L18 Array Design
L18 Array Design
2
Mechanical Engineering Department, National Institute of Technology,
Warangal-506004, A.P.,India, [email protected]
1. INTRODUCTION
In a machining process, turning operation plays an important role
in reducing a particular work piece from the original stock to the
desired shape and size. In order to achieve economic objective of
*Corresponding Author: [email protected]
Journal of Metallurgical Engineering, 1(1-2) January-December 2011
17
The effects of shape of cutting edge, work piece hardness, feed rate
and cutting speed on surface roughness and resultant forces were
experimentally investigated [5] by using a four-factor two-level
factorial design. An experimental investigation was conducted to
determine the effects of cutting speed, feed, effective rake angle and
nose radius on the surface roughness in the finish hard turning of
the bearing steel based on a 3 4 full factorial deign [6]. An L 9
orthogonal array has been used [7] to determine the optimum levels
for the parameters insert radius, feed rate, and depth of cut on surface
roughness while turning AISI 1030 steel bars.
An abductive network technique was adopted [8] to construct a
prediction model for surface roughness and cutting force and once
the process parameters (cutting speed, feed rate and depth of cut)
are given, the surface roughness and cutting force can be predicted
by this network. Artificial neural network approach has been
proposed [9] for modeling cutting forces. By seeing the literature, it
can be observed that the study of factorial effects and the empirical
model building was performed based on OA or factorial designs,
particularly in case of force modeling. Further, tool related factors
are excluded from most of the studies.
Central composite designs, which are a combination of 2-level
factorials and one-factor-at-a-time experiments, are known to be best
fit for fitting a second-order model [10]. In recent past, researchers
have been using central composite designs for developing surface
roughness models [11-13]. One of the key issues in empirical based
research is selection of experimental designs. It has been observed
that researchers adopted different experimental designs for similar
works. It might be of curiosity to verify the performance of
orthogonal array design and Central composite designs with respect
to cutting force. In this work, an attempt has been made to study
the effectiveness of the two designs for the same work-tool
combination. Further, in the present work, both process parameters,
namely, cutting speed, feed and depth of cut, and tool parameters,
namely, side cutting edge angle, inclination angle and normal rake
Journal of Metallurgical Engineering, 1(1-2) January-December 2011
19
angle are considered for the development of the cutting force model
while turning AISI 1015 steel with HSS tool. Experiments were
conducted based on central composite face centered design and L18
orthogonal array design. Separate models were developed using
the data obtained from each design. Confirmation experiments were
conducted to verify the adequacy of the models.
2. PROCEDURES AND METHODS
2.1 Cutting Force Model
The proposed relationship between the cutting force and machining
independent variables can be represented by the following:
Force = kAm Bn Cp Dq Er Fs
(1)
Where x1, x2, x3, x4, x5, x6 are the independent variables, c0, c1, c2,..
c56 are the constants and y is the response. Equation (3) is useful
when the second order effects of variables and the two way
interactions among the variables are significant. In the present study,
the parameters of equations (2) and (3) have been estimated by the
multiple linear regression using a SPSS software package.
2.2 Materials and Processes
The experiments were carried out on TMX-2030 engine lathe. The
HSS tools (Co- 10%, W-9.3%, Cr-4.0%, Mo-3.6%, C-1.26%) with
required cutting angles were ground on a tool and cutter grinding
machine using the standard procedure [1]. Tool geometry used was
as follows: end cutting edge angle 10, normal side clearance angle
8, and normal end clearance angle 8, were fixed and remaining
side cutting edge angle, inclination angle and normal rake angles
were changed during experimentation.
Table 1
The Chemical Composition of AISI 1015 Steel
Element
Si
Mn
Cr
Ni
Mo
Fe
0.157
0.155
0.598
0.037
0.021
0.012
0.006
0.001 99.0
Table 2
Level of Control Factors
Factor
symbol
Factor
Inclination angle(degrees)
Cutting speed(m/min)
Feed (mm/rev)
Depth of cut(mm)
Level1(-1)
10
20
30
10
20
15
25
40
60
80
0.052
0.104
0.156
0.2
0.4
0.6
21
Table 3
The Experimental Layout: L 18 Orthogonal Array
Exp.No. A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
1
1
0
0
0
+1
+1
+1
1
1
1
0
0
0
+1
+1
+1
Force(kgf)
1
0
+1
1
0
+1
0
+1
1
+1
1
0
0
+1
1
+1
1
0
1
0
+1
0
+1
1
1
0
+1
+1
1
0
+1
1
0
0
+1
1
1
0
+1
1
0
+1
1
0
+1
1
0
+1
1
0
+1
1
0
+1
1
0
+1
+1
1
0
0
+1
1
0
+1
1
+1
1
0
1
0
+1
1
0
+1
+1
1
0
+1
1
0
1
0
+1
0
+1
1
0
+1
1
3.00
8.50
15.50
18.50
2.50
11.00
16.00
7.00
5.00
5.00
15.00
7.00
12.00
9.00
5.00
4.00
12.00
8.00
The material used in the tests for controlled machining was AISI
1015 steel. The chemical composition of the AISI 1015 steel with a
137 HB hardness, is given in Table 1. The steel bar stock was 65 mm
diameter, 300 mm length and these bars were trued, centered and
cleaned by removing a 2 mm depth of cut from the outside surface,
prior to the actual machining tests. The main cutting force was
measured with a multi component digital force indicator (IEICOS
made and model 652). The force signals were amplified by a
3-channel charge amplifier. The range of force measurement is
0-100 kg.
2.3 Experimental Design
Design of experimental techniques was used for execution of the
plan of experiments, for six variables at three levels, whereby the
levels are the values taken by the factors. The factors to be studied
22
and the level of each factor are given in Table 2. The levels of each
factor were selected based on machining data hand book [14].
Experiments were conducted as per central composite face centered
(CCF) design [10] and orthogonal array based designs [15]. This
research assumes that the three-four- and five-factor interactions
are negligible, because high order interactions are normally assumed
highly impossible in practice. For six factors, the CCF design consists
of 45 runs, which includes a 26-1 fractional factorial portion
(32 experiments), 12 axial points and a central point. For six 3-level
factors, the smallest (in terms of number of experiments) orthogonal
array design is L18 (21 37), which consists of eight columns, and
one 2-level factor and seven 3-level factors can be accommodated.
For the present work, the factors side cutting edge angle (A),
inclination angle (B), normal rake angle (C), cutting speed (D), feed
rate (E), and depth of cut (F) were assigned to columns 2, 3, 4, 5, 7
and 8, and columns 1 and 6 were kept empty. The empty columns
provide the necessary degrees of freedom for error estimation. The
experimental layouts along with the response (main cutting force)
obtained are shown in Tables 3 and 4. In the tables, 1 indicates
level 1 of the factor, 0 indicates level 2 of the factor and +1 indicates
level 3 of the factor. Experiments were conducted in random order
to avoid any bias.
Table 4
The Experimental Layout : CCF (6) Design
Exp.No. A
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
1
10
1
B
1
1
1
1
1
1
1
1
+1
+1
C
1
1
1
1
+1
+1
+1
+1
1
1
D
1
1
+1
+1
1
1
+1
+1
1
1
E
1
+1
1
+1
1
+1
1
+1
1
+1
F
1
+1
+1
1
+1
1
1
+1
+1
1
Force(kgf)
3.00
20.00
8.50
7.00
5.00
6.00
1.50
15.00
8.00
7.00
Table Contd
23
Table 4 Contd
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
1
1
1
1
1
1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
+1
1
+1
0
0
0
0
0
0
0
0
0
0
0
0
+1
+1
+1
+1
+1
+1
1
1
1
1
1
1
1
1
+1
+1
+1
+1
+1
+1
+1
+1
0
0
1
+1
0
0
0
0
0
0
0
0
0
0
1
1
+1
+1
+1
+1
1
1
1
1
+1
+1
+1
+1
1
1
1
1
+1
+1
+1
+1
0
0
0
0
1
+1
0
0
0
0
0
0
0
0
+1
+1
1
1
+1
+1
1
1
+1
+1
1
1
+1
+1
1
1
+1
+1
1
1
+1
+1
0
0
0
0
0
0
1
+1
0
0
0
0
0
0
1
+1
1
+1
1
+1
1
+1
1
+1
1
+1
1
+1
1
+1
1
+1
1
+1
1
+1
0
0
0
0
0
0
0
0
1
+1
0
0
0
0
1
+1
1
+1
+1
1
+1
1
1
+1
1
+1
+1
1
1
+1
+1
1
+1
1
1
+1
0
0
0
0
0
0
0
0
0
0
1
+1
0
0
3.00
19.00
3.00
16.00
6.00
5.00
7.00
7.50
2.50
19.00
2.50
16.50
6.00
5.50
2.50
22.00
7.00
6.50
6.00
5.00
2.00
15.50
8.50
8.00
8.00
9.00
9.00
8.00
9.00
8.00
4.50
12.00
4.00
12.00
8.00
8.00
first one concerned the analysis of the effects of factors and of the
Interactions. Models for cutting force in terms of process parameters
and tool parameters were developed in second phase. Finally, the
comparison between the models has been made.
3.1 Analysis of the Factors and Interactions
From L18 orthogonal array design, factor affects at three levels can
be obtained and interaction affects cannot be studied. Since the
experimental design is orthogonal, it is then possible to separate
out the effect of each parameter at different levels. The influence of
each control factor on the response considered i.e. cutting force, has
been performed with level mean analysis. A level mean of a factor
is the average of the response value of experiments in which the
factor is at the particular level. For example, the mean value of the
response for the side cutting edge angle at level 1, 2 and 3 can be
calculated by averaging the response for experiments 1-3 & 10-12,
4-6 & 13-15 and 7-9 & 16-18 respectively. The mean of the response
for each level of the other cutting parameters can be computed in a
similar manner. The control factor with the strongest influence is
determined by the difference between mean values of the factor at
high and low levels.
From the factorial portion of CCF design, both factor and
interaction effects (at two levels) can be obtained. It can be observed
from axial and central portion of CCF design, considering
experiments from 33 to 45, factor effects (at three levels) of each
factor can be obtained when all other factors are at 0 levels. Using
the experimental data, level means have been calculated. The level
means obtained from L18 design, factorial portion of CCF design,
and axial portion of CCF design are given in Table 5 to 7. The
influence of each control factor can be more clearly presented with
response graphs. A response graph shows the change of the response
when the settings of the control factor are changed from one level to
the other. The slope of the line determines the power of influence of
a control factor. Corresponding response plots are presented in Figs.
1 to 3.
Journal of Metallurgical Engineering, 1(1-2) January-December 2011
25
Table 5
Average Response for L 18 Design
Level 1
Level 0
Level +1
A
9.00
9.67
8.67
B
9.75
9.00
8.58
C
10.33
8.33
8.67
D
9.75
9.00
8.58
E
5.08
9.58
12.67
F
5.08
9.25
13.00
Table 6
Average Response for Factorial Portion of CCF Design
Level 1
Level +1
8.31
8.31
8.28
8.34
9.34
7.28
8.56
8.06
4.59
12.03
4.34
12.28
Table 7
Average Response for One Factor at a Time Analysis
Level 1
Level 0
Level +1
8.50
8.00
8.00
8.00
8.00
9.00
9.00
8.00
8.00
9.00
8.00
8.00
4.50
8.00
12.00
4.00
8.00
12.00
26
27
Table 8
Interaction Matrices for the Cutting Force
AXB B1
B2
A1
8.25 8.38
A2
8.31 8.32
AXC C1 C2
A1
9.43 7.19
A2
9.25 7.38
AXD D1 D2
A1
8.50 8.12
A2
8.63 8.00
AXE
A1
A2
E1
4.75
4.43
E2
11.89
12.18
AXF
A1
A2
F1
F2
4.44 12.18
4.25 12.38
BXC C1 C2
B1
9.31 7.25
B2
9.38 7.31
BXD D1 D2
B1
8.43 8.13
B2
8.69 8.00
BXE
B1
B2
E1
4.50
4.69
E2
12.06
12.00
BXF
B1
B2
F1
F2
4.44 12.12
4.25 12.44
CXD D1 D2
C1
9.63 9.06
C2
7.50 7.06
CXE E1 E2
C1
5.19 13.50
C2
4.00 10.56
CXF
C1
C2
F1
4.88
3.81
F2
13.81
10.75
DXE
D1
D2
E1
E2
4.63 12.50
4.56 11.56
DXF F1
F2
D1
4.56 12.56
D2
4.13 12.00
EXF F1
F2
E1
2.50 6.69
E2
6.19 17.87
28
29
Parameter estimate
Intercept
ln(C)
ln(E)
ln(F)
Standard error
0.126
0.027
0.040
0.040
42.901
-5.644
21.632
21.635
5.392
-0.154
0.873
0.875
Sig.
0.000
0.000
0.000
0.000
df
F-value
Sig.
Model
Error
Total
3
14
17
5.864
8.482E-02
5.949
322.609
0.000
1.955
6.059E-02
R-square = 0.986
Parameter Estimate
Constant
C
D
E
F
CxE
Cx F
Dx E
Ex F
Standard Error
8.304
-1.000
-0.265
3.721
3.971
-0.437
-0.500
-0.219
1.875
0.082
0.096
0.096
0.096
0.096
0.099
0.099
0.099
0.099
Sig.
100.953
-10.451
-2.767
38.886
41.498
-4.436
-5.070
-2.218
19.011
0.000
0.000
0.009
0.000
0.000
0.000
0.000
0.033
0.000
df
Model
Error
Total
8
37
45
Sum of Squares
Mean Square
1171.222
11.517
1182.739
146.403
0.311
F-value
Sig.
470.352
.000
R-square=0.990
Table 11
Cutting conditions used in confirmation tests
Test
2
3
4
20
30
20
10
20
10
25
15
5
40
60
40
0.156
0.104
0.156
F
0.6
0.4
0.6
31
by:
The cutting force model developed using CCF design was given
CCF design
Experiment Model
Error (%)
16.5
8.00
21.00
16.54
8.28
20.30
0.24
3.50
3.33
L18 design
Experiment Model
16.50
8.00
21.00
16.95
7.74
21.68
Error (%)
2.73
3.37
3.24
2.
Both L18 and CCF (6) designs have been showing same
prediction accuracy for cutting force. From cutting force
equation, it can be observed the absence of quadratic effects
of factors, and the linear effect of factors has been only
identified. In such cases, the L18 design is sufficient to reveal
the information regarding the process.
3.
4.
5.
33
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34