International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6
Effect of Machining Parameters on Material Removal
Rate (MRR) and Surface Roughness in Cylindrical
Grinding of Inconel 718
AbuBakkar Siddik.J, Arun Kumar.A, Gurumoorthy.G, Mattuvarkulali.M, Rekha.R,
Department of Mechanical Engineering,
Saranathan College of Engineering,
Trichy, Tamil Nadu, India.
mattuvarkulali@gmail.com
Abstract— Cylindrical grinding machining is the most
popular machining process of removing metal from a work piece
surface in the form of tiny chips by the action of irregularly
shaped abrasive particles. It has wide range of applications like
automobile, aircraft, and marine industries. Precision and quality
have been the critical issues for all these industries. To enhance
the quality of machined parts, and to reduce the machining costs
and to increase the production rate, it is very important to select
the optimal machining parameters. The success of any grinding
operation depends upon the proper selection of various operating
conditions like work speed, feed rate, depth of cut etc.
Optimization of grinding process still remains one of the most
challenging problems because of its high complexity and non-
linearity while solving it. This research aims to optimize and
analyze cylindrical grinding process on Inconel 718. It has High
tensile strength and hardness, high thermal resistance and low
machinability. It is emerging in the fields like aerospace,
petroleum and nuclear industries. Thus optimizing cylindrical
grinding process for this material may reduce production cost in
industries. In the present study, L-9 orthogonal array is formed
based on Taguchi Design of Experiments and it is used to
optimize the effect of cylindrical grinding parameters on the
surface roughness and Material Removal Rate (MRR). For all
the three levels of input values main effect plot and Signal to
Noise (S/N) ratio are obtained. The results of the analysis are
evaluated to find the optimum input values for high surface
finish with maximum MRR.
Keywords—Cylindrical Grinding; Inconel 718; Taguchi L9
Orthogonal array; surface roughness, Material Removal Rate
(MRR).
I. INTRODUCTION (HEADING 1)
Components in today’s world are well known for their
surface finish. Cylindrical grinding is an essential process for
final machining of components requiring smooth surfaces and
precise tolerances. As compared with other machining
processes, grinding involves costly operation that should be
utilized under optimal conditions. Although widely used in
industry, grinding remains perhaps the least understood of all
machining processes. The major operating input parameters
that influence the output parameters are work speed, feed rate,
depth of cut, coolant flow, work material properties, etc.[16].
The effect of these parameters in Material Removal Rate
(MRR) and Surface Roughness (Ra) is focused in this study.
Material Removal rate is known as the rate at which material
is removed from the work piece. It is the amount of material
removed per unit time. Surface Roughness is defined as the
deviation of the surface in the direction normal to the plane
with respect to the expected surface. Cylindrical Grinding is
mainly used to obtain high surface finish and any machining
process aims to maximize Material Removal Rate (MRR) and
minimize Surface Roughness. In our project optimal process
parameters for grinding Inconel 718 is identified. The selected
material Inconel 718 is known for its high thermal stability
and work hardening ability. It is found in one of the most
difficult to cut materials. Taguchi Design of Experiments
(DOE), a statistical approach, recently applied in engineering,
biotechnology, marketing and advertising [15] is used for this
purpose. Various experiments on cylindrical grinding were
analyzed successfully using Taguchi’s DOE method [1, 2, 13-
15].The most important stage in the design of experiment lies
in the selection of the control factors. Work speed, feed rate
and depth of cut are the control factors selected [1 - 5], whose
effect on responses (MRR and Surface Roughness) is
analyzed. Depending upon the controllable factors an
Orthogonal Array (OA) table is set and experiments are
carried out based on this table. [18]. Surface Roughness is
measured using Surface Roughness Tester and MRR is
calculated from the change is weight measured using Load
Cell. The effect of these control factors on the responses can
be studied clearly with the help of graphs. So the relationship
between controllable factors and responses is obtained in the
form of Main Effect Plots and Contour Graphs. Various
softwares are available for this purpose. Minitab is one such
software which is known to relate the input and output
parameters effectively. [9]. The main objective of this paper is
to study the grinding behavior on Inconel 718 which can be
utilized to predict the grinding performance and achieve
optimal operating process parameters for Inconel 718.
152
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6

II. MATERIAL AND MACHINE

A. Inconel 718
Inconel 718 (UNS Designation NO7718) is chosen as the
TABLE I. CHEMICAL COMPOSITION OF INCONEL 718
work piece material and is shown in Fig. 1.
Percentage
Element
(%)

Nickel 53.55

Iron 16.82

Chromium 19.54

Niobidium 4.98

Molybdenum 2.96

Titanium 0.79

Cobalt 0.41

Aluminium 0.37

Manganese 0.18

Fig. 1. Work piece Material – Inconel 718 rod Silicon 0.15

Rest Balance
Inconel 718 is a nickel base super alloy containing
approximately 50% nickel. Nickel is the main dominant
element of Inconel 718. It imparts Niobium that gives TABLE II. PROPERTIES OF INCONEL 718
enlarged strength without decrease in ductility. It can
Property Value
withstand at the temperature range -220º to 780ºC, therefore it
is used in cryogenic tanks. It has high oxidation resistance,
corrosion resistance even at very high temperature and Yield Strength 1035 Mpa
maintains a high mechanical strength. Inconel 718 is widely Ultimate Strength 1240 MPa
used in aircraft gas turbine, reciprocating engines, space
vehicles (e.g., rocket engine parts), nuclear power plants, Thermal Conductivity 6.5 W/mK
chemical application, high temperature fasteners, springs,
rings and pulp and paper industry [1]. Among the nickel-based Density
3

super alloys, Inconel 718 is the most frequently used. 8.22 g/cm
However properties such as low thermal conductivity, rapid Melting Range 0

work hardening, ability to react with tool materials under 1370-1430 C

atmospheric conditions, formation of built-up edge, weld to
the cutting edges and presence of abrasive carbides in their
microstructure causes poor machinability of these materials
and restrict the wider usage [12, 14]. They are known to be
among the most difficult-to-cut materials. Several researchers
have studied the effect of cutting conditions in machining of
nickel based super alloys [8].
The results of these studies have showed that poor
thermal conductivity, chemical reactivity and elastic modulus
are the common problems encountered in the machining
process [9]. Moreover high cutting forces and high
temperature generated during machining leads to poor surface
quality and shortens the grinding wheel life [10]. They have
the peculiar Work Hardening ability which causes plastic
deformation of tool or work piece or both when high cutting
forces and temperature are involved in machining. The
chemical composition and physical properties of Inconel 718
used in this project are shown in table I and table II
Hardness 34 HRC
The two work pieces used for the experiment are 80mm in
length and have a diameter of 28mm each.
B. Cylindrical Grinding Machine
Machining is carried out using Cylindrical Grinding
machine shown in Fig. 2. The cylindrical grinding machine is
a type of grinding machine used to shape the outside of an
object. It can work on a variety of shapes; however the object
must have a central axis of rotation. This includes but is not
limited to such shapes as a cylinder, an ellipse or a crankshaft.
Cylindrical grinding is defined as having four essential
actions:
 The work (object) must be constantly rotating
 The grinding wheel must be constantly rotating

153
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6
 The grinding wheel is fed towards and away from
the work
 Either the work or the grinding wheel is traversed
with respect to the other.
While the majority of cylindrical grinders employ all four
movements, there are grinders that only employ three of the
four actions.
Fig. 2. Cylindrical Grinding Machine
It has an Aluminium Oxide Grinding wheel of the
following specifications:
A 60 N S V 10 C
The Wheel (300mm in diameter and 20mm thick) rotates
at a constant speed of 1800rpm in the cylindrical grinding
machine which has the following specifications.
III. EXPERIMENTAL WORK
A. Taguchi’s Design of Experiments method
The Design of Experiments (DOE) is considered as one of
the most comprehensive approach in product/process
developments. It is a statistical approach that attempts to
provide a predictive knowledge of a complex, multi-variable
process with few trials. Traditional DOE methods became
laborious and complex, if the number of factors increase. To
overcome this problem Taguchi suggested a specially
designed method called the use of orthogonal array to study
the entire parameter space with lesser number of experiments
to be conducted. A quick exploration in related journals, as
well as the World Wide Web, discloses that the method is
being successfully accomplished in assorted areas of
applications are wide which includes manufacturing, military,
automobile, aerospace and other industries. The Taguchi
method is aimed at the manufacturing situations. It has been
extensively elaborated and analyzed in published research
works. The Taguchi approach is a structured approach for
determining the “best’’ combination of inputs to produce a
product or service. Design of Experiments (DOE) is an
important tool for designing processes and products.
Traditional Design of Experiments focused on how different
design factors affect the average result level whereas statistical
and engineering methodology aim at reducing the performance
“variation” of a system.
Various input parameters involved in process are known as
factors and are represented in any one of the following
methods.
Signal factor- is an input to the system. Its value/level
may change.
Control factor - is also an input to the system.
Values/level is fixed at the optimum level for the best
performance.
Noise factor - is an uncontrollable factor. Its level is
random during actual performance.
Taguchi thus, recommends the use of the loss function to
measure the performance characteristics that are deviating
from the desired target value. The value of this loss function is
further transformed into signal-to-noise (S/N) ratio. Usually,
there are three categories of the performance characteristics to
analyze the S/N ratio. They are: nominal-the-best, larger-the-
better, and smaller-the-better.
Orthogonal Arrays: These are not unique to Taguchi.
They were discovered considerably earlier. However, Taguchi
has simplified their use by providing tabulated sets of standard
orthogonal arrays and corresponding linear graphs to fit
specific projects. Taguchi’s orthogonal arrays are highly
fractional orthogonal designs. These designs can be used to
estimate main effects using only a few experimental runs.
Signal-to-Noise Ratio: A signal-to-noise (S/N) ratio is a
performance measure, which estimates the effect of the noise
factors on the quality characteristic. For each of the three
optimization goals S/N ratio has been developed. These S/N
ratios are proposed to provide a product design that
simultaneously places the response on a target and a minimum
variance.
Taguchi’s emphasis on minimizing deviation from target
led to develop measures of the process output that incorporate
both output as well as the variation. These measures are called
signal to noise ratios. The signal to noise ratio provides a
measure of the impact of noise factors on performance. The
larger the S/N, the more robust the product is against noise.
[16]
Calculation of the S/N ratio depends on the experimental
objective:
Bigger is the better:
Smaller is the better:
Nominal is the better:
154
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6

Number of experiments used to design the orthogonal

array for 4 parameters and 3 levels of grinding parameters is
The use of Taguchi’s parameter design involves the steps found out from the following formula [5].
shown in Fig. 3.
Minimum experiments = [(L-1) X p] + 1
= [(3-1) X 4] + 1 = 9
= L9
The four control factors and three levels are arranged in an
L9 Orthogonal array table as shown in the Table V and VI.

TABLE V. ORTHOGONAL ARRAY (OA) L9

Experiment Control Factors

No. 1 2 3 4
1 1 1 1 1
2 2 2 2 1
3 3 3 3 1
4 1 2 3 2
5 2 3 1 2
6 3 1 2 2
7 1 3 2 3
8 2 1 3 3
9 3 2 1 3

Fig. 3. Steps in Taguchi’s Design of Experiments TABLE VI. OA WITH CONTROL FACTORS

The design factors also known as control factors and Experiment Control factors
responses for this experiment are shown in the following No. Work speed Feed Rate Depth of Coolant flow
Table III. (m/min) (m/min) Cut (mm) rate (l/min)
1 5 0.67 0.01 0.65
TABLE III. SELECTED FACTORS AND RESPONSES 2 10 3 0.02 0.65
3 20 6 0.03 0.65
Factors Responses
4 5 3 0.03 1.43
Work Speed (m/min) Material Removal
Rate (mm3/min) 5 10 6 0.01 1.43
Feed Rate (m/min)
6 20 0.67 0.02 1.43
Depth of Cut (mm) Surface Finish (µm)
7 5 6 0.02 3.33
Coolant Flow Rate (l/min)
8 10 0.67 0.03 3.33
9 20 3 0.01 3.33
Three levels are assigned for all these factors as shown in
the Table IV.
IV. EXPERIMENTAL RESULTS
TABLE IV. LEVELS FOR CONTROL FACTORS A. Surface Roughness:
S. Factors Levels Surface roughness often shortened to roughness, is a
No component of surface texture. It is quantified by the deviations
1 2 3
in the direction of the normal vector of a real surface from its
ideal form. If these deviations are large, the surface is rough.
If they are small, the surface is smooth. Roughness plays an
1. Work 5 10 20
Speed(m/min)
important role in determining how a real object will interact
with its environment. Rough surfaces usually wear more
2. Feed 0.67 3 6 quickly and have higher friction coefficients than smooth
Rate(m/min) surfaces. Roughness is often a good predictor of the
performance of a mechanical component, since irregularities
3. Depth of 0.01 0.02 0.03 in the surface may from nucleation sites for cracks or
Cut(mm) corrosion. On the other hand, roughness may promote
adhesion.
4. Coolant flow rate 0.65 1.43 3.33
(l/min) In this experiment Surface Roughness Tester shown in Fig.
4 is used to measure surface roughness. The Surface

155
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6

Roughness values obtained for the experiments are shown in
the Table VII below.
3 m/min, depth of cut = 0.03 and coolant flow rate = 1.43
l/min).
The Signal to Noise ratio for surface roughness was
calculated using Minitab Software. To enhance the surface
roughness ‘Smaller is better’ condition is used. The response
table showing the average for each parameter at each level for
SN ratio is shown in Table VIII. Delta value is calculated from
the highest average minus lowest average of each factor. This
response table indicates the rank based on the delta value,
which compare the relative magnitude of each effect.
From the table it is understood that minimum surface
roughness is obtained for Level 2 of work speed (10 m/min),
Level 3 of feed rate (6 m/min), Level 1 of depth of cut (0.01
mm) and Level 2 of coolant flow rate (1.43 l/min).

TABLE VIII. RESPONSE TABLE FOR SN RATIOS

RESPONSE TABLE FOR SN RATIO
LEVEL WORK FEED DEPTH OF FLOW
SPEED RATE CUT RATE
(m/min) (m/min) (mm) (l/min)
1 10.33 11.617 11.625 10.120
2 13.489 10.407 11.069 12.099
3 9.923 11.720 11.050 11.525
DELTA 3.566 1.313 0.575 1.979
RANK 1 3 4 2
The effect of input parameters on surface roughness of
Inconel 718 is shown in Fig. 5.

Fig. 4. Surface Roughness Tester

TABLE VII. EXPERIMENTAL CALCULATION FOR SURFACE ROUGHNESS

Experiment Work Feed Depth Coolant Surface
Number Speed Rate of Cut Flow Roughness
(m/min) (m/min) (mm) Rate (µm)
(l/min)

1 5 0.67 0.01 0.65 0.271

2 10 3 0.02 0.65 0.352
3 20 6 0.03 0.65 0.311
Fig. 5. Main Effects Plot for Means of Surface Roughness
4 5 3 0.03 1.43 0.174
5 10 6 0.01 1.43 0.283
The Main effects plot show that work speed has major
effect on Surface Roughness followed by coolant flow rate,
6 20 0.67 0.02 1.43 0.285 feed rate and depth of cut. Initially the Surface Roughness
7 5 6 0.02 3.33 0.201 value decreases steeply with increase in work speed up to
certain limit beyond which it increases. Similarly flow rate
8 10 0.67 0.03 3.33 0.326 and feed rate also shows a linear relationship with Surface
9 20 3 0.01 3.33 0.271 Roughness up to a certain limit beyond which it reverses. As
the depth of cut increases surface roughness also increases
This table shows that minimum surface roughness is steadily throughout the experimental period.
achieved in experiment 4 (work speed = 5 m/min, feed rate =
The graphical representation of effect of control factors is
shown using the contour graphs shown in Fig. 6, Fig. 7, Fig. 8,

156
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6

Fig. 9, Fig. 10 and Fig. 11. From these graphs the variation in
Contour Plot of Surface roughnes vs feed rate(m/min), depth of cut(mm)
surface roughness for various levels of input parameters can
6
be identified. The graphs are also helpful in finding the surface 0.25 Surface
0.20 roughness(µm)
roughness that could be achieved for any value of input < 0.20
5 0.20 – 0.25
parameters. 0.25 – 0.30

feed rate(m/min)
0.30 – 0.35
> 0.35
Contour Plot of Surface roughnes vs work speed(m/min), flow rate (l/min) 4

20.0
Surface
0.25 0.30 roughness(µm) 3
0.30 < 0.20 0.30
17.5 0.20 – 0.25
work speed(m/min)

0.25 – 0.30
0.30 – 0.35 2
15.0 > 0.35
0.25

12.5 1
0.30
0.010 0.015 0.020 0.025 0.030
10.0 0.25
depth of cut(mm)
7.5 0.20

0.30 Fig. 9. Effect of feed rate and depth of cut

5.0
1.0 1.5 2.0 2.5 3.0
flow rate (l/min)
Contour Plot of Surface roughnes vs feed rate(m/min), flow rate(l/min)
Fig. 6. Effect of work speed and coolant flow rate 6
0.25 Surface
roughness(µm)
0.20 < 0.20
5
Contour Plot of Surface roughnes vs work speed(m/min), feed rate(m/min) feed rate(m/min)
0.20
0.25
– 0.25
– 0.30
0.30 – 0.35
20.0 > 0.35
Surface
roughness(µm)
4 0.30
0.30 < 0.20
17.5 0.20 – 0.25
0.25
work speed(m/min)

0.25
0.25 – 0.30 3
0.30 – 0.35
15.0 > 0.35

2 0.30
12.5
0.25
1
10.0 0.30
1.0 1.5 2.0 2.5 3.0
0.20
7.5 flow rate (l/min)

0.30
5.0
1 2 3 4 5 6 Fig. 10. Effect of feed rate and coolant flow rate
feed rate(m/min)
Contour Plot of Surface roughnes vs depth of cut(mm), flow rate (l/min)
Fig. 7. Effect of work speed and feed rate 0.030
0.25 Surface
roughness(µm)
< 0.20

Contour Plot of Surface roughnes vs work speed(m/min), depth of cut(mm) 0.20 – 0.25
0.025 0.25 – 0.30
depth of cut(mm)

0.30 – 0.35
20.0 > 0.35
Surface
roughness(µm)
0.30
0.30 < 0.20
17.5 0.20 – 0.25 0.020 0.30
work speed(m/min)

0.25 0.25 – 0.30

0.25 0.30 – 0.35
15.0 > 0.35 0.25
0.015
12.5
0.20
10.0 0.20 0.30
0.010
1.0 1.5 2.0 2.5 3.0
0.20
7.5 flow rate (l/min)

0.30
5.0
0.010 0.015 0.020 0.025 0.030 Fig. 11. Effect of depth of cut and coolant flow rate
depth of cut(mm)
B. Material Removal Rate
Fig. 8. Effect of work speed and depth of cut Material Removal Rate is calculated by measuring the
weight of the component before and after machining. The
following formula is used for this purpose.

157
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6

TABLE X. RESPONSE TABLE FOR SN RATIOS

Where,
RESPONSE TABLE FOR SN RATIO
V = Material Removal Rate (mm3/min,) LEVEL WORK FEED DEPTH OF FLOW
SPEED RATE CUT RATE
= Difference in Weight of the Work piece before and (m/min) (m/min) (mm) (l/min)
after machining. (Kg) 1 72.10 61.89 70.09 72.10

= Density of Inconel 718(kg/m3) 2 72.10 76.05 72.10 70.09

t = Machining time (min)
3 72.10 78.36 74.11 74.11
Using this formula MRR is calculated for the experiments
and the results are plotted in Table IX. DELTA 0.00 16.47 4.02 4.02

TABLE IX. EXPERIMENTAL CALCULATIONS FOR MRR

RANK 4 1 2.5 2.5
Experiment Work Feed Depth Coolant Material
Number Speed Rate of Cut Flow Removal The Main Effects Plot for Means of MRR is shown in Fig.
(m/min) (m/min) (mm) Rate Rate 12. From this graph it is evident that feed rate has a major
(l/min) (mm3/min)
effect on MRR followed by depth of cut and flow rate. Also
from this table and main effects plot we could notice that work
speed has least or no effect on MRR. As the feed rate
1 5 0.67 0.01 0.65 6347 increases MRR increases drastically. Depth of cut shows
2 10 3 0.02 0.65 10427 linear relation which shows that as the depth of cut increases
the MRR increases steadily. MRR decreases initially with
3 20 6 0.03 0.65 6347 increases in coolant flow rate and work speed up to a certain
4 5 3 0.03 1.43 5213 limit beyond which it increases.
5 10 6 0.01 1.43 986
6 20 0.67 0.02 1.43 10427
7 5 6 0.02 3.33 1973
8 10 0.67 0.03 3.33 6347
9 20 3 0.01 3.33 6347

This tables shows that out of the nine experiments

conducted maximum MRR is achieved in experiment 2 (work
speed = 10 m/min, feed rate = 3 m/min, depth of cut = 0.02
mm and coolant flow rate = 0.65 l/min) and experiment 6
(work speed = 20 m/min, feed rate = 0.67 m/min, depth of cut
=0.02 and coolant flow rate = 1.43 l/min).
The Response table for SN ratios with Delta values and
Fig. 12. Main Effects Plot for Means of MRR.
rank is shown in Table X. The Rank is calculated using the
delta values. The contour plot to study the influence of various
From this table it is evident that maximum material control factors combination in MRR is shown in Fig. 13, Fig.
removal rate is obtained at Level 3 of feed rate (6 m/min), 14, Fig. 15, Fig. 16, Fig. 17 and Fig. 18. The contour plots
Level 3 of depth of cut (0.03 mm) and level 3 of Coolant flow help in finding the range of input parameters that would yield
rate (3.33 l/min). The table shows that all the three levels of maximum Metal Removal Rate. Similarly it is also helpful in
work speed have same effect on MRR. deciding the input parameters that could yield the required
Material removal rate.

158
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6

Contour Plot of MRR(mm^3/min) vs feed rate(m/min), work speed(m/min) Contour Plot of MRR(mm^3/min) vs depth of cut(mm), feed rate(m/min)
6 0.030
10000 8000 8000 MRR(mm^3/min) 4000 8000 MRR(mm^3/min)
10000 < 2000 10000 < 2000
2000 – 4000 2000 – 4000
5 6000 4000 – 6000 4000 – 6000
6000 – 8000 6000 – 8000
0.025
8000 – 10000 8000 – 10000
> 10000 > 10000
feed rate(m/min)

depth of cut(mm)
4

0.020
3 10000

6000 2000

2 0.015
4000

6000
1
2000 2000 2000 2000 6000
0.010
5.0 7.5 10.0 12.5 15.0 17.5 20.0 1 2 3 4 5 6
work speed(m/min) feed rate(m/min)

Fig. 13. Effect of feed rate and work speed

Fig. 16. Effect of depth of cut and feed rate

Contour Plot of MRR(mm^3/min) vs depth of cut(mm), work speed(m/min)

Contour Plot of MRR(mm^3/min) vs flow rate (l/min), feed rate(m/min)
0.030
4000 8000 MRR(mm^3/min) 4000 8000 MRR(mm^3/min)
10000
< 2000 10000 < 2000
2000 – 4000 3.0 2000 – 4000
4000 – 6000 4000 – 6000
0.025 6000 6000 – 8000 6000 – 8000
8000 – 10000 8000 – 10000
4000 > 10000 2.5
depth of cut(mm)

8000 > 10000

flow rate (l/min)

0.020 2.0
10000

2000

1.5
0.015 6000

4000 6000

1.0 8000
2000 6000
0.010 2000 6000 10000
5.0 7.5 10.0 12.5 15.0 17.5 20.0
1 2 3 4 5 6
work speed(m/min)
feed rate(m/min)

Fig. 14. Effect of depth of cut and work speed

Fig. 17. Effect of coolant flow rate and feed rate

Contour Plot of MRR(mm^3/min) vs flow rate(l/min), work speed(m/min)

Contour Plot of MRR(mm^3/min) vs flow rate (l/min), depth of cut(mm)
8000 4000 MRR(mm^3/min)
< 2000 8000 4000 MRR(mm^3/min)
3.0 2000 – 4000
10000 < 2000
6000
3.0 2000 – 4000
4000 – 6000
6000 – 8000 4000 – 6000
8000 – 10000 6000 – 8000
2.5 > 10000 8000 – 10000
2.5
flow rate (l/min)

6000 > 10000

flow rate (l/min)

6000

4000
2.0
2.0 4000

1.5
1.5
6000 2000
2000
1.0 4000
8000 1.0 8000
2000 6000 6000
2000 6000 6000 10000
5.0 7.5 10.0 12.5 15.0 17.5 20.0
0.010 0.015 0.020 0.025 0.030
work speed(m/min)
depth of cut(mm)

Fig. 15. Effect of coolant flow rate and work speed

Fig. 18. Effect of coolant flow rate and depth of cut

C. Conclusion
This paper is an attempt to find the effect of prominent
input parameters work speed, feed rate, depth of cut and
coolant flow rate on surface roughness and MRR while

159
 International Journal of Advanced Research Methodology in Engineering & Technology,
Volume 1, Issue 2, March 2017, ISBN 978-1-63535-889-6

grinding Inconel 718 using Cylindrical Grinding Machine. [9] K.Saravanakumar, A.K. Shaik Dawood, and M.R. Prateesh Kumar,
The following conclusions are arrived. “Optimization of CNC Turning Process Parameters on Inconel 718 using
Genetic Algorithm”, IRACST- Engineering Science and Technology,
 Work speed is the most influencing parameter for Vol 2, No.4, 2012.
surface roughness, whereas feed rate varies MRR [10] Qu N.S., Zhang Q.L., Fang X.L.Ye E.K., Zhu D, “ Experimental
Investigation on Electrochemical Grinding of Inconel 718”, 15
greatly than any other control factors. Machining Innovations conference for Aerospace Industry, Elsevier
2015.
 Work speed has least or no effect on Material
Removal Rate. [11] R. Bhanu Pavan, G. Bhanu Kiran, R.R. Srikant, A. Venu Gopal, “
Investigations on Grinding of Inconel 718 using newly developed
 The least value for surface roughness is obtained for Graphene Nanoplatelets Impregnated Grinding Wheels, All India
Manufacturing Technology, Design and Research Conference, 2014.
level 2 of work speed (10 m/min), level 3 of feed rate
[12] Chenwei Dai, Wenfeng Ding, Jiuhua Xu, Yucan Fu, Tianyu Yu, “
(6 m/min), level 1 of depth of cut (0.01mm) and level Influence of grain wear on material removal behaviour during grinding
2 of coolant flow rate (1.43 l/min). nickel-based super alloy with a single diamond grain”, International
Journal of Machine Tools and Manufacture, Elsevier, Volume 113, ,
 Similarly maximum material removal rate is achieved pages 49-58, February 2017.
for level 3 of feed rate (6 m/min), depth of cut (0.03 [13] Hartaj Singh, Mahant Bachittar Singh, “Taguchi Optimization of
mm) and coolant flow rate (3.33 l/min). Process Parameters : A review and case study”, International Journal of
Advanced Engineering Research and Studies.
 Speed of rotation of work speed does not have any [14] M. , K. V. Subbaiah, Ch. Srinivasa Rao, K. Narayana Rao, “Application
significant effect on Material Removal Rate. of Taguchi Approach and Utility Concept in solving and Multi Objective
Problem when Turning AISI 202 Austenitic Stainless Steel”, Journal of
 Out of the nine experiments mentioned in L9 Engineering Science and Technology Review, pg 55-61, 2014.
Orthogonal array table, minimum surface roughness [15] Srinivas Athreya, Dr. Y. D. Venkatesh, “Application of Taguchi Method
is obtained in experiment 4. for Optimization of Process Parameters in improving the Surface
Roughness of Lathe Facing Operation”, International Refereed Journal
 Similarly maximum MRR is achieved in experiment of Engineering and Sciences, Vol. 1, Issue 3, Nov 2015, pg 13-19.
2 and experiment 6. [16] J.S. Pang, M. N. M. Ansari, Omar S. Zaroog, Moaz H. Ali, S.M. Sapuan,
“Taguchi design optimization of machining parameters of CNC end
References milling process of halloysite nanotube with aluminium reinforced epoxy
matrix (HNT/AI/Ep) hybrid composite”, HBRC Journal, Elseveir.com,
[1] Jae-Seob Kwak, Sung-Bo Sim, Yeong-Deug Jeong, “An analysis of Vol. 10, pg 138-144, 2014.
grinding power and surface roughness in external cylindrical grinding of [17] J. A. Ghani, I. A. Choudhury, H. H. Hasssan, “Application of Taguchi
hardened SCM440 steel using response surface method”, International method in the optimization of end milling parameters”, Elsevier,
Journal of Machine Tools and Manufacture, Elsevier, Volume 46, Issues Volume 145, Issue 1, January 2014, pg 84-92.
3-4, March 2016, pages 304-312.
[18] K. Mekala, J. Chandradas, K. Chandrasekaran, T.T.M. Kannan, E.
[2] Lijohn P George, K Varughese Job, I M Chandran, “Study of Surface Ramesh and R. Narasing Babu, “Optimization of Cylindrical Grinding
Roughness and its Prediction in Cylindrical Grinding Process based on Parameters of Austenitic Stainless Steel Rods (AISI 316) by Taguchi
Taguchi Method of Optimization”, International Journal of Scientific method.
and Research Publications, Volume 3, Issue 5, May 2013.
[3] Sandeep Kumar, Onkar Singh Bhatia, “Review of Analysis and
Optimization of Cylindrical Grinding Process Parameters on Material
Removal Rate on En15AM Steel”, IOSR Journal of Mechanical and
Civil Engineering, pg 35-43, 2015.
[4] Suresh P. Thakor, Prof. D. M. Patel, “An Experimental Investigation on
Cylindrical Grinding Process Parameters for En 8 using Regressing
Analysis”, International Journal of Engineering Development and
Research, Vol 2, Issue 2, ISSN 2321-9939.
[5] M.Melvin Jagadeesh Sridar, M.Manickam, V.Kalaiarasan, M.Abdul
Ghani Khan, Ttm.Kannan, “Optimization of cylindrical Grinding
Process Parameters of OHNS Steel using Design of experiments
Concept”, International Journal on Engineering Trends and Technology,
Volume 17 Number 3, 2014.
[6] M. Mekala, J. Chandradas, K. Chandrasekaran, T.T.M. Kannan, E.
Ramesh and R. Narasing Babu Lohithaksha M Maiyar, Dr.
R.Ramanujam, K.Venkatesan, Dr.J.Jerald, “Optimization of Machining
Parameters for End Milling of Inconel 718 Super Alloy using Taguchi
based Grey Relational Analysis”, International Conference on Design
and Manufacturing(IconDM), pg 1276-1282, 2013.
[7] S. Dhanabalan, K. Sivakumar, C. Sathiya Narayanan, “Optimization of
machining parameters of EDM while machining Inconel 718 for form
tolerance and orientation tolerance”, Indian Journal of Engineering and
Materials Sciences.
[8] Bijaya Bijeta Nayak, Siba Shankar Mahapatra, “Optimization of WEDM
process parameters using deep cryo treated Inconel 718 as Work
Material”, Engineering Science and Technology, an International
Journal, pg 161-170, 2016.

160