Studies on material removal rate of al6061 while turning with coolant and without coolant using taguchi method

IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163| pISSN: 2321-7308
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Volume: 04 Issue: 09 | September-2015, Available @ http://www.ijret.org 75
STUDIES ON MATERIAL REMOVAL RATE OF AL6061 WHILE
TURNING WITH COOLANT AND WITHOUT COOLANT USING
TAGUCHI METHOD
Deepak D1
, Rajendra B2
1Author
Assistant Professor, Department of Mechanical and Manufacturing Engineering, Manipal Institute of
Technology, Manipal University, Manipal -576104, India,. nie.deepak@gmail.com
2Corresponding Author
Professor, Department of Mechanical and Manufacturing Engineering, Manipal Institute of
Technology, Manipal University, Manipal -576104, India., rajbeedu@yahoo.co.in
Abstract:
Material Removal Rate (MRR) is one of the key attribute of machining process which influences productivity. In this work the
effect of various turning process parameters on MRR produced on Al6061 (as cast condition) is investigated. Also, the effect of
using coolant on MRR while turning is also determined. MRR is found to increase almost linearly with increase in feed rate.
Increase in depth of cut and cutting speed is found to increase the MRR by 70.66 % and 16.36 % respectively.
Keywords: Al6061, Material Removal Rate, Turning Process, Spindle Speed, Depth of Cut, ANOVA, Taguchi Method
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1. INTRODUCTION
ALUMINIUM alloys are popularly used in most of the
modern day applications due to its lightweight and other
attractive mechanical and thermal properties. Machinability
of this material possesses relative easiness compared to
other metals. Machinability quantifies the machining
performance, and may be defined by various criteria, such as
tool life, surface finish, chip evacuation, material removal
rate and machine-tool power consumption (Songmene et. al,
2011), etc. Pure aluminium possess relatively low
mechanical properties, which are improved by alloying the
metal with other metals such as copper, manganese, silicon,
magnesium, zinc, etc. Aluminium with magnesium and
silicon as alloys are commercial designated as Al 6xxx
series alloys. Among aluminium alloys Al 6061 exhibits
excellent mechanical properties, corrosion resistance
(Xuewu Lia,2015) and weldability (Omega Research, 2002)
which finds the applications in aircraft, missiles and space,
ground and marine transportation, machine parts and
architectural applications. Toh et. al. (2004) studied the
surface integrity effects on turned 6061 and 6061-T6
aluminium alloys. Investigations on machining of 6061
aluminium alloy with Minimum Quantity of Lubricant
(MQL), dry and flooded lubricant conditions were made by
Sreejith (2008). Machining effects were analyzed with
respect to the cutting forces, surface roughness of the
machined work-piece and tool wear. It was found that MQL
condition is good alternative to flooded coolant conditions.
Authors concluded that properly employed MQL can
replace the flooded coolant environment which is presently
employed in most of the cutting/machining applications,
thereby machining will be environmental friendly and
improve the machinability characteristics. Mukesh Kumar
et. al. (2009) studied the effect of coated carbide tool on
6061-t4 aluminium. The effects of cutting parameters such
as speed, depth of cut and cutting feed rate on the surface
roughness was investigated by the authors and regression
model was developed. Halil Demir et al (2009) studied the
effect of artificial aging on the machinability of 6061 Al-
alloy as-received, solution heat treated and then aged
conditions. It was found that at different aging times (at
1800
C) and the cutting speed significantly affected the
surface roughness of the machined surface. But, cutting
forces were not significantly influenced by aging and cutting
speed except for solution heat treated work pieces having
the lowest hardness. Optimization of cutting parameters was
carried by Carmita (2013) to minimize the energy
consumption in turning of AISI 6061 T6. Machine tools
shows their impact on environment due to energy
consumption. Higher feed rate was found to minimize
energy consumption but it led to higher surface roughness.
Influence of cutting parameters on cutting force and surface
finish was investigated by Rao et. al. (2013). Feed rate was
found to have significant influence on cutting force as well
as surface roughness. Depth of cut was found to have
significant influence on cutting force, but has an
insignificant influence on surface roughness. Authors have
also developed the optimum combination of feed rate and
depth of cut to reduce power consumption as well as to
achieve the better surface finish. Vinod et. al. (2014) studied
the effects of tool overhang on selection of machining
parameters and surface finish. Authors found that too large
and very small tool overhangs results in poor surface finish.
Further, optimum range of tool overhang with minimum tool
vibrations was established. Recently, Richárd Horváth et. al.
(2015) studied the effect of turning the aluminum with tools
having different cutting edge materials and tool edges
shapes on the surface roughness. Raykar et al (2015)
investigated the effect of high speed turning of Al 7075

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which is a high strength aluminium alloy. The performance
of coated and uncoated carbide cutting tool was also
investigated at high cutting speeds. Suitable cutting
parameters with appropriate cutting tool for high speed
turning of Al 7075 have been suggested by the authors.
Jayaraman et. al. (2014) carried out optimization of
machining parameters on turning of AA 6063 T6 aluminium
alloy. In most of these works, multi-response optimization is
carried out by the authors using Grey Relational Analysis
(GRA) to the optimize the process parameters for the
responses such as surface roughness, power consumption,
material removal rate and cutting time which are found to be
the most important parameters in turning.
2. MATERIALS AND METHODS
2.1 Experimental Setup and Work-piece
Figure 1 shows the experimental set up used in the present
work. Experiments were conducted using CNC turning
center manufactured by ACE machine tools. The cutting
tool used is silicon carbide insert. The coolant used is SAE
40. The work-piece used in the present work is Auminum
6061 in as cast condition having diameter 40 mm and length
150 mm.
Fig. 1 Experimental set up (Deepak et. al, 2015)
2.2 Design of Experiments. The process parameters
considered in the present study are shown in the Table 1.
The levels of these parameters are chosen based on the pilot
study conducted at various settings. Experiments were
designed using Taguchi method to use the experimental
resources optimally.
Table.1. Process Parameter And Their Levels
Factor/Level 1 2 3
Cutting Speed (m/min) A 308 369 429
Feed (mm/rev) B 0.05 0.1 0.15
Depth of Cut (mm) C 1 1.5 2
Experimental design is done with L9 Taguchi orthogonal
array. Experiments were conducted at various levels of the
process parameters as shown in the Table 2. Each trial is
conducted in two types of test conditions. In the first
condition machining is carried out without using coolant
(called dry machining) and in second condition machining is
carried by supplying the coolant while machining. The MRR
of each experimental trial is measured by volume loss
method (cm3
/min). Table 2 also shows the corresponding
MRR values obtained in each experimental condition as
mentioned in the design. The experimental results were
analyzed using analysis of variance (ANOVA) to estimate
the relative effect of each process parameters.
Table.2. Experimental Plan and Results
A B C With coolant Without coolant
MRR1 MRR2 MRR1 MRR2
308 0.05 1 8.41 9.25 7.41 7.41
308 0.1 1.5 22.22 22.22 18.51 18.51
308 0.15 2 44.44 49.99 44.44 38.88
369 0.05 1.5 14.33 15.55 13.33 12.11
369 0.1 2 35.55 35.50 31.10 31.10
369 0.15 1 28.69 32.36 26.69 26.69
429 0.05 2 20.74 20.74 18.14 15.55
429 0.1 1 20.76 20.76 20.72 20.72
429 0.15 1.5 47.62 51.56 46.62 46.62
3. RESULTS AND DISCUSSION
3.1 The Effect of Operating Parameterson MRR
The present work investigates the effect of operating
parameters such as cutting speed, feed rate and depth of cut
on MRR. Figure 2 and Figure 3 shows the main effects plots
of MRR obtained while machining of sample work pieces in
dry mode (machining without using coolant) as well as
machining by using coolant respectively. It is seen from
these figures that the MRR increases with increase in the
cutting speed (spindle speed). Between level 1 and level 2,
the cutting speed increases by 19.80 % and MRR increases
by 3.40 %. Between level 2 and level 3, the cutting speed
increases by 16.26 % resulting in increasing of MRR by
12.67 %. At higher cutting speeds the cutting force increases
which leads to easy shearing of work material. Hence, the
MRR is found to increase with increase in cutting speed.
However, higher cutting speeds promotes rapid tool wear.
Further, it is observed from the main effect plots shown in
Figure 2 and Figure 3 that increase in feed rate leads to
increase in MRR almost linearly. Between level 1 and level
2, the MRR is found to increase by 94.87 % compared 62.17
% between level 2 and level 3. This is due to the fact that at
higher feed rates, thickness of the uncut chip increases
resulting in increase in MRR. In addition, the effect of depth
of cut on MRR is also shown in same figures. It is seen that,
increase in depth of cut increases the MRR by 44.60 %
(level 1 to level 2) and 19.85 % (level 2 to level 3). Volume
of the material removal is more for the increase of depth of

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cut. Increase in depth of cut beyond the limit leads to higher
thrust force which attempts to push the cutting tool radially
outward thereby affects the MRR. The relative effects of
chosen process parameters are determined by ANOVA
shown in Table 3 and Table 4.
Fig. 2. Effect of operating parameters on MRR in while
machining without using coolant
Fig. 2. Effect of operating parameters MRR when
machining with coolant
Table.3. Anova For Machining Without Coolant
Source DF SS MS % C
A 2 30.44 15.22 1.93
B 2 1155.41 577.71 73.38
C 2 318.87 159.44 20.25
Error 2 69.91 34.96
Total 8 1574.63
Table.4. Anova For Machining With Coolant
Source DF SS MS % C
A 2 52.37 26.18 3.82
B 2 1020.95 510.47 74.45
C 2 208.73 104.36 15.22
Error 2 89.33 44.66
Total 8 3.0292
Based on the Means Square (MS) values of MRR obtained
due to variations in different process parameters, the
percentage contribution (% C) of each process parameter is
determined. (MS = Sum of Square (SS) / Degree of freedom
(DF)). From the ANOVA tables it can be inferred that feed
rate is most influential process parameters affecting the
MRR followed by depth of cut and cutting speed
respectively.
3.2 Comparative Analysis Of MRR Generated
While Machining Without Coolant And With
Coolant Supply
The mean MRR obtained at different levels of the each
process parameters in dry machining i.e., machining without
supply of coolant as well as machining with coolant is
calculated and is shown in Table 5. From Table 5, it is seen
that higher MRR occurs at cutting speed 308 m/min (level
3), feed rate 0.15 mm/rev (level 1) and depth of cut 2 mm
(level 3). Hence this settings for the process parameters
(A3B3C3) can be considered as optimum settings for turning
parameters to obtain the maximum material removal rate.
Confirmation experiments were conducted in the above
settings and results of these experiments were within the
confidence interval established. It also is observed from the
Table 5 that components that were machined with supply of
coolant exhibited higher MRR. This is due to lesser thermal
stress developed in both work-piece and the cutting tool.
The percentage increase in MRR at each level of different
process parameters is shown in Table 6.
Table.5. Average MRR At Deferent Levels of Process
Parameters
Table.6. Percentage Improvement In MRR
Level A B C
1 15.80 % 20.45 % 9.47 %
2 14.89 % 11.65 % 11.45 %
3 8.20 % 10.75 % 15.47 %
4. CONCLUSION
Following conclusions are drawn from the present
experimental work.
 It is observed that the feed rate is most influential process
parameters that influence MRR while turning of
Aluminum 6061 followed by depth of cut and cutting
speed.
 MRR is found to increase almost linearly (185 %) with
increase in feed rate. Increase in depth of cut and cutting
speed is found to increase the MRR by 70.66 % and 16.36
% respectively.
 Machining of the work piece by the supply of coolant is
With coolant Without Coolant
Level A B C A B C
1 26.09 14.84 20.01 22.53 12.32 18.27
2 27.00 26.17 28.92 23.50 23.44 25.95
3 30.36 42.44 34.49 28.06 38.32 29.87
04.27 27.61 14.46 5.54 26.00 11.59

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found to produce higher material rate compared to
machining without using coolant.
REFERENCES
[1]. Carmita Camposeco-Negrete, 2013, Optimization of
cutting parameters for minimizing energy consumption
in turning of AISI 6061 T6 using Taguchi
methodology and ANOVA, Journal of Cleaner
Production, Volume 53, 15 pp. 195–203
[2]. Deepak D, Rajendra B, 2015, Investigations on the
surface roughness produced in turning of Al6061 (As-
Cast) by Taguchi method” in International Journal of
Research in Engineering and Technology, Volume: 04
Issue: 08
[3]. Horváth, R., & Drégelyi-Kiss, Á, 2015, Analysis of
surface roughness of aluminium alloys fine turned:
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performance optimization, Measurement, vol-65,
pp.181–192
[4]. Halil Demir, Süleyman Gündüz, 2009, The effects of
aging on machinability of 6061 aluminium alloy,
Materials and Design vol 30, 1480–1483
[5]. Jayaraman, P., Kumar, L. M., 2014, Multi-response
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