Process monitoring and effects of process parameters on responses in turn-milling operations based on SN ratio and ANOVA

•Experimentation on turn-milling processes on CNC.•Identification of significant frequencies for analysis of AOE.•ANOVA and its mechanism over SN ratios for analysis of process parameters.•Mechanism of vibration diagnosis, roughness and hardness variation briefed.•Failure Mode and Effective Control Analysis adopted for prognostics.

Process monitoring in machining constitutes machine performance and machine condition for performing the desired objective. The optimality and effect of machining parameters on machine performance monitoring in tangential and orthogonal turn-milling processes is been studied. Surface Roughness (Ra) and Surface Hardness (H) has been taken as machine performance responses and Tool Vibrations (VIB) as machine condition monitoring response. Laser Doppler Vibrometer (LDV) is used for online capturing of tool vibrations and is analyzed using VibSoft analyzer for processing Acousto-optic emissions (AOE). Single cut machining on A-axis of CNC Vertical Milling center using HSS end mill cutters is adopted. Process parameters like cutter (tool) speed, feed rate and depth of cut with constant rotation of workpiece on A-axis are chosen while machining Brass material under dry condition. Statistical design of experiments (DOE) based on Taguchi’s Orthogonal Array (OA) is adopted for experimentation and Signal-to-Noise ratio (SN ratio) of the responses is used for finding optimality of process parameters. The influence and contribution of the process parameters on the responses is been studied with help of Analysis of Variance (ANOVA).