Int J Adv Manuf Technol (2011) 54:465–478
DOI 10.1007/s00170-010-2964-0
ORIGINAL ARTICLE
The use of D-optimal design for modeling and analyzing
the vibration and surface roughness in the precision turning
with a diamond cutting tool
Chih-Cherng Chen & Ko-Ta Chiang &
Chih-Chung Chou & Yan-Ching Liao
Received: 16 June 2010 / Accepted: 23 September 2010 / Published online: 6 October 2010
# Springer-Verlag London Limited 2010
Abstract Using a diamond cutting tool in the precision
turning process, the vibration of tool-tip has an undesirable
effect on the machined surface’s quality. The objective of
this paper is to present the mathematical models for
modeling and analyzing the vibration and surface roughness
in the precision turning with a diamond cutting tool.
Machining parameters including the spindle speed, feed rate
and cutting depth were chosen as numerical factor, and the
status of lubrication was regarded as the categorical factor. An
experimental plan of a four-factor’s (three numerical plus one
categorical) D-optimal design based on the response surface
methodology was employed to carry out the experimental
study. A micro-cutting test is conducted to visualize the effect
of vibration of tool-tip on the performance of surface
roughness. With the experimental values up to a 95%
confidence interval, it is fairly well for the experimental
results to present the mathematical models of the vibration and
C.-C. Chen
Department of Automatic and Control Engineering,
ChungChou Institute of Technology,
No.6, Lane 2, Sec. 3, Shanjiao Rd., Yuanlin Town,
Changhua, Taiwan 51001, Republic of China
e-mail: jcchen@dragon.ccut.edu.tw
K.-T. Chiang (*) : C.-C. Chou : Y.-C. Liao
Department of Mechanical Engineering,
Hsiuping Institute of Technology,
No. 11, Gungye Rd.,
Dali City, Taichung, Taiwan 41280, Republic of China
e-mail: kota@mail.hit.edu.tw
K.-T. Chiang
e-mail: vgear2001@yahoo.com.tw
C.-C. Chou
e-mail: george@mail.hit.edu.tw
Y.-C. Liao
e-mail: Liao@mail.hit.edu.tw
surface roughness. Results show that the spindle speed and the
feed rate have the greatest influence on the longitudinal
vibration amplitude, and the feed rate and the cutting depth
play major roles for the transverse vibration amplitude. As the
spindle speed increases, the overall vibration of tool-tip tends
to more stable condition which leads to the results of the best
machined surface. The effects of the feed rate and cutting
depth provide the reinforcement on the overall vibration to
cause the unstability of cutting process and exhibit the result
of the worst machined surface.
Keywords Vibration . Surface roughness .
D-optimal design . Precision turning . Response surface
methodology (RSM)
1 Introduction
Among metal-cutting techniques the precision turning has
become one of the important metal manufacturing processes
and is widely used in the field of high technology of industrial
application. As a result of the quality characteristics of
machined parts, the vibration conditions, occurring among
the cutting tool, chuck, and workpiece, play an important role
in machining performance. Especially, the vibration of cutting
tool has an undesirable effect on the machined surface, quality
of workpiece and the tool wear, which lowers down the
productivity and increases the cost of production. The
dynamic phenomena of cutting tool induced by the interaction
of elastic system in the cutting process cause the relative
displacement between tool and workpiece, which generates
the vibration of cutting tool [1, 2]. The appearance of
vibrations is mainly subjected to the cutting dynamics
process under various cutting conditions. Moreover, the
major detrimental effect of vibration for the workpiece
466
further worsens the quality of machined surface. Surface
roughness is widely used in the index of a machined surface
quality since a reasonably good surface finish is good for
improving the tribological properties, fatigue strength,
corrosion resistance, and esthetic appeal of the machined
product [3, 4]. Excessive vibration can also cause the
damage to the cutting tool and interfere with the feed rate,
cutting speed, and cutting depth. In the past efforts, most
researches reported in the literature focused on using virtual
vibration signals to analyze the effects of cutting tool
vibrations on the machined surface, and proposed the
predicted vibrations model which are determined by the
cutting process dynamics.
The amplitude and natural frequency of cutting tool
vibrations under the resonance during cutting process are
related to the dynamic cutting force and the chip-thickness
variation acting on the cutting tool. The variation of cutting
tool vibrations in the finish cutting process is observed
through the monitor of surface roughness growth on the
machined surface. Mer and Diniz [5] carried out the
experiments for correlating the variation of the tool
vibration, tool wear, tool life, and surface roughness in the
finish turning with the coated carbide tools. Thomas et al.
[6] investigated the effect of cutting tool vibrations on
surface roughness during lathe dry turning of mild carbon
steel under different cutting parameters including the
cutting speed, feed rate, cutting depth, tool nose radius,
tool overhang, and workpiece length. Jang et al. [7]
proposed a measuring technique of online real-time
roughness, which is a monitoring algorithm dealing with
the relative cutting vibrations between tool and workpiece,
so as to study the correlation between surface roughness
and cutting vibration in hard turning process. Abouelatta
and Madl [8] proposed the mathematical prediction model
of surface roughness based on cutting parameters and tool
vibrations in turning operations. Dimla [9] described a tool-
wear monitoring procedure in a metal-turning operation
using vibration features. The monitoring procedure revealed
that the vibration signals’ features are related to the wear
qualification of cutting tool-wear. Risbood et al. [10]
utilized the fitted network for predicting the surface finish
and dimensional deviation by measuring cutting forces and
vibrations in the turning process. Consequently, the cutting
tool vibrations had been reported to be much more
significant than other monitoring signals [5–10] in predicting
surface roughness.
The demand of precision machining for the highly
durable molds of complex and precise components has
been increasing. Diamond cutting tool is well known as a
preferred tool for precision machining. Although the
diamond cutting tools reveal severe wear in the machining
process of ferrous metals [11], the diamond cutting tools are
widely used for the machining of various hardened non-
Int J Adv Manuf Technol (2011) 54:465–478
ferrous materials in the manufacturing industry. Diamond
possesses the characteristics of highest hardness, quite
strong resistance to wear, perfect chemical stability, and
satisfactory service life, as well as the least sharpness as
finished [12, 13]. The diamond cutting tools easily have the
finest cutting edge radius and highly integrated edge
quality. Sreejith et al. [14] had evaluated the performance
of polycrystalline diamond (PCD) cutting tools during the
machining process of carbon/phenolic ablative composites.
Davim and Mata [15] presented an optimization study of
surface roughness on turning fiber-reinforced plastics with
diamond cutting tools. Hence, it is important duty to
acquire the machinablity evaluation in the precision
machining process with diamond cutting tools. Especially,
using the diamond cutting tools in the precision cutting
process, the control of cutting tool vibrations is found to
exert a great influence on the accuracy of precision
machining products [16–18]. Bispink [16] and Takasu et
al. [17] investigated the influence of vibration signals with
small amplitude upon surface roughness in diamond
machining process. The relative vibrations in the feed
cutting direction are considered to be a predominant factor
in the generation of good machined surface. Cheung and
Lee [18] proposed a model-based simulation system for the
analysis of surface roughness generation in ultra-precision
diamond turning. The simulation system is based on a
surface roughness model, which takes into account the
effect of processing parameters, tool geometry, and relative
vibrations between the tool and the workpiece.
In this study, an attempt had been made to investigate the
machinability evaluation of A6061-T6, an aluminum alloy,
in precision turning with the diamond cutting tool. The
evaluation of machinability performances adopts the sur-
face roughness to identify the quantitative estimation of
cutting tool vibrations under various cutting conditions. A
micro-cutting test is conducted to visualize the effect of
tool-tip vibration on the performance of surface roughness.
The features of tool-tip vibration are extracted form the
singular spectrum analysis (SSA)-processed vibration signals
[19]. In this study, the spindle speed, feed rate, and cutting
depth were chosen as the numerical factor, and the status of
lubrication was regarded as the categorical factor. A four-
factor (three numerical plus one categorical) D-optimal
design is employed to determine the experimental runs
for the operating conditions of cutting process. In this
paper, a mathematical model based on the response
surface methodology (RSM) is proposed for modeling
and analyzing the vibration and surface roughness in the
precision machining process. The RSM is a statistical
modeling approach to determine the relationship between
various process parameters and responses with the
various desired criteria, and further to search the
significance of these process parameters on the coupled
Int J Adv Manuf Technol (2011) 54:465–478
responses. It employs a sequential experimentation strategy
for building the empirical model. Therefore, RSM is a
collection of mathematical and statistical procedures that are
useful for the modeling and analysis of problems; the response
is affected by several variables and the main objective is to
optimize this response [20]. Using the experimental design
and applying the regression analysis, one can gain the
modeling of the desired response with several independent
input variables. Consequently, the RSM is utilized to
describe and identify, with a great accuracy, the influence
of the interactions between different variables on the
response when they are varied simultaneously [21–26]. In
this paper, a mathematical model based on the RSM is
proposed for modeling and analyzing the vibration and
surface roughness in the precision machining process with
the diamond cutting tool.
2 Experimental design and procedure
2.1 Equipment, cutting tool, and materials
In this study, the experiments were performed: (a) to
understand the process of cutting tool vibrations in the
precision-turning process, and (b) to provide appropriate
experimental data to establish the mathematical model of
surface roughness so as to investigate the influences of cutting
tool vibrations under the various cutting conditions. A series
of turning experiments were carried out in order to obtain
experimental data in the different lubricant conditions on a
Vcenter-55/70 CNC ultra-precision lathe, which have a
maximum spindle speed of 4,500 rpm, maximum turning
diameter 260 mm, and a maximum power of 35 kW.
TNMN160408 PCD tool inserts made by Diku Inc. were
employed in this study. The cutting tool inserts was
clamped onto a tool holder, type MTJNRL-2020K16; its
major geometry is the working rake angle of 5°, the
working side-cutting edge angle of 60°, the tool flank angle
of 6°, and the edge radius of 0.05 mm. The PCD tool inserts
posses the characteristics of high thermal conductivity
(700 W/mK), high hardness (6,500∼8,000 HV), lower
thermal expansion (1.45×10−6 1/°C), and lower friction
coefficient (0.1∼0.3).
The workpiece material used in this study is the A6061-
T6 aluminum alloy (ASTM B211 grade) with the following
chemical compositions in mass%: 0.40 to 0.8 Si, 0.7 Fe
max, 0.15 to 0.40 Cu, 0.15 Mn max, 0.8 to 1.2 Mg, 0.04 to
0.35 Cr, 0.25 Zn max, 0.15 Ti max and bal. Al. T6 temper
6061 aluminum alloy has an ultimate tensile strength of at
least 290 MPa and yield strength of at least 241 MPa.
Before cutting, the workpiece material was made into
cylindrical bars with 40 mm diameter and 100 mm length.
The metal cutting process was designed and machined by
467
using Solidworks CAD/CAM software. The completion
and positioning of cutting process were machined and
controlled by using CNC software.
2.2 Experimental design
Figure 1 is a schematic diagram of the experimental setup.
The monitoring system of cutting condition is composed of
data acquisition system. The data acquisition system
consists of two signal measurement sensors (accelerometer)
and a SSA device. In order to detect the vibration condition
in the turning process, the vibration signals were measured
using two 353B16 ICP accelerometers that was placed
close to the tool and sensed the vibration in the transverse
(x-axis) and longitudinal (z-axis) direction, respectively.
The vibration signals along the cutting speed direction
(transverse direction) was found to be highly sensitive to
the performance of roughness on the machined surface. The
sensitivity of the accelerometer was 10 mV/g (±15%), and
its measurement range was 0.7∼20 kHz. These sensed
vibration signals collected in the time domain were then
sent to the SSA device for the calculation of root mean
square (RMS) value of vibration signal for each experiment.
The RMS value of vibration signal represents the square root
of the average of the squared value of the vibration amplitude.
Therefore, the vibration signals acquired through the
accelerometer were processed by the SSA device for the
analysis of frequency domain. SAA is a non-parametric
technique of time series analysis based on principles of
multivariate statistics. The procedure of SSA decomposes
a given time series into a set of independent additive
time series [19]. The main function of singular spectrum
analyzer is to represent the spectrum characteristics of a
given time series signal in the frequency domain. When
the cutting operation is in process, the sensors dynamically
collect the raw vibration signals. These vibration signals
obtained in time domain are transformed to frequency domain
by the fast Fourier transform (FFT). The power spectrum
density analysis is performed according to the output of
FFT. The vibration signals called spectrum in the frequency
domain were analyzed for different cutting processes. In
the experimental setup, the singular spectrum analyzer is
a real-time spectrum analyzer (four-channel real-time
analyzer, G-Tech Instrument Inc.) which displays the
singular amplitude of frequency domain immediately.
The measured signal bandwidth was set within 5 kHz.
In the cutting process, the cutting length and diameter
was kept the same so that no further vibrations are induced
by the deflection of workpiece. The cutting length and
diameter were fixed at 80 and 40 mm in the experimental
design, respectively. In order to visualize the effect of tool-
tip vibrations on the surface roughness, a micro-cutting test
is conducted as follows. The spindle speed was varied from
468 Int J Adv Manuf Technol (2011) 54:465–478

Fig. 1 Schematic diagram of

the experimental setup
Chuck

Workpiece
Longitudinal
Vibration
Accelerometer

Transverse
Vibration
Accelerometer

Real-time Computer
spectrum analyzer

2,000 to 3,000 rpm, the feed rates were changed between
0.02 and 0.10 mm/revolution, and the cutting depth was set
from 0.04 to 0.12 mm. For the purpose of comparison and
identification of the damping effect induced by the
lubrication which is introduced into the dynamic system
of tool-tip and workpiece, the coolant mist and lubrication
were used in the cutting process. The composed mineral oil
(ILD CUT 481) was used as the lubricant liquid (cutting
fluid), and the coolant mist is composed of approximately
20% of lubricant liquid and 80% of dry compressed air. The
jet flushing system was employed to provide an impinging
jet between the tool-tip and workpiece. The lubricant liquid
and coolant mist were flushed at a pressure of 147 and
294 kPa, respectively. Table 1 shows the setting of
experimental parameters and instrument under cutting
A6061-T6 aluminum alloy in the precision turning process.
In the present study, the frequency and amplitude of
vibration signals were considered as the criterion and would
affect the machinability evaluation in the precision turning
process. The value of surface roughness here was adopted
as the machinability evaluation of A6061-T6 machined in
the precision turning process. The measurements of the
surface roughness for the machined surface were performed
by using a Mitutoyo SurfTest-402 with a cut-off length of
80 mm and sampling length of 60 mm. The maximum
surface roughness (Rmax) was used to evaluate the surface
roughness of the machined surface. The frequency and
amplitude in the power spectrum density plots of the
vibration signals were recorded to identify the quantitative
estimation of cutting tool vibrations under various cutting
conditions. In the precision turning process, the lower both
amplitude of vibration signals and Rmax are, the better the

Table 1 Experimental parameters

and instrument Working conditions Unit Description

Lathe Vcenter-55/70 CNC

Workpiece A6061-T6
Holder type MTJNRL-01
Insert type TNMN160408 polycrystalline diamond (PCD)
Cutting length mm 80
Cutting diameter mm 40
Spindle speed (N) rpm 2,000–3,000
Feed rates (f) mm/rev 0.02–0.10
Cutting depth (αP) mm 0.04–0.12
Cutting fluid ILD CUT 481
Flushed pressure kPa 147(Lubricant liquid), 294(Coolant mist)
Accelerometers 353B16 ICP
Data acquisition Real-time spectrum analyzer
Int J Adv Manuf Technol (2011) 54:465–478 469

indication of the response characteristics. Those desired
responses are regard as the smaller-the-better characteristics
and influence each other relatively.
According to the previous analysis in the real cutting
process, the spindle speed (X1), the feed rate (X2), and the
depth of cut (X3) were actually chosen as the three
numerical factors for investigation. The status of lubrication
(X4) set up three categories including the full lubrication
(100% of lubricant liquid), coolant mist (20% of lubricant
liquid and 80% of dry compressed air), and dry cutting (no
lubricant fluid) during the cutting process. The status of
lubrication was regard as the categorical factor. Table 2
shows the controllable parameters and their levels in the
coded and actual values.
3 D-optimal design of the response surface methodology
The D-optimal design is designed for use with categorical
factors as an alternative to the general–optimal design
option. The general–optimal design builder may produce
designs with more runs than the experiments are willing to
run. The D-optimal criterion was developed to select design
points in a way that minimizes the variance associated with
the estimates of specified model coefficients. The occasion
for using D-optimal design instead of general–optimal
designs generally fall into two types: (a) standard factorial
or fractional factorial designs require too many runs for the
amount of resources or time allowed for the experiment, (b)
the process space contains factor settings that are not
feasible or are impossible to run.
A response surface-based D-optimal design was used to
determine the experimental run for the operating conditions
of cutting process. The procedures of D-optimal design
consist of the defining level, selection of the fitting model,
and the chosen design points. The design points chosen
from the set of candidate points depend on the selected
model [20]. As presented in Table 2, three numerical factors
are varied over five levels, while one categorical factor is at
three categories. In this study, the quantitative form of
relationship between the desired response and independent
input variables can be represented in the following:
Y ¼ f ðX1 ; X2 ; X3 ; X4 Þ ð1Þ
where, Y is the desired response and f is the response
function (or response surface). In this particular case, the
approximation of Y was proposed by using the fitted
second-order polynomial regression model which is called
the quadratic model. The quadratic model was exactly
suitable for studying carefully the interactive effects of
combinative factors on the performance evaluations. The
quadratic model of Y can be written as follows:
X
4 X
4 X
4
Y ¼ a0 þ ai Xi þ aii Xi2 þ aij Xi Xj ð2Þ
i¼1 i¼1 ij
where a0 is constant, ai, aii, and aij represent the coefficients
of linear, quadratic and cross product terms, respectively.
This model using the quadratic model of f in this study not
only aims to investigate the response over the entire factor
space, but also to locate the region of desired target where
the response approaches to its optimum or near optimal
value. In general, the quadratic model of desired response
(Y) can be expressed as follows by matrix from as:
Y ¼ Xaþ" ð3Þ
where X is a matrix of model terms evaluated at the data
points, ɛ is an error vector. The unbiased estimator ɛ of the
regression coefficient vector α is estimated by using the
least-squares error method as follows.
a ¼ ðXT XÞ1 XT Y ð4Þ
where is XT the transpose of the matrix X.
The algorithm of D-optimal design for choosing design
points is to select the set of design points by the selected
quadratic model, which results in 18 minimum model
points, and five points of them are used to estimate the

Table 2 Design schema of machining parameters and their levels

Parameters Code Levels

1 2 3 4 5

Numerical −2 −1 0 +1 +2
Categorical 1 2 3

Spindle speed (rpm) X1 2,000 2,250 2,500 2,750 3,000

Feed rate (mm/rev) X2 0.02 0.04 0.06 0.08 0.10
Cutting depth (mm) X3 0.04 0.06 0.08 0.10 0.12
Lubrication X4 Full lubrication Coolant mist Dry
470 Int J Adv Manuf Technol (2011) 54:465–478

lack-of-fit and replicates as well. The 28 experimental runs
based on D-optimal design were performed to provide the
suitable framework for this cutting experimentation, as
shown in Table 3. It also displays the run numbers and the
observed responses. Each cutting experiment was carried
out two times at different time under the same conditions to
ensure that the experimental data were repeatable.
4 Results and discussion
4.1 Identification of cutting tool vibration
For identifying the elastic deformations of the machine-
fixture-tool-work (MFTW) system and their influence
under the no-cutting condition, the power spectrum density
plots and the vibration amplitudes in the longitudinal and
transverse direction of the cutting tool were collected.
These sensed vibration signals collected in the time and
frequency domain were regarded as the basic reference to
compare the quantitative estimation of cutting tool vibra-
tions under various cutting conditions. This process is to
identify the the MFTW system dynamic parameters such as
system damping and stiffness in standstill under various
cutting conditions. Time domain signal analysis is essential
to understand the overall vibration level generated in
cutting process. The vibration raw signals of longitudinal
and transverse direction on the cutting tool were recorded
within 150 ms. Figure 2 reveals the vibration amplitudes in
the longitudinal and transverse direction of the cutting tool
under the no-cutting and dry cutting conditions. The no-
cutting condition sets up the status of spindle speed to be

Table 3 Design layout and experimental results

Run Numerical factor Categorical factor Responses

Spindle speed Feed rate Cutting depth Lubrication Roughness Vibration amplitude

X1 X2 X3 X4 Rmax (Y1, μm) Longitudinal (Y2,mGs) Transverse (Y3,mGs)

1 3,000 0.02 0.08 Full 0.12 12.33 13.14

2 2,250 0.04 0.08 Dry 0.17 11.81 12.54
3 3,000 0.02 0.12 Dry 0.26 12.64 13.41
4 2,000 0.1 0.04 Coolant mist 0.38 16.43 17.28
5 2,250 0.08 0.08 Coolant mist 0.28 17.22 18.13
6 2,000 0.06 0.12 Dry 0.20 12.96 13.61
7 2,000 0.02 0.08 Coolant mist 0.13 15.09 15.90
8 2,000 0.02 0.04 Full 0.12 11.45 12.32
9 3,000 0.06 0.04 Dry 0.17 16.22 17.32
10 3,000 0.1 0.12 Full 0.40 16.67 17.70
11 2,500 0.1 0.12 Dry 0.47 13.76 14.08
12 3,000 0.1 0.04 Full 0.37 14.63 15.37
13 2,500 0.02 0.04 Dry 0.14 10.66 11.57
14 3,000 0.02 0.04 Coolant mist 0.12 16.46 17.75
15 3,000 0.02 0.08 Full 0.10 13.52 14.49
16 2,500 0.06 0.08 Full 0.18 14.37 15.44
17 3,000 0.1 0.04 Full 0.40 15.08 15.82
18 2,000 0.1 0.08 Full 0.41 14.32 15.12
19 2,000 0.02 0.12 Full 0.11 11.75 12.68
20 2,000 0.06 0.04 Dry 0.18 11.59 12.65
21 2,500 0.04 0.06 Coolant mist 0.16 14.63 15.91
22 3,000 0.1 0.08 Coolant mist 0.39 17.07 17.77
23 2,500 0.1 0.04 Dry 0.40 12.84 13.98
24 2,000 0.02 0.12 Full 0.14 10.61 11.93
25 3,000 0.1 0.08 Coolant mist 0.38 17.58 18.96
26 2,000 0.1 0.12 Coolant mist 0.40 20.82 21.67
27 3,000 0.02 0.12 Coolant mist 0.12 15.63 17.06
28 2,000 0.1 0.08 Full 0.41 14.29 16.06
Int J Adv Manuf Technol (2011) 54:465–478
Fig. 2 The vibration amplitude
of a longitudinal and b transverse
direction on the cutting tool
under the no cutting and dry
cutting conditions
2,000 rpm. The dry cutting condition employs the cutting
parameter setup of spindle speed of 2,000 rpm, feed rate of
0.10 mm/rev and cutting depth of 0.12 mm. It shows that
the amplitude of vibration signals under cutting process is
generally larger than under no-cutting process. It also
displays that the change of the vibration amplitudes is
obviously performed in the cutting process. When the
material of workpiece was cut, large amplitude vibrations
induced by cutting force were generated on the cutting tool,
especially in the transverse direction. The power spectrum
density plots of other vibration signals in the frequency
domain under the no-cutting and dry cutting conditions are
shown in Fig. 3. It is observed that the characteristics of the
peaks appear at the frequency within 0∼1 kHz under the no
cutting and dry cutting conditions. These peaks are
regarded as the excited natural frequency induced by the
structure of machine. The frequencies of the characteristic
peaks at the low frequency band are found to be not very
sensitive to the cutting conditions. But, it exists another
characteristic peaks that appeared at the high frequency
471
band of 3.5∼4.5 kHz in the longitudinal direction under
cutting process. It was caused by the interaction between
the tool-tip and the elastic recovery induced by the feed
force of cutting tool. These peaks present the status of the
relative movement between cutting tool and workpiece, and
are regarded as dominant factors affecting the surface
roughness.
4.2 The analysis of the proposed quadratic mathematical
model
In order to ensure the goodness of fit of the quadratic model
obtained in this study, the test for significance of the
regression model, the test for significance on individual
model coefficients and the test for lack-of-fit need to be
performed [20–26] as shown in Table 4. These tests are
performed as analysis of variance (ANOVA) procedure by
calculating the “F-value”, the “Prob. > F”, the determination
coefficients (R2), adjusted R-squared (R2 adjusted) and the
adequate precision (AP). The values of “F-value” and the
472 Int J Adv Manuf Technol (2011) 54:465–478

Fig. 3 The power spectrum

density of a longitudinal and b
transverse direction on the
cutting tool under the no
cutting and dry cutting
conditions

“Prob. > F” imply a statistical significance on the regression
model and the particular linear, quadratic, or interaction
terms. Usually, as the desired confidence level is set to 95%,
the value of “Prob. > F” smaller than 0.05 signifies that the
regression model is considered to be statistically significant,
which is desirable as it demonstrates that the terms in
the model have a significant effect on the responses. The
determination coefficient R2 is defined as the ratio of the
explained variation to the total variation and is a measure
of the degree of fit. When R2 approaches to unity, the
better the response model fits the actual data, the less it
exists the difference between the predicted and actual
values. The adjusted R-squared (R2 adjusted) presents a
measure of the amount of variation around the mean

Table 4 The ANOVA for the fitted models

Final quadratic models Roughness, Rmax (Y1) Longitudinal vibration amplitude (Y2) Transverse vibration amplitude (Y3)

F value 64.90 19.50 16.70

Prob.>F <0.0001 <0.0001 <0.0001
R2 0.9910 0.9707 0.9715
R2 adjusted 0.9757 0.9209 0.9441
Adequate precision (AP) 22.572 17.548 14.508
Lack of fit Not significant Not significant Not significant
Int J Adv Manuf Technol (2011) 54:465–478 473

16:9674 þ 0:0241 X1  11:4168 X2 þ 52:4639 X3  4:4  106 X1 2 þ 403:4521 X2 2 þ 45:0103 X3 2  0:0115 X1 X2  0:0191 X1 X3 þ 308:1804 X2 X3

19:1201 þ 0:0244 X1  19:5061 X2 þ 48:1062 X3  4:4  106 X1 2 þ 403:4521 X2 2 þ 45:0103 X32  0:0115 X1 X2  0:0191 X1 X3 þ 308:1804 X2 X3
explained by the model, adjusted for the number of

29:2351  0:0183 X1 þ 136:5337 X2  1:8515 X3 þ 4:48  106 X1 2  824:025 X2 2 þ 199:3333 X32  0:0156 X1 X2  0:0194 X1 X3 þ 472:2632 X2 X3
23:8237  0:0163 X1 þ 136:1521 X2  8:3605 X3 þ 4:48  106 X12  824:025 X22 þ 199:3333 X32  0:0156 X1 X2  0:0194 X1 X3 þ 472:2632 X2 X3

35:4338  0:020 X1 þ 131:7326 X2 þ 13:3919X3 þ 4:48  106 X1 2  824:025X22 þ 199:3333 X32  0:0156 X1 X2  0:0194 X1 X3 þ 472:2632 X2 X3
20:9396 þ 0:0249 X1  4:0384 X2 þ 41:6046X3  4:4  106 X1 2 þ 403:4521X22 þ 45:0103X32  0:0115 X1 X2  0:0191 X1 X3 þ 308:1804 X2 X3
terms in the model. The adjusted R-squared (R 2

0:1626 þ 0:0003 X1  3:2745 X2  0:5469 X3  6:8  108 X1 2 þ 55:3632 X22  1:2686 X32  2:7  105 X1 X2 þ 0:0003 X1 X3  0:6568 X2 X3

0:1721 þ 0:0003 X1  2:9622 X2  0:4968 X3  6:8  108 X1 2 þ 55:3632 X22  1:2686 X32  2:7  105 X1 X2 þ 0:0003 X1 X3  0:6568 X2 X3
0:3068 þ 0:0003 X1  3:5093X2 þ 0:3191 X3  6:8  108 X12 þ 55:3632 X22  1:2686 X32  2:7  105 X1 X2 þ 0:0003 X1 X3  0:6568 X2 X3
adjusted) decreases as the number of terms in the model
increases if those additional terms don’t add value to the
model. Furthermore, the value of AP in this model,
which compares the range of the predicted value at the
design point to the average prediction error, is well
above 4. The value of the ratio is greater than 4, which
presents the adequate model discrimination. These
models obtained higher values of the R2, R2 adjusted,
and AP at the same time.
In this study, the final quadratic models given in the
actual terms regarding responses surface roughness (Y1,
μm), longitudinal vibration amplitude (Y2, mGs), and
transverse vibration amplitude (Y3, mGs) are stated in
Table 5. Since each combination of categorical levels has
an equation that predicts the response, three equations are
presented for each status of lubrication. From the results
of Table 4, for each final quadratic model F-values
ranging from 16.70 to 64.90 implies that the models are
significant. The obtained R2 and R2 adjusted values are
close to one if the fit is good and a variation in the
measured values can be explained by the chosen model.
Figure 4a–c display the normal probability plot of the
residuals for each response, Y1, Y2, and Y3. Notice that the
residuals generally fall on a straight line, which implies
that the errors are normally distributed. Furthermore, it
adequately supports the least-squares fit. The results of
comparison prove that the predicted values of Y1, Y2, and
Y3 are close to those readings recorded in the experiment
with a 95% confidence interval.

4.3 The effect of machining parameters on the vibration

amplitude

In the cutting process, the machining parameters adopting

the X1, X2, and X3 were chosen as the three numerical
factors so as to investigate the influences on the vibration
Table 5 Model equations for each observed response

amplitude. Figure 5a shows the response surface and

Equation

contour plot for the longitudinal Y2 in relation to the X1

and X2 with the X3 maintained at the middle levels under
dry cutting condition. From Fig. 5a, it can be seen that an
increase in both the high value of spindle speed and feed
rate leads to an increase of the value of longitudinal
vibration amplitude. As the spindle speed increases, the
general trend of increase in the excited vibration
appearance of longitudinal direction with the increase in
the spindle speed is clearly observed at lower value of
feed rate. As seen above, the longitudinal vibration
Full lubrication

amplitude increases with increasing the feed rate. In the

Coolant mist
Dry cutting

Y2, mGs
Y3, mGs

Y2, mGs
Y3, mGs

Y2, mGs
Y3, mGs
Response

precision-turning process, the vibration stability of

Y1, μm

Y1, μm

Y1, μm

cutting tool affects the quality of the machined surface.

The status of feed rate corresponds to the amount of
474 Int J Adv Manuf Technol (2011) 54:465–478

resistance force acting on the tip of cutting tool. This

resistance force for the workpiece is regarded as the cutting
force. An increase in the feed rate causes an increase in the
resistance force of longitudinal direction. Further increase
in the feed rare causes the excited vibration appearance to
appear more discontinuous chip. Figure 5b depicts that the
influences of X1 and X2 on the transverse vibration
amplitude (Y3) with keeping the X3 at the middle levels
under dry cutting condition. There is an increase in the
transverse vibration amplitude with the increase in the feed
rate. In Fig. 5b, the value of transverse vibration amplitude
is shown to gently increase with an increase of spindle
speed, up to 2,500 rpm, and then decreases with a further
increase in the spindle speed. This event has been attributed
to the increase of rotation stability in the high spindle
speed, which results in decreasing the vibration amplitude.
Overall, the value of transverse vibration amplitude is
greater than the longitudinal vibration amplitude with the
same machining parameters.
In the cutting process, the resistance force acting on the
cutting tool is mainly generated by the status of feed rate

Longitudinal vibration
amplitude (Y2 , Gms)

Feed rate ( X 2, mm/rev)

Spindle speed (X 1 ,rpm)

Transverse vibration
amplitude (Y3 , mGs)

Feed rate (X 2 , m/rev)

Spindle speed ( X 1 , rpm)

Fig. 5 The response surface and contour plot of a longitudinal

Fig. 4 Normal probability plot of residuals for each response: a vibration amplitude (Y2) and b transverse vibration amplitude (Y3)
surface roughness (Y1), b longitudinal vibration amplitude (Y2), and c between the effect of spindle speed (X1) and feed rate (X2) at X3 =
transverse vibration amplitude (Y3) 0.8 mm under dry cutting condition
Int J Adv Manuf Technol (2011) 54:465–478
and depth of cut. The increase of cutting depth causes an
increase in the resistance force at the tool-tip to excite more
vibration appearance. The effects of X2 and X3 on both the
Y2 and Y3 with keeping the X1 at the middle levels under
dry cutting condition are presented in Fig. 6a and b,
respectively. From Fig. 6a, it can be obviously seen that the
longitudinal vibration amplitude increases with increasing
the cutting depth at the higher value of feed rate. In general,
the increase of cutting depth improves the resistance force,
especially in the transverse component. In Fig. 6b, the value
of transverse vibration amplitude is shown to gently
increase with an increase of cutting depth. This result has
been attributed to the transverse component of resistance
force at the tip of cutting tool, which presents more and
larger vibration amplitudes in the transverse direction.
According to the data obtained from the experiments for
various cutting conditions in Table 3, it is found that the
overall value of transverse vibration amplitude has enlarged
by 6.7% as compared with the longitudinal vibration
amplitude. As the results of analysis discussed above, the
longitudinal vibration amplitude is principally influenced
by both the spindle speed and feed rate. Besides, the feed
a transverse direction. From the visualized time domain
Longitudinal vibration
amplitude (Y2 , mGs)
Cutting depth (X 3 , mm)
Feed rate ( X 2 , mm/rev)
b
Transverse vibration
amplitude (Y3 , mGs)
Cutting depth (X 3 , mm)
Feed rate ( X 2 , mm/rev)
Fig. 6 The response surface and contour plot of a longitudinal
vibration amplitude (Y2) and b transverse vibration amplitude (Y3)
between the effect of feed rate (X2) and cutting depth (X3) at X1 =
2,500 rpm under dry cutting condition
475
rate and the cutting depth play major roles for the value of
transverse vibration amplitude.
4.4 The damping effect of lubrication
The cutting fluid penetrates into the chip–tool interface to
provide the lubrication, reduce the cutting temperature and
improve tool life. In reality, the higher machining efficiency,
better surface quality and cutting conditions are affected by
the effect of cutting fluid. The lubrication of chip–tool
interface corresponds to the amount of resistance force acting
on the tip of cutting tool. The status of lubrication in this study
set up three categories including the full lubrication, coolant
mist, and dry cutting condition in order to investigate the
influences on the vibration amplitude. Figure 7 reveals the
vibration amplitudes of longitudinal and transverse direction
on the cutting tool under the full lubrication and dry cutting
conditions. The cutting condition employs the cutting
parameter setup of spindle speed 2,500 rpm, feed rate
0.06 mm/rev and cutting depth 0.08 mm. It shows that the
amplitude of vibration signals under the full lubrication
condition is generally smaller than under the dry cutting
process. It also can be apparently seen that the change of
vibration amplitudes was obviously performed in the
vibration data, there are reduced from 16.04 to 13.71 mGs
in the transverse direction. When the cutting fluid penetrates
into the chip–tool interface, the friction generated between
cutting tool and workpiece decreases. Therefore, the lubri-
cation of chip–tool interface proposes cutting tool with the
damping effect.
4.5 The machinability evaluation of surface roughness
Figure 8 shows the response surface and contour plot for
the surface roughness Rmax (Y1, μm) in relation to the
cutting parameters of X1 and X2, while the X3 is kept at the
middle level under the dry cutting condition. As can be
seen from this figure, the value of surface roughness is
shown to slowly increase with an increase of spindle speed.
However, the increase is diminished after 2,500 rpm and
the value of surface roughness nearly stays constant. This
event has been attributed to the more stability of overall
vibration in the tip of cutting tool as the spindle speed
increases, which leads to the results of the best machined
surface and the continuous chip. Figure 9a displays the
relation between the surface roughness and the vibration
amplitude in the status of various spindle speed. The effect
of spindle speed on the value of surface roughness is
presented in Fig. 9a, which shows that the change of
surface roughness is identical to the results of Fig. 8.
Figure 8 also displays that the surface roughness tends to
considerably increase with the increase in the feed rate. The
476 Int J Adv Manuf Technol (2011) 54:465–478

Fig. 7 The vibration amplitude

of a longitudinal and b transverse
direction on the cutting tool
under the dry and full lubrication
cutting conditions

effect of feed rate presents the reinforcement on the overall

vibration to cause the unstability of cutting process, and
exhibit the result of worst machined surface. From Fig. 9b,
it displays the relation between the surface roughness and
the vibration amplitude in the status of various feed rate,
which can be proved that the effect of feed rate improves all
the values of the surface roughness and the vibration
amplitude.
The effects of X2 and X3 on the surface roughness Rmax
Surface roughness
(Y1, μm) with keeping the X1 at the middle levels under dry
Rmax (Y1 , µm )
cutting condition are shown in Fig. 10. The value of surface
roughness increases with the increase of both the value of
feed rate and the cutting depth. It is clearly observed that
the increase of surface roughness caused by the effect of
Feed rate (X 2, mm/rev)
Spindle speed ( X 1 , rpm) feed rate looks greater than the effect of cutting depth. The
results can be explained in terms of vibration amplitudes
generated in the longitudinal and transverse direction. From
Fig. 8 The response surface and contour plot of surface roughness
Rmax (Y1, μm) between the effect of spindle speed (X1) and feed rate Fig. 9c, it displays the relation between the surface
(X2) at X3 =0.8 mm under dry cutting condition roughness and the vibration amplitude in the status of
Int J Adv Manuf Technol (2011) 54:465–478 477

Surface roughness
Rmax (Y1 , µm )

Cutting depth (X 3 , mm)

Feed rate (X 2 , mm/rev)

Fig. 10 The response surface and contour plot of surface roughness

Rmax (Y1, μm) between the effect of feed rate (X2) and cutting depth
(X3) at X1 =2,500 rpm under dry cutting condition

damping coefficient of cutting tool-tip; hence, the machined

surface has lower value of surface roughness.
From the results of Section 4.4, the lubrication of cutting
fluid presents the damping effect to the tip of cutting tool,
which result in the stability of cutting tool during cutting
process, and hence the machined surface exhibits a good
quality. Figure 11 illustrates the relation between the
surface roughness and the vibration amplitude in the three
categories of lubrication; it also demonstrates that the effect
of lubrication reduces all the values of the surface
roughness and the vibration amplitude.

5 Conclusions

This research adopts the RSM to derive the mathematical

model for modeling and analyzing the vibration and surface
roughness in precision turning of A6061-T6 with a diamond
cutting tool. An experimental plan of a four-factor (three
numerical plus one categorical) D-optimal design based on the

Fig. 9 The effects of a spindle speed (X1), b feed rate (X2), and c
cutting depth (X3) on the surface roughness and vibration amplitude

various cutting depth, and the cutting depth has only

obviously affected on the vibration amplitudes of transverse
direction. Consequently, the overall vibration in the tip of
cutting tool is unfavorable to the roughness of the machined
surface. Therefore, the best surface roughness is achieved at
the highest spindle speed and lowest both feed rate and
cutting depth as expected. These results had been attributed
to the increase in spindle speed and decrease in both feed
rate and cutting depth, which leads to the decrease in the Fig. 11 The effect of Lubrication on the surface roughness and
cutting force and promotes the equivalent stiffness and vibration amplitude
478
RSM was employed to carry out the experimental study.
According to the developed mathematical model, the machin-
ability evaluation in the precision-turning process has been
analyzed and draws the following conclusions:
(1) The results of ANOVA and comparisons of experi-
mental data represent that the mathematical model of
the value of surface roughness and vibration amplitude
is fairly well fitted with the experimental values with a
95% confidence interval.
(2) The longitudinal vibration amplitude is principally
influenced by the spindle speed and the feed rate. For
the transverse vibration amplitude, the feed rate and
the cutting depth play major roles.
(3) As the spindle speed increases, the overall vibration on
the tip of cutting tool tends to more stability condition
which leads to the results of the best machined
surface.
(4) The effects of feed rate and cutting depth provide the
reinforcement on the overall vibration to cause the
unstability of cutting process and exhibit the result of
worst machined surface.
(5) The lubrication of cutting fluid possesses the damping
effect to the tip of cutting tool and benefit the stability
of cutting tool during cutting process. Hence, the
machined surface exhibits a good quality.
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