting speed (V- m/min), feed rate (f – had a significant effect on surface roughness (0.72-0.66μm)
mm/rev) and depth of cut (d - mm). at higher spindle speed (2000rpm).

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 10, October 2014)
The change in feed rate (0.04-0.08 mm/min) had no The predicted values of roughness were found to match
significant effect on surface roughness (0.71-0.72μm) at closely with the observed values. The optimum values of
lower spindle speed (1000 rpm). A feed rate less than 0.06 input parameters were identified as nose radius = 1mm,
and depth of cut less than 0.70 had been preferred for cutting speed = 3500rpm and feed = 0.1mm.
obtaining good surface finish.
Sahoo P. [18] presents an experimental study of III. CONCLUSIONS
roughness characteristics of surface profile generated in On the basis of the experimental results and derived
CNC turning of AISI 1040 mild steel and optimization of analysis by earlier researchers the studies may be
machining parameters based on genetic algorithm. The concluded as below:
 The surface roughness is continuously improved with
three level rotatable central composite designs were
employed for developing mathematical models for
predicting surface roughness parameters. Response surface the increase in cutting speed, but increase in feed rate
methodology was applied successfully in analyzing the and depth of cut causes a significant deterioration of

 The results obtained using the Response Surface

effect of process parameters on different surface roughness surface roughness.
parameters. The second order mathematical models in
terms of machining parameters were developed based on Methodology provides a systematic, efficient and
experimental results. The experimentation was carried out easy-to-use approach for the cutting process

 Significance of interactions and square terms of

considering three machining parameters depth of cut, optimization.
spindle speed and feed rate as independent variables and
three different roughness parameters Centre line average parameters is more clearly predicted in Response

 The Response surface methodology shows

roughness, root mean square roughness and mean line peak surface methodology.
spacing as response variables. It was seen that the surface
roughness parameters decrease with increase in depth of significance of all possible combinations of

 Response surface methodology technique requires

cut and spindle speed but increase with increase in feed interactions and square terms.
rate. The models selected for optimization had been
validated with F-test. The adequacy of the models of almost double Time for conducting experiments as

 Response surface methodology technique can model

surface roughness has been established with Analysis of that needed for Taguchi technique.
Variance (ANOVA). Genetic Algorithm was used to
determine the optimum machining parameters in order to the response in terms of significant parameters, their
obtain the best possible surface quality. The confirmatory interactions and square terms which is not provided

 3D surfaces generated by Response surface

tests conducted with the optimum parameter combinations by other technique.
show good agreement with the predictions.
Subramanian M. et al [23] used RSM and GA to Predict methodology can help in visualizing the effect of

 Optimization plot is a special feature which can be

Surface Roughness Based on Process Parameters in CNC parameters on response in the entire range specified
Turning of AL7075-T6‖ that deals with the study and
development of a regression model to predict surface obtained from Response surface methodology. Thus
roughness in terms of geometrical parameter, nose radius of Response surface methodology is a better tool for
cutting tool TNMG insert and machining parameters, optimization and can better predict the effect of
cutting speed and cutting feed rate for machining AL7075- parameters on response.
T6, using Response Surface Methodology (RSM). The
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