Optimization of machining parameters With Coated Carbide Tool Using PSO method

Raghunath.K1, Rajkumar.D2, Rajesh.S3

1, 2, Third Year Mechanical Engineering, Kalasalingam University, Krishnankoil.
3: Assistant Professor, Mechanical Engineering, Kalasalingam University, Krishnankoil.
Contact No:+91 94861237641, +91 94862256602.
Mail ID: ragunathkrishnan@gmail.com1, kdkumar2001@gmail.com2

Abstract:Globalization of world market creates a challenge in products marketing. Due to the high
competition induces the manufactures to produce the better quality products within a short period of time
as well as low cost. Précised product could be produced while utilizing the machines at optimum working
condition. Optimum machining parameters are of great concern in the manufacturing environments,
where the economy of the machining operation plays a key role in competitiveness in the market. This
project is based on Particle Swarm Optimization (PSO) method to optimize turning operation with
multiple performance characteristics using MAT LAB Program. Solving multiple performance
characteristics problem with conventional technique like Taguchi would be difficult one. In order
alleviate this problem, in this work attempt has been made to optimize the machining parameters with the
help of PSO. In this present work, Surface roughness and material removal rate were taken as output
parameters to optimize the important input parameters like speed, feed and depth of cut. The result revels
that, the PSO technique is very useful to optimize the turning parameters.

Key words: speed, feed, Depth of Cut, Particle swarm optimization, MATLAB, Surface roughness,
material removal rate

I. Introduction another criterion, called productivity which is

directly related to the profit level and also
Quality and productivity play significant role in
goodwill of the organization. Every
today’s manufacturing market. From customers’
manufacturing industry aims at producing a
viewpoint quality is very important because the
large number of products within relatively lesser
extent of quality of the procured item (or
time. In this project EN8 material is taken work
product) influences the degree of satisfaction of
piece material and titanium coated tungsten
the consumers during usage of the procured
carbide tool is taken for optimization of process
goods. Therefore, every manufacturing or
parameters.
production unit should concern about the quality
of the product. Apart from quality, there exists
EN-8 finds wide varieties of application not only and its performance during the machining which
for forgings, castings, axle, shafts, crankshafts includes surface roughness. The turning
and connecting rods but also used as low cost experiments were carried out in order to obtain
die material in tool and die making industries. experimental data in the dry condition on a CNC
This steel can be hardened and tempered to Industrial Lathe, which have a maximum spindle
provide a greater strength and wear resistance in speed of 6000 rpm, maximum turning diameter
comparison to low carbon steels. Optimization is 150 mm and a maximum power of 10 hp. The
the process of finding the conditions that gives cut material was the EN 8 steel in the form of
the maximum and minimum value of the round bars with 50 mm diameter and 40 mm
objective functions. This study investigated the cutting length. EN8 steel Chemical composition
optimization of CNC turning operation in weight % 0.36%C, 0.02%Mo, 0.20%Ni,
parameter for AISI 1040 steel using the Particle 0.27%Si, 0.22%Cu, 0.020%P0.66%Mn,
swam Optimizations method. The controllable 0.06%Al, 0.21%Cr, 0.016%S, 0.06%.The
input parameters were the speed (rpm), feed cutting tool used was as Titanium Coated
(mm/rev), and depth of cut (mm). Nine Tungsten Carbide Tool. The physical and
experimental runs based on Particle swam mechanical properties of Titanium Coated
Optimization method were performed. The Tungsten Carbide Tool mixed are 2473K
property of surface finish is selected as the melting point, 3.98g/cm3 in density, 21W/mK
quality targets or the response variables. An thermal conductivity, 0.01Ωm electrical
optimal parameter combination of the turning resistance, 882mPa bending strength, and
operation was obtained via Particle swam 3000HV hardness. Titanium Coated Tungsten
Optimizations method. By analyzing the matrix, Carbide Tool (VBMT 16 04 08) tool type, was
the degree of influence for each controllable clamped onto a tool holder specially
process factor onto the individual quality targets manufactured for holding the cutting tool
can be found. The optimal parameter geometry. The geometry of the insert is as
combination is then tested for accuracy of follows: 5◦ relief angle, 9.525 mm inscribed
conclusion with a test run using the same circle and 0.8 mm inch nose radius. The
parameters. experimental set up was shown in the Fig 1. In
this study, surface roughness was considered as
II. Experimental Procedure
the criterion and would affect the results of
cutting process.
The purpose of this study is to establish
a relationship between the machining parameters
 Fig 1 Experimental set up

Besides, the measurements of the surface 30mm. The average surface roughness (Ra) was
roughness for being machined surface were used to evaluate the surface roughness of
performed by using a Surfcom 130 A with a cut- machined surface.
off length of 40 mm and sampling length of

Table: 1- Factor- Level table

Control factors Level 1 Level 2 Level 3
Speed (rpm) 950 1450 1950
Feed rate (mm/rev) 0.08 0.19 0.30
Depth of cut (mm) 0.8 1.0 1.2
 Table-2: orthogonal array L9 (34) for conducting experiment
S. No Speed Feed Depth of cut Surface roughness (µm)
(rpm) (mm/rev) (mm)
1 950 0.08 0.8 1.932
2 950 0.19 1.0 2.062
3 950 0.3 1.2 4.693
4 1450 0.08 1.0 0.839
5 1450 0.19 1.2 3.441
6 1450 0.3 0.8 7.015
7 1950 0.08 1.2 1.365
8 1950 0.19 0.8 8.847
9 1950 0.3 1.0 3.029

The table 1 and 2 shows the factor level
table and L9 orthogonal table used for this
experiment. In this study, L9 Taguchi standard
orthogonal array is adopted as the experimental
design. The most suitable array is L9, which
needs 9 runs and has 8 degrees of freedoms
(DOF). 2 and 3 stand for the values of the
factors. The experimental parameters used and
the corresponding responses are given in Table2.
The first column of the table is assigned to the
speed (n), the second to the feed (f), and the
third to the negative back rake angle (dc). The
roughness measurement results are given in the
right and column.
The machining parameters have been
selected based on the data book available for the
cutting insert. In this experiment, Titanium
Coated Tungsten Carbide make sandvik cutting
insert has been used and the recommended
cutting condition is taken for experiment as a
minimum and maximum value of cutting speed.
The machining operation done with help of CNC
turning machine and necessary data for surface
has been measure online with the help of
perthometer as per the ASTM standard (D99).
The values Ra have been measured for every 6
mm of the machined surface. For each
machining the Ra values have been measured at
4 places at average value is shown in the table 2
right column.
III. Result and Discussion
Based on the outcome of the
experimentation result it is decided to use
particle swarm optimization technique to find
optimal parameter for EN 8 material. For this
purpose mat lab code has been developed and it
is used to find the optimal parameter. The output
of the program result that the optimum
parameters are The optimum cutting parameters
obtained in Table III are found to be speed of been utilized for conducing the confirmation
1950 rpm, feed rate of 0.3 mm/rev. and depth of experiment. The outcome of the confirmation
cut 0.80 mm. The fig 2 shows the output of the shows that result obtained for this parameter
PSO contains 7.8% error. Thus the developed model
will very closer to the expected value.
Program and its iterations. The
optimized values derived from the mat lab have

if we take many numbers experimentation PSO

will provide better solution than limited of
IV. Conclusion
experiment.
From the experimentation and
optimization it is evident that the increase in
speed will increase the surface roughness where
as decrease in feed rate and depth of cut will
decrease the surface roughness. It is evident that