Journal of the Chinese Institute of Engineers

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Application of integrated Taguchi and TOPSIS

method for optimization of process parameters
for dimensional accuracy in turning of EN25 steel

Singaravel Balasubramaniyan & Thangiah Selvaraj

To cite this article: Singaravel Balasubramaniyan & Thangiah Selvaraj (2017): Application
of integrated Taguchi and TOPSIS method for optimization of process parameters for
dimensional accuracy in turning of EN25 steel, Journal of the Chinese Institute of Engineers, DOI:
10.1080/02533839.2017.1308233

To link to this article: http://dx.doi.org/10.1080/02533839.2017.1308233

Published online: 13 Apr 2017.

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Journal of the Chinese Institute of Engineers, 2017
http://dx.doi.org/10.1080/02533839.2017.1308233

Application of integrated Taguchi and TOPSIS method for optimization of process

parameters for dimensional accuracy in turning of EN25 steel
Singaravel Balasubramaniyana and Thangiah Selvarajb
a
Mechanical Engineering Department, Vignan Institute of Technology and Science, Hyderabad, India; bProduction Engineering Department, National
Institute of Technology, Tiruchirappalli, India

ABSTRACT ARTICLE HISTORY

The turning process is one of the fundamental machining operations wherein optimization of parameters Received 20 August 2015
leads to better machining performance. This study has applied integrated Taguchi and Technique for Order Accepted 14 March 2017
Preference by Similarity to Ideal Solution (TOPSIS) methods to determine the optimum process parameters
KEYWORDS
in turning operation of EN25 steel using coated carbide tools. The process parameters considered Turning; EN25steel; process
are cutting speed, feed rate, and depth of cut. The objective is to minimize circularity and cylindricity parameters; integrated
simultaneously. An orthogonal array, Signal to Noise (S/N) ratio, and TOPSIS are employed to analyze the Taguchi; TOPSIS
effects of input parameters on the output parameters. In this study, a decision matrix is formed using S/N
ratios; then the TOPSIS method is used to transmogrify a multi-criteria optimization problem into a single-
criterion problem. The result revealed that the proposed method is appropriate for solving multi-criteria
optimization of process parameters. Results also showed that cutting speed of 215 m/min, feed rate of
0.07 mm/rev, and depth of cut of 1.5 mm are the optimum combination of process parameters.

1. Introduction a tolerance zone bounded by two concentric cylinders within

Turning is a primary and important machining process for metal
cutting in engineering industries to obtain the desired shape
and size. The achievement of high performance and selection of
appropriate process parameters are significant tasks in turning
operations. Generally, the process parameters are selected using
handbook data and prior experience. But in some situations
this does not give accurate results. The proper optimization of
machining parameters leads to higher productivity and better
output values in terms of low cutting force, high surface finish,
long tool life, and power consumption (Liu, Guo, and Chen 2016;
Yang and Chiang (2014)).
The economic benefit of using turning operations is providing
components with appropriate dimensional accuracy. There are
various parameters involved in the estimation of dimensional
accuracy. Some of the dimensional accuracy parameters are
circularity and cylindricity. These dimensional accuracy param-
eters directly influence the assembly accuracy of the turned
component.
Circularity is the difference between the maximum and mini-
mum radius. Inaccuracy in circularity leads to unacceptable vibra-
tion and heat. Circularity measurement of the circular work piece
is the fundamental product feature in assembly, where the posi-
tion handling and mating are employed. In quality control and
inspection roundness measurement is a critical parameter, which
leads to determination of cutting force and chattering. This is also
an advanced tolerance analysis, which greatly affects assembly
accuracy (Cho and Tu 2001). A cylindricity tolerance specifies
which the surface must lie. In the case of cylindricity, unlike that
of circularity, the tolerance applies simultaneously to both circular
and longitudinal elements of the entire surface. The cylindricity
tolerance is a composite control of form that includes circularity,
straightness, and taper of a cylindrical feature (Mustafa and Ali
2011).
When good mechanical strength and corrosion resistance
are required, high tensile steel is preferred over carbon steel.
These steels include EN19, EN24, EN25, and EN26. High tensile
steels are generally preferred for heavy duty drive shafts, con-
necting rods, pumps, and gear shafts. Babu, Buvanashekaran,
and Balasubramanian (2012) investigated process parameters
optimization of the laser hardening process of EN25 steel. Babu,
Buvanashekaran, and Balasubramanian (2013) investigated
sub-surface microstructure analysis of EN25 steel.
The Taguchi method uses statistical and engineering concepts
to improve the quality of products by optimizing the design
parameters. Selection of orthogonal array, determination of S/N
ratio, and Analysis of variance (ANOVA) are the main steps in the
Taguchi technique (Peng et al. 2015). This method is most suita-
ble for single-response optimization. Generally, most industrial
processes involve multi-response problems. Hence the Taguchi
method is combined with the Multi-Criteria Decision Making
(MCDM) concept to convert a single-criterion optimization
problem into a multi-criteria optimization problem. MCDM meth-
ods can be used to select the optimum machining conditions.
Technique for Order Preference by Similarity to Ideal Solution

CONTACT  Singaravel Balasubramaniyan  vel_singara@yahoo.co.in

© 2017 The Chinese Institute of Engineers
2   S. BALASUBRAMANIYAN AND T. SELVARAJ
(TOPSIS) is an MCDM method used to obtain optimum solutions
from a given number of alternatives for solving multiple criteria
problems. The basic concept of this method is that the optimum
solution has the shortest distance from positive ideal solution
and farthest from the negative solution. The advantage of this
method is that tangible and intangible factors are determined
in a systematic way and generate the best solution for multiple
criteria problems (Azadeh, kar, and Hatefi 2011; Adalarasan and
Shanmuga Sundaram 2016).
2.  Literature review
The literature review has been carried out from two perspec-
tives, specifically turning process parameters optimization for
dimensional accuracy and process parameters optimization
using TOPSIS.
2.1.  Review based on process parameter optimization for
dimensional accuracy
Tzeng et al. (2009) investigated turning parameters’ effect on
roughness and roundness value using Grey Relational Analysis
(GRA) in turning of SKD11 steel. Based on Grey relational grade,
cutting speed was the influencing factor for roundness value.
Cho and Tu (2001) developed a mathematical model for round-
ness measurement of machined components. This proposed
model provided the advanced tolerance analysis of circular
and cylindrical parts. This parameter greatly affects the assem-
bly accuracy. Dhar et al. (2006) analyzed the effect of coolant
on chip temperature and dimensional accuracy in turning of
medium carbon steel. The result revealed that dimensional
accuracy improved by application of coolant. Marcos-Bárcena et
al. (2005) analyzed roundness measurement in turning of alumi-
num–copper alloys. The roundness value decreased when the
feed rate was decreased. Feed rate was the important param-
eter to find the deviation of roundness value. Mustafa and Ali
(2011) optimized cutting parameters and work piece length in
turning of Al2017 aluminum material for geometric tolerance
and surface quality. The Taguchi method was used to optimize
the effect of cutting parameter on response. Regression analysis
was used develop a model to make relationship between input
and output parameters. Feed rate was the significant factor for
cylindricity. Kilic, Aguirre-Cruz, and Raman (2007) developed a
mathematical model for cylindricity measurement in turning
operations. The result revealed good correlation between devel-
oped and theoretically derived models.
2.2.  Review based on process parameters optimization
using TOPSIS method
In manufacturing, simultaneous assessment of multi responses
is an important issue. The TOPSIS method is a multi-objective
optimization method, which is simple and an appropriate pro-
cedure to solve multi-response problems efficiently. Gadakh
(2012) used TOPSIS for solving multiple criteria problems in
Electric Discharge Machining (EDM). Three examples were con-
sidered for this study to demonstrate the proposed method. This
method is computationally very simple, comprehensive, and can
simultaneously consider any number of quantitative and quali-
tative selection attributes. Senthil, Vinodh, and Singh (2014) con-
ducted parameter optimization using TOPSIS in wire EDM. The
result obtained using the proposed approach has been found
to be acceptable. Gauri, Chakravorty, and Chakraborty (2011)
optimized process parameters in ultrasonic machining using
TOPSIS. The result revealed that optimized machining param-
eters leads to better machining performance. Rao (2006) used
combined TOPSIS and AHP methods for evaluation of machi-
nability in turning operations. Two examples were considered
to show the applicability of the proposed method. The result
mentioned that the combined method was used to optimize
the process parameters simultaneously and was also applicable
to all types of machining parameters’ optimization. Thirumalai
and Senthilkumaar (2013) optimized machining parameters
using NSGA II and TOPSIS methods in turning of Inconel 718.
TOPSIS was used for the selection of better alternatives from
the non-dominated solutions. Dewangan, Gangopadhyay, and
Biswas (2015) investigated surface integrity and dimensional
accuracy during EDM of AISI P20 steel. In their study, EDM pro-
cess parameters were optimized using the TOPSIS method.
The result revealed that selected optimal process parameters
were used to improve the machining performance. Gok (2012)
optimized cutting parameters to minimize surface roughness
using fuzzy TOPSIS and GRA methods. The result showed that
the fuzzy TOPSIS method has good agreement with the GRA
method. Tiwary, Pradhan, and Bhattacharyya (2014) optimized
process parameters in a micro-EDM process for machining of
titanium alloy using the TOPSIS method. This proposed meth-
odology was effective in solving multi-objective problems.
Koyee, Eisseler, and Schmauder (2014) optimized machining
parameters using hybrid Taguchi and MCDM methods to obtain
better surface parameters in face turning of stainless steel. The
results indicated that the proposed method provided necessary
procedures to optimize process parameters simultaneously.
Adalarasan and Sundaram (2015) used integrated Taguchi and
GRA methods to optimize process parameters of friction weld-
ing. The result revealed the effectiveness of the approach. Lan
(2009) optimized surface roughness, tool wear, and MRR simul-
taneously using combined Taguchi and TOPSIS methods. They
emphasized that this proposed method was a novel optimi-
zation technique which contributed a satisfactory solution to
multiple objectives of CNC turning. Singh, Datta, and Mahapatra
(2011) used application of TOPSIS in the Taguchi method for
optimal process parameter selection in turning of GFRP polyes-
ter composites. TOPSIS with Taguchi was capable of solving mul-
tiple objective problems. This method had been used to convert
a multi-objective problem into a single equivalent objective
problem.
Based on the literature review, it has been found that very few
research studies have been reported for the application of inte-
grated Taguchi and TOPSIS methods in turning process parame-
ter optimization. Also, dimensional accuracy related work, solved
using multi-objective optimization, has been reported only in
a few works. Hence an effort has been made to estimate the
optimum process parameters for simultaneous minimization of
circularity and cylindricity in turning of EN25 steel with coated
carbide tools.
 JOURNAL OF THE CHINESE INSTITUTE OF ENGINEERS   3

3.  Experimental procedure the objective of this study is to estimate the process parameters
required to obtain minimum circularity and cylindricity. Hence the
EN25 steel is used as the work material. It possesses more
concept of ‘smaller-the-better’ is considered for output param-
mechanical strength than carbon steel. Table 1 shows the chem-
eters in this study. A general purpose Coordinate Measuring
ical composition of EN25 steel. This material possesses more
Machine (CMM-model EV-002) with accuracy of 4.5  microns is
mechanical strength and corrosion resistance than carbon steel
used for measurement of circularity and cylindricity. The experi-
and it is widely used in heavy duty drive shafts and gear shafts.
mental results are presented in Table 3.
The work piece is a round rod with 38 mm diameter and 120 mm
length. The turning operations were conducted on CNC turning
center with 7.5 KW spindle power in dry environment. 4. Methodology
The cutting tool material used is Chemical Vapor Deposition
The Taguchi method focuses on improving the product qual-
(CVD) multi-layer coating (TiN/TiCN/Al2O3) of fine grained tung-
ity by optimizing design parameters using statistical methods.
sten carbide 6% cobalt substrate with ISO geometry of CNMG
Orthogonal array is a statistical design experimental tool which
120404. In the coated element, TiN provides better heat resistance
reduces the number of tests required, reduces cost, and reduces
and lower coefficient of friction; TiCN provides wear resistance
time of the experiments. The objective function of the Taguchi
and thermal stability and Al2O3 provides crater wear resistance
method is the estimation of S/N ratio. But this method is mainly
due to high-temperature conditions and hardness.
suitable for single-objective optimization problems (Chien, Lin,
A Taguchi orthogonal array is used to study the effect of pro-
and Chen 2011).
cess parameters on performance characteristics with minimum
In the past decade for solving multiple criteria industrial prob-
number of experiments. In this work, mixed level design of L18
lems, MCDM methods have emerged as one of the most powerful
orthogonal array was applied to conduct turning operations with
and effective tools. They are more suitable for solving multiple
different combinations of input parameters. Table 2 shows the
criteria or objectives with different units of measurement. Also
levels of selected machining parameters and their values.
they are used to select the optimum solution from a finite number
Three types of objectives are used in the Taguchi method
of alternatives. TOPSIS is used to define the positive ideal solution
namely smaller-the-better, larger-the-better, and nomi-
and the negative ideal solution. The maximization of benefit cri-
nal-the-better. The dimensional accuracy parameters directly
teria and minimization of negative criteria is acheived by positive
influence the assembly accuracy of the turned component. Hence
ideal solution. The minimization of benefit criteria and maximi-
Table 1. Chemical composition (wt %) of EN25 steel. zation of cost criteria is achieved by negative ideal solution. The
optimum alternative is closest to the positive ideal solution and
Material C Si Mn Ni Cr Mo S P Fe
farthest from negative ideal solution (Azadeh et al. 2011). TOPSIS
EN 25 0.293 0.185 0.629 2.49 0.577 0.51 0.02 0.02 Balance
steel efficiently analyzes tangible attributes and the number of alter-
natives, but in this method there exist a need to estimate the
weight factor of each output parameter. Hence an attempt has
been made to integrate Taguchi and TOPSIS methods to estimate
Table 2. Machining parameters and their levels. the optimum combination of process parameters in turning of
Levels EN25 steel.
The following steps are involved to estimate the optimum
Factors Symbol Level 1 Level 2 Level 3
combination of process parameter and coated tool using inte-
Cutting speed (m/min) v 95 155 215
Feed (mm/rev) f 0.07 0.15 0.23 grated Taguchi and TOPSIS methods in turning of EN25 steel (Lan
Depth of cut (mm) d 0.5 1.0 1.5 2009; Singh, Datta, and Mahapatra 2011).
Step 1. Problem description and establishment of its objectives.
In the present work, non-beneficial attributes,. (i.e.) minimiza-
Table 3. Experimental results. tion objective is selected for circularity and cylindricity.
Cutting speed Feed rate Depth of Circularity Cylindricity Step 2. Determination of S/N ratios.
Sl. No (m/min) (mm/rev) cut (mm) (mm) (mm) In the measurement of objective function, S/N ratio is employed
1 95 0.07 0.5 0.0148 0.0148 to find optimal process parameters in Taguchi method. The ratio
2 95 0.15 1 0.0183 0.0182 between mean value (signal) and standard deviation (noise) gives
3 95 0.23 1.5 0.0215 0.0196
4 155 0.07 0.5 0.0143 0.0136 S/N ratio of the objective function. The optimum combination of
5 155 0.15 1 0.0178 0.0167 process parameters shows the highest level of S/N ratio.
6 155 0.23 1.5 0.0208 0.0184 If the objective function is to maximize, larger-the-better char-
7 215 0.07 1 0.0125 0.0128
8 215 0.15 1.5 0.0166 0.0146 acteristics are considered:
9 215 0.23 0.5 0.0189 0.0174 ( )
10 95 0.07 1.5 0.0151 0.0147 S 1 ∑n 1
11 95 0.15 0.5 0.0192 0.0196 ratio = − 10 × log10
i=1 2
. (1)
12 95 0.23 1 0.0239 0.0232 N n yi
13 155 0.07 1 0.0131 0.0141
14 155 0.15 1.5 0.0144 0.0183 If the objective function is to minimize, smaller-the-better char-
15 155 0.23 0.5 0.0199 0.0219
16 215 0.07 1.5 0.0129 0.0123 acteristics are considered:
17 215 0.15 0.5 0.0137 0.0187 ( ∑n )
S 1
18 215 0.23 1 0.0177 0.0209 ratio = − 10 × log10 yi2 .
N n i=1 (2)
4   S. BALASUBRAMANIYAN AND T. SELVARAJ

where yi = observed value of objective function, n = number of max xi0 (k) represents highest value of xi0 (k); min xi0 (k) is the low-
experiments, μ = mean, and σ = standard deviation. In this study, est value of xi0 (k):
a smaller-the-better characteristic is considered for circularity
and cylindricity. ⎡ 0.2605 0.2915 ⎤
Step 3. Formation of decision matrix. ⎢ 0.5880 0.6174 ⎥
⎢ ⎥
The decision matrix is used to indicate the output val- ⎢ 0.8367 0.7342 ⎥
ues obtained in the experiments. The decision matrix Dmxn is ⎢ ⎥
⎢ 0.2075 0.1583 ⎥
expressed as: ⎢ ⎥
0.5453 0.4819
⎢ ⎥
⎡ X11 X12 … … X1n ⎤ ⎢ 0.7856 0.6347 ⎥
⎢ ⎥ ⎢ 0.0000 0.0627 ⎥
⎢ X21 X22 … … X2n ⎥ ⎢ ⎥
Dmxn =⎢ … … … … … ⎥. (3) ⎢ 0.4376 0.2701 ⎥
⎢ ⎥ ⎢ ⎥
⎢ … … … … … ⎥ =⎢
0.6378 0.5466 ⎥.
⎢ ⎥ N 18×2 (7)
⎣ Xm1 Xm2 … … Xmn ⎦ ⎢ 0.2915 0.2809 ⎥
⎢ ⎥
⎢ 0.6621 0.7342 ⎥
where Xij represents output values of ith alternative on jth attrib- ⎢ ⎥
1.0000 1.0000
ute, m represents the number of alternatives, and n represents ⎢ ⎥
the number of attributes: ⎢ 0.0723 0.2152 ⎥
⎢ 0.2183 0.6261 ⎥
⎢ ⎥
⎡ 36.594 36.594 ⎤ ⎢ 0.7174 0.9091 ⎥
⎢ 34.750 34.798 ⎥ ⎢ ⎥
⎢ ⎥ ⎢ 0.0485 0.0000 ⎥
⎢ 33.351 34.154 ⎥ ⎢ 0.1414 0.6601 ⎥
⎢ ⎥ ⎢ ⎥
⎢ 36.893 37.329 ⎥ ⎣ 0.5366 0.8354 ⎦
⎢ 34.991 35.545 ⎥
⎢ ⎥ Equation (7) shows the normalized decision matrix N18 × 2.
⎢ 33.638 34.703 ⎥ Step 5. Determination of weighted normalized decision matrix.
⎢ 38.061 37.855 ⎥
⎢ ⎥ The product of normalized decision matrix and its relative
⎢ 35.597 36.712 ⎥ weight generates weighted normalized decision matrix:
⎢ 34.470 35.189 ⎥
D18×2 =⎢ ⎥. (4) W ij = Nij × Wj (8)
⎢ 36.420 36.653 ⎥
⎢ ⎥ where Nij represents the normalized decision matrix and Wj
⎢ 34.333 34.154 ⎥
⎢ 32.432 32.690 ⎥ represents the weight factor of each output parameter. In this
⎢ ⎥ study, equal weights are consiered for all objectives:
⎢ 37.654 37.015 ⎥
⎢ 36.832 34.750 ⎥
⎢ ⎥ ⎡ 0.0867 0.0970 ⎤
⎢ 34.022 33.191 ⎥ ⎢ 0.1958 0.2056 ⎥
⎢ ⎥ ⎢ ⎥
⎢ 37.788 38.201 ⎥ ⎢ 0.2786 0.2445 ⎥
⎢ 37.265 34.563 ⎥ ⎢ ⎥
⎢ ⎥ ⎢ 0.0691 0.0527 ⎥
⎣ 35.040 33.597 ⎦ ⎢ 0.1816 0.1604 ⎥
⎢ ⎥
Equation (4) represents the decision matrix D18 × 2. ⎢ 0.2616 0.2113 ⎥
⎢ 0.0000 0.0209 ⎥
Step 4. Normalization of input data. ⎢ ⎥
The calculated S/N ratio of selected objectives is normalized ⎢ 0.1457 0.0899 ⎥
using Equations (5) and (6). ⎢ 0.2124 0.1820 ⎥
W 18×2 =⎢ ⎥. (9)
If the output value is maximization type, then the normaliza- ⎢ 0.0978 0.0935 ⎥
tion equation is: ⎢ ⎥
⎢ 0.2205 0.2445 ⎥
⎢ 0.3333 0.3333 ⎥
xi0 (k) − min xi0 (k) ⎢ ⎥
xi∗ (k) = . (5) ⎢ 0.0240 0.0716 ⎥
max xi0 (k) − min xi0 (k) ⎢ ⎥
⎢ 0.0726 0.2084 ⎥
If the output value is minimization type, then the normalization ⎢ 0.2388 0.3027 ⎥
⎢ ⎥
equation is: ⎢ 0.0161 0.0000 ⎥
⎢ 0.0470 0.2198 ⎥
max xi0 (k) − xi0 (k) ⎢ ⎥
xi∗ (k) = . (6) ⎣ 0.1787 0.2782 ⎦
max xi0 (k) − min xi0 (k)
Equation (9) shows the weighted decision matrix W18 × 2.
where xi∗ (k) represents normalized value of the kth element in Step 6. Determination of positive ideal solution (A+) and neg-
ith sequence, xi0 (k) represents original sequence of S/N ratio, ative ideal solution (A−).
where i = 1,2,3 … , m and k = 1,2, … n with m = 18 and n = 3: A+ and A− are determined using Equations (10) and (11):
 JOURNAL OF THE CHINESE INSTITUTE OF ENGINEERS   5

Table 4. Performance table for the relative closeness.

{( ) ( )}
A+ = max Wij | j ∈ J , min Wij | j ∈ J � (10) Symbol Parameter Level 1 Level 2 Level 3 Optimum level
v Cutting 0.392758 0.535119 0.64688 3
{( ) ( )} speed
A− = min Wij | j ∈ J , max Wij | j ∈ J � (11) f Feed rate 0.836316 0.495434 0.243006 1
d Depth of 0.505435 0.502273 0.567048 3
cut
J = 1,2,3, …, n
where J is associated with the benefit criteria
J′ = 1,2,3, …, n Table 5. ANOVA for relative closeness.
where J′ is associated with cost criteria
Source SS DOF MS F-Calculation Prob > F P
A+Circularity = 0.0000 Cutting 0.19467 2 0.09734 38.61 0.0000 14.95
speed
Feed rate 1.06388 2 0.53194 211.03 0.0000 81.69
Depth of 0.016 2 0.008 3.17 0.816 1.23
A−Circularity = 0.5 cut
Error 0.02773 11 0.00252 2.13
Total 1.30228 17 100

A+Cylindricity = 0.0000
Table 6. Results of confirmation experiments.

A−Cylindricity = 0.5 Output parameters

Setting Relative
Conditions levels Circularity Cylindricity closeness
Step 6. Determination of separation measure.
Initial parameter v3-f1-d1 0.0133 0.0125 0.8732
The separation of positive ideal solution (Si+ ) is determined by: settings
√ � �2 Optimal process parameters
Si+ = Σ Wij − A+j , (12) Experiment v3-f1-d3 0.0129 0.0123 0.9659

j = 1, where i = 1, 2, … , m.

The separation of negative ideal (Si−) solution is determined by: Table 7. Separation measure of positive ideal solution, negative ideal solution, rel-
ative closeness value, and rank.
√ � �2
Si− = Σ Wij − A−j , (13) Sl. No (Si+ ) (Si− ) (Ci) Rank
1 0.1955 0.5120 0.7236 5
j = 1, where i = 1, 2, … , m. 2 0.4263 0.2810 0.3973 12
Step 7. Determination of relative closeness (Ci) to positive ideal 3 0.5566 0.1559 0.2188 16
4 0.1305 0.5780 0.8157 4
solution: 5 0.3638 0.3446 0.4864 10
( ) 6 0.5050 0.2117 0.2954 15
Ci = Si− ∕ Si+ + Si− , (14) 7 0.0313 0.6852 0.9561 2
8 0.2571 0.4606 0.6417 7
The larger the relative closeness Ci value shows closer to opti- 9 0.4200 0.2901 0.4085 11
mum performance of the alternatives. 10 0.2024 0.5047 0.7137 6
Step 8. Rank the alternatives using value of relative closeness. 11 0.4943 0.2149 0.3029 14
12 0.7071 0.0000 0.0000 18
Step 9. Determination of optimum parameters levels. 13 0.1135 0.6075 0.8425 3
Optimum process parameter levels are determined using 14 0.3315 0.4332 0.5664 9
higher level of relative closeness value and the values are 15 0.5790 0.1484 0.2040 17
16 0.0242 0.6901 0.9659 1
v = 215 m/min, f = 0.07 mm/rev, and d = 1.5 mm in the turning of 17 0.3375 0.4616 0.5776 8
EN25 steel. Table 4 shows the Performance table for the relative 18 0.4964 0.24584 0.3311 13
closeness value.
Step 10. Calculation of ANOVA.
ANOVA is employed to analyze the experimental results and simultaneous minimization of circularity and cylindricity. The
find the significant effect of process parameters. The significant enhancement of relative closeness from the initial machining
effects for controlling the responses, contribution of the param- parameters to the optimal combination of machining parame-
eters in terms of their percentage, and error variance in the pro- ters is 0.9351. From the result of verification test, there is a good
cess are determined by ANOVA. Feed rate is the major significant agreement between initial process parameter setting and actual
process parameter. Table 5 demonstrates the results of ANOVA. machining tests for minimization of dimensional accuracy param-
Step11. Validation test. eters using integrated Taguchi and TOPSIS methods.
The validation tests are carried out to confirm the optimal
control factors achieved during the investigation. The validation
5.  Results and discussions
test result shows that the relative closeness value of the optimal
machining parameter combination (v3-f1-d3) is higher than that Table 3 shows the input and output values of turning oper-
of the initial setting parameter conditions (v3-f1-d1). ation using L18 orthogonal matrix. The S/N ratio of each out-
Table 6 presents the results of the validation experiments put parameter of circularity and cylindricity are calculated
using the optimal combination of machining parameters for using Equation (1). Integrated Taguchi and TOPSIS methods
6   S. BALASUBRAMANIYAN AND T. SELVARAJ
Figure 1. Main effects plot for relative closeness.
use relative closeness to analyze the experimental results. The
higher level of relative closeness values is used to find combina-
tion of machining parameters and the calculated relative close-
ness values is shown in Table 7. In this study, non-beneficial or
minimization objective type is considered. In multi-objective
optimization, weight factors are involved for deriving an equiva-
lent single-objective optimization. These weight factors for each
output parameter are assigned equal importance.
As mentioned earlier, the higher level of relative closeness val-
ues are used to determine optimum machining parameter com-
bination for minimizing circularity and cylindricity. Based on the
main effects plot (Figure 1) and performance table (Table 4), the
optimum machining parameters are cutting speed of 215 m/min,
feed of 0.07 mm/rev, and depth of cut of 1.5 mm.
The optimum combination of machining parameter levels
shows that minimum dimensional accuracy error values are
obtained in the combination of higher level of cutting speed,
lower level of feed rate, and depth of cut. Generally, cutting speed
can produce circularity and cylindricity in a number of ways, such
as by elastic deformation of the work piece due to cutting force,
tool wear, thermal distortion, built-up edge (BUE) formation, and
radial spindle error. In many cases, circularity and cylindricity are
produced by cutting force due to the effect of cutting speed,
which is induced by tool-work piece combination. In turning the
deflection of the work piece is reduced due to the reduction of
cutting force at higher level of cutting speed, consequently pro-
ducing minimum value of circularity and cylindricity. Analyzing
only the circularity and cylindricity of the machined work piece
does mean that the work piece meets the specified quality cri-
teria. Factors such as machine tools, work and tool holders, and
oscillation of the work piece can distort the dimensional accu-
racy of the work piece beyond specified tolerances. Therefore, this
study focused on the effect of process parameters on circularity
and cylindricity of the work piece.
Generally, at higher cutting speeds, the correspondingly
higher shear strain rates within the primary shear zone favor
propagation of the adiabatic shear band further along the shear
zone (Barry, Byrne, and Lennon 2001). Shear localization results
in a cyclic variation of forces (both cutting and thrust) with a
significant variation in magnitude (Komanduri and Hou 2002).
The consequent vibration or chatter during the cutting process
limits the rate of material removal and plays an important role
in tool wear. Hence, circularity is generally affected by cutting
forces. Similar results were obtained by Rafai and Islam (2009).
Also optimum value indicates higher level of cutting speed and
lower level of feed rate to reduce the circularity and cylindricity
errors. At higher level of cutting speed, cutting force values are
reduced and also at lower level of feed rate, cutting force are
reduced due to smaller co-efficient of friction, hence minimum
errors are obtained at optimum conditions.
The effects of machining parameters on responses with their
percentage contribution are determined by ANOVA. Feed rate is
the major influencing process parameter. Finally, validation tests
are carried out for verification of improvement of objective param-
eters with the help of optimum level machining parameters.
The coated element presented in a CVD coated tool acts as a
thermal barrier. This barrier is used to reduce the heat between
tool and work piece. The presence of TiN in a CVD coated tool
is used to reduce the friction and interface temperature during
machining. The TiN layer acts as a lubricant and lowers the heat
generation at chip tool interface and reduces the micro hardness
of the surface. The result of micro hardness indicates that a TiN
coated carbide insert is slightly less hard than a ZrCN coated tool.
Also, a TiN coated carbide tool provides good surface roughness
while machining hard material. Generally, a TiN layer provides
smooth surface of insert, which is used for protecting the insert
from built-up edge and improves the surface finish and tool life.
This layer prevents heat isolation from oxide layer on cutting edge
which is used to prevent rapid wear. Compared with ZrCN coated
tool, TiN coated tool provides enhanced rate of material removal
and reduced surface roughness and micro hardness.
It is noticed that when compared with other MCDM methods,
such as Multi-Objective Optimization by Ratio Analysis (MOORA),
VlseKriterijumska Optimizacija I Kompromisno Resenje in Serbian
(VIKOR), GRA, the integrated Taguchi and TOPSIS approach is easy
to understand and execute. This method employs simple ratio
analysis with fewer mathematical computations, which is helpful
to the decision-makers who may not have a strong background in
mathematics. Also, this method involves minimum computational
time due to its smaller number of computational steps. Another
significant benefit of this method is that its computational steps
are not affected by the addition of any parameter (for example
v in VIKOR and ξ in GRA methods) as happens in other multi-ob-
jective optimization techniques. For this purpose, the integrated
 JOURNAL OF THE CHINESE INSTITUTE OF ENGINEERS   7

Taguchi and TOPSIS approach is highly desirable for various deci- Disclosure statement
sion-making problems.
No potential conflict of interest was reported by the authors.

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