Optimization of Surface Roughness in Face Turning Operation in Machining of En-8

ISSN: 22503676
K. ADARSH KUMAR* et al.

[IJESAT] INTERNATIONAL JOURNAL OF ENGINEERING SCIENCE & ADVANCED TECHNOLOGY
Volume-2, Issue-4, 807 812
OPTIMIZATION OF SURFACE ROUGHNESS IN FACE TURNING

OPERATION IN MACHINING OF EN-8
K. Adarsh Kumar1,Ch.Ratnam2, BSN Murthy3, B.Satish Ben4, K. Raghu Ram Mohan Reddy5
1
Professor, Department Of Mechanical Engineering, Andhra University, Visakhapatnam. chratnam@gmail.com

3
Associate Professor, Department Of Mechanical Engineering, GITAM University, Visakhapatnam.,
Bsnmurthy_au@yahoo.co.in
2, 4, 5
Assistant Professor, Department Of Mechanical Engineering, GITAM University, Visakhapatnam.
adarsh@gitam.edu, satishben@yahoo.com, raghu.kappa@gmail.com
Abstract:
Surface finish is one of the prime requirements of customers for machined parts. The purpose of this research paper is
focused on the analysis of optimum cutting conditions to get lowest surface roughness in facing by regression analysis. This
present paper presents an experimental study to investigate the effects of cutting parameters like spindle speed, feed and
depth of cut on surface finish on EN-8. A multiple regression analysis (RA) using analysis of variance is conducted to determine
the performance of experimental measurements and to it shows the effect of cutting parameters on the surface roughness. Multiple
regression modeling was performed to predict the surface roughness by using machining parameters. The investigation of influence of
cutting conditions in facing operation of EN-8 in this paper. Machining was done using cemented carbide insert. The objective was to
establish correlation between cutting speed, feed rate and depth of cut and optimize the turning conditions based on surface
roughness. These correlations are obtained by multiple regression analysis (RA).
Key words: Machining; Dry Facing, EN-8, Surface roughness; Regression analysis (RA).
-----------------------------------------------------------------------***----------------------------------------------------------------------1. INTRODUCTION:
1.1. Facing Operations:
Surface roughness has received serious attention for many

years. It has formulated an important design feature in many
situations such as parts subject to fatigue loads, precision fits,
fastener holes, and aesthetic requirements. In addition to
tolerances, surface roughness imposes one of the most critical
constraints for the selection of machines and cutting parameters
in process planning [3]. Surface finish is the method of
measuring the quality of a product and is an important
parameter in machining process. It is one of the prime
requirements of customers for machined parts. Productivity is
also necessary to fulfill the customers demand. For this purpose
quality of a product and productivity should be high. In
addition to the surface finish quality is also an important
characteristic in turning operation and high MRR is
always desirable[2]. Even in the occurrence of chatter or
vibrations of the machine tool, defects in the structure of the
work material, wear of tool, or irregularities of chip formation
contribute to the surface damage in practice during machining
[1].
Facing is the process of removing metal from the end of a work

piece to produce a flat surface. Most often, the work piece is
cylindrical, but using a 4-jaw chuck you can face rectangular or
odd-shaped work to form cubes and other non-cylindrical
shapes.
Figure 1: Facing Operation

When a lathe cutting tool removes metal it applies considerable
tangential (i.e. lateral or sideways) force to the work piece. To
safely perform a facing operation the end of the work piece
must be positioned close to the jaws of the chuck. The work
piece should not extend more than 2-3 times its diameter from
the chuck jaws unless a steady rest is used to support the free
end.
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ISSN: 22503676

1.2. Measurement of Surface Roughness:

The surface roughness was done as coarse, rough, medium and
fine. The hand feel and visional inspection were used for theses
classifications. There are many ways to define surface
roughness depending on its applications like Ra, Rt, Rq, Rk,
but roughness average Ra is widely used in industry for the
mechanical components for indication of surface roughness,
also known as arithmetic aver-age (AA) or centre line average
(CLA) [ISO-4287, 1997]. Is the area between surface profile
and centre line [1], hence in this study Ra is used for indication
of surface roughness [4]
1
=
()
0
Whereas L is the sample length, Y(x) is the profile along the
direction x. Also
1
=
=1
Where n is the total number of samples and Yi is the height of

profile at ith position.
Surface roughness plays an important role in product quality.
X. Wang [5] focuses on developing an empirical model for the
prediction of surface roughness in finish turning. The model
considers the following working parameters: work piece
hardness (material); feed; cutting tool point angle; depth of cut;
spindle speed; and cutting time. One of the most important data
mining techniques, nonlinear regression analysis with
logarithmic data transformation, is applied in developing the
empirical model [5].
A popularly used model for estimating the surface roughness
value is as follows [5] pp.634 and [1] pp.166.
2
=
32
Where Ri = ideal arithmetic average (AA) Surface
roughness ( in or mm),
f = feed (in rev-1 or mm rev-1 )
Cutting parameters
Cutting speed (rpm)
Feed (mm/rev)
Depth of cut (mm)
Level 1
100
0.14
0.5
Level 2
360
0.15
1.0
Level 3
560
0.16
1.5
Tab: 1 Cutting parameters

C
Si
Mn
0.4%
0.25%
0.8%
0.015%
0.015%
Tab: 2 Chemical composition of EN-8.

Co
TiC
WC
8%
15%
77%
Tab: 3 Typical composition of Cemented Carbide cutting
The surface roughness was measured by using Mitutoyo SJ-310
instrument. The dependent variable is surface roughness. In
total 27 experiments were conducted and responses are
shown in the Table 8. It gives the various cutting
parameters for each experiment the results are measured
and shown in the last column of the same Table 8. The
different units used here are cutting speed (rpm) Feed(mm/rev), depth of cut (DOC) mm, surface roughness Ra m. Mini-Tab software was used for Regression analysis.
Dry Facing process was used.
Fig 2: Experimental set up
2. EXPERIMENTAL SET UP AND CUTTING

CONDITIONS
The experiment was conducted using one work piece
material namely EN-8 with coated ceramic tool. .The tests
were carried for a length of 60X 60 mm in a Madras Machine
tool mfrs. Ltd lathe. The cutting parameters are shown in the
Table 1. Three levels of cutting speed, three levels of feed and
three levels of depth of cut were used and are shown in the
Table 1. The different alloying elements present in a work piece
and cutting insert are shown in the table 2 & 3.
Fig 3 : Mitutoyo SJ-310 for Surface roughness Measurement

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3. REGRESSION ANALYSIS (RA):

It is used to investigate and model the relationship between a
response variable and one or more predictors. Minitab provides
least square, partial least square and logistic regression
procedures. A multiple regression analysis was conducted on

the tested data. Coefficients of The analysis of variance results
of the regression model also supported linear relationships in
the model (Table 5)
The regression equation is

DOC (mm) . . .. (3.1)
P
VIF
0.000
0.000
1.000
0.000
1.000
0.000
1.000
Surface Roughness Ra (m) = 9.59 - 0.00476 Speed (rpm) - 31.6 Feed (mm/rev) + 0.559
Predictor
Coef
SE Coef
T
Constant
9.5868
0.2334
41.07
Spindle speed(rpm)
-0.00476086
0.00006647
-71.63
Feed(mm/Rev)
-31.556
1.533
-20.58
DOC (mm)
0.55889
0.03066
18.23
S = 0.0650437 R-Sq = 99.6% R-Sq (adj) = 99.6%
PRESS = 0.137065 R-Sq (pred) = 99.45%
Source
Regression
Residual Error
Total
DF
3
23
26
SS
MS
24.9027
8.3009
0.0973
0.0042
25.0000
Table 5: Analysis of Variance
Source
Spindle speed(rpm)
DF
1
F
1962.08
P
0.000
Seq SS
21.7048
Feed(mm/Rev)
1
1.7924
DOC (mm)
1
1.4056
Table 6: Sequential sum of squares:
Obs
4
6
Spindle speed (rpm)

100
100
Surface Roughness (Ra) Fit

SE Fit
4.4900
4.6569 0.0254
5.3400
5.2158 0.0254
Table 7: Unusual Observations:
Residual
-0.1669
0.1242
St Resid
-2.79R
2.08R
R denotes an observation with a large standardized residual
Fig 4: Residual plots for surface roughness

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Speed N(rpm)
100
100
100
100
100
100
100
100
100
360
360
360
360
360
360
360
360
360
560
560
560
560
560
560
560
560
560
Experimental Ra (m)
4.98
5.3
5.44
4.49
5.01
5.34
4.33
4.59
4.88
3.81
3.97
4.28
3.46
3.69
4.01
3.15
3.41
3.66
2.73
3.11
3.37
2.42
2.73
2.98
2.18
2.49
2.62
Average error
Table 8: Values of Predicted Surface Roughness and error
No of Experiments
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Feed (mm/rev)
0.14
0.14
0.14
0.15
0.15
0.15
0.16
0.16
0.16
0.14
0.14
0.14
0.15
0.15
0.15
0.16
0.16
0.16
0.14
0.14
0.14
0.15
0.15
0.15
0.16
0.16
0.16
D.O.C(mm)
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
0.5
1
1.5
Predicted Ra (m)
4.9695
5.249
5.5285
4.6535
4.933
5.2125
4.3375
4.617
4.8965
3.7319
4.0114
4.2909
3.4159
3.6954
3.9749
3.0999
3.3794
3.6589
2.7799
3.0594
3.3389
2.4639
2.7434
3.0229
2.1479
2.4274
2.7069
= 0.047411
Error
0.0105
0.051
-0.0885
-0.1635
0.077
0.1275
-0.0075
-0.027
-0.0165
0.0781
-0.0414
-0.0109
0.0441
-0.0054
0.0351
0.0501
0.0306
0.0011
-0.0499
0.0506
0.0311
-0.0439
-0.0134
-0.0429
0.0321
0.0626
-0.0869
Fig 5: Comparison of Experimental surface roughness and Predicted Surface Roughness

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ISSN: 22503676

Fig 6: Surface roughness Vs Cutting speed at Constant Depth

of cut = 0.5 mm
Fig 9: Surface roughness Vs Depth of cut at Constant Cutting

speed =360 rpm
Fig 7 : Surface roughness Vs Depth of cut at Constant Cutting

speed =100 rpm

of cut = 1.5 mm

of cut = 1 mm
Fig 11: Surface roughness Vs Depth of cut at Constant

Cutting speed =560 rpm

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ISSN: 22503676

CONCLUSION:
In this paper the effect of machining parameters speed, feed,
depth of cut, are studied on surface roughness for face turning
operation using EN-8. Regression Analyses (RA) technique is
used to study the effect of these parameters and their
interaction on surface roughness. An empirical equation is
formed by using Regression Analyses (RA) in Mini-Tab
software to predict the surface roughness. The surface
roughness model produced during this research work may be
used in enhancing the surface quality of a product as cutting
parameters are optimized and can give better surface finish. In
this paper observed the results the influence of cutting speed
and feed rate and depth of cut on surface roughness, the test
was performed and it was seen that the effect of feed rate is
greater than the effect of cutting speed from figure 6 to 11
shows a result, to improve the surface roughness, a good
combination of cutting speed and feed rate needs to be
selected. The feed has the variable effect on surface
roughness. The relationship between feed rate and surface
roughness is proportional, figure 6,8,10 shows the relation that
increasing the feed rate, increases the surface roughness. On
surface roughness, the effect of feed rate is more considerable
than cutting speed.
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ISSN: 22503676

K. ADARSH KUMAR* et al.

Volume-2, Issue-4, 807 812