Investigation of the Effect of Cutting Parameters on Surface Roughness in Dry Turning of Hardened Steel Using the Taguchi Method (original) (raw)
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Strojniski Vestnik-journal of Mechanical Engineering, 2010
The surface roughness in the turning of AISI 8660 hardened alloy steels by ceramic based cutting tools was investigated in terms of main cutting parameters such as cutting speed, feed rate, depth of cut in addition to tool’s nose radius, using a statistical approach. Machining tests were carried out with PVD-coated ceramic cutting tools under different conditions. An orthogonal design, signal-to-noise ratio and analysis of variance were employed to find out the effective cutting parameters and nose radius on the surface roughness. The obtained results indicate that the feed rate was found to be the dominant factor among controllable factors on the surface roughness, followed by depth of cut and tool’s nose radius. However, the cutting speed showed an insignificant effect. Furthermore, the interaction of feed rate/depth of cut was found to be significant on the surface finish due to surface hardening of steel. Optimal testing parameters for surface roughness could be calculated. More...
Measurement, 2011
This study focuses on optimizing turning parameters based on the Taguchi method to minimize surface roughness (Ra and Rz). Experiments have been conducted using the L9 orthogonal array in a CNC turning machine. Dry turning tests are carried out on hardened AISI 4140 (51 HRC) with coated carbide cutting tools. Each experiment is repeated three times and each test uses a new cutting insert to ensure accurate readings of the surface roughness. The statistical methods of signal to noise ratio (SNR) and the analysis of variance (ANOVA) are applied to investigate effects of cutting speed, feed rate and depth of cut on surface roughness. Results of this study indicate that the feed rate has the most significant effect on Ra and Rz. In addition, the effects of two factor interactions of the feed rate-cutting speed and depth of cut-cutting speed appear to be important. The developed model can be used in the metal machining industries in order to determine the optimum cutting parameters for minimum surface roughness.
Selection of Appropriate Cutting Parameters to Achive Optimum Surface Roughness with Taguchi
International Journal of Scientific and Technological Research, 2019
In this study, AISI 1040 steel, which has a hardness of 41 HRc which is frequently used in the field of automotive industry, has been turned with a CNC lathe. The test list was made by creating L9 orthogonal array in the cutting speed, cutting depth and feed parameters with Taguchi method. The work pieces are machined on CNC lathes using Ti+Al2O3+TiN coated carbide inserts. The experiments were done with dry conditions without any coolant. According to the results of the experiments, the surface roughness values (Ra) were examined. With this method signal/noise (S/N) ratio is determined and the results of the experiments in the three parameters of the surface roughness of the most significant effect is reached from the results of feed. Finally, Taguchi control experiments were applied. The obtained results show that the Taguchi estimate is about 90% accurate. In the analysis of variance, the confidence level of progress was 95%.
Journal of Production Engineering, 2017
In this research work an attempt has been made to try to investigate the effects of cutting parameters such as feed rate cutting speed and depth of cut on surface roughness in turning operation of 16MnCr5 steel, is a case hardening steel with by the support of Taguchi technique. An orthogonal array, signal to noise (S/N) ratio and analysis of variance (ANOVA) were used to determine the effects and contributions of cutting speed, feed rate and depth of cut on the response variable. Turning operations were carried out by Tungsten carbide coated cutting tool inserts. The experiments were conducted at three different cutting speeds (400, 600 and 800 rpm) with three different feed rates (0.06, 0.12 and 0.18 mm/rev) and a constant depth of cut (0.5, 1.0 and 1.5 mm). The cutting parameters are optimized using signal to noise ratio and the analysis of variance.obtained result data revelled that depth of cut has most significant effect over surface roughness followed by cutting speed while feed rate has lowest effect.
Optimization of turning parameters for surface roughness and tool life based on the Taguchi method
The International Journal of Advanced Manufacturing Technology, 2007
In this study, the effect and optimization of machining parameters on surface roughness and tool life in a turning operation was investigated by using the Taguchi method. The experimental studies were conducted under varying cutting speeds, feed rates, and depths of cut. An orthogonal array, the signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) were employed to the study the performance characteristics in the turning of commercial Ti-6Al-4V alloy using CNMG 120408-883 insert cutting tools. The conclusions revealed that the feed rate and cutting speed were the most influential factors on the surface roughness and tool life, respectively. The surface roughness was chiefly related to the cutting speed, whereas the axial depth of cut had the greatest effect on tool life.
Materials & Design, 2007
Nickel-base superalloy Inconel 718 is a high-strength, thermal-resistant. Because of its excellent mechanical properties, it plays an important part in recent years in aerospace, petroleum and nuclear energy industries. Due to the extreme toughness and work hardening characteristic of the alloy, the problem of machining Inconel 718 is one of ever-increasing magnitude. This investigation optimized the machining characteristics of Inconel 718 bars using tungsten carbide and cermet cutting tools. The approach is based on Taguchi method, the signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) are employed to study the performance characteristics in turning operations. The roundness and flank wear of the ultrasonically and conventionally machined workpieces were measured and compared.
2014
This project is based upon the study which means it is derived from experiment and observation rather than theory. For the fulfilment of objective our first motive is selection of cutting tool & work tool material selection of various process and performance parameters after parameterssss selection aims to study various techniques for the optimization for that purpose literature review and industrial survey is conducted. The objective of this study was to utilize Taguchi methods to optimize surface roughness in turning mild steel, EN-8 and EN-31. The turning parameters evaluated are cutting speed of 200, 250, and 300 m/min, feed rate of 0.08, 0.12 and 0.15 mm/rev, depth of cut of 0.5 mm and tool grades of TN60, TP0500 and TT8020, each at three levels. The experiment was designed and carried out on the basis of standard L9 Taguchi orthogonal array. The results show that the Taguchi method is suitable to solve the stated problem with minimum number of trials as compared with full factorial design.
IJSRD, 2013
In present area of advance technology, the qualitative and quantitative requirement of customer is frequently change so the demand of the hour is increasing. Maintaining the economic production with optimal use of resources is of prime concern for the engineers. Metal machining is one of them. Metal machining with various process parameters is one of them. The experimental and theoretical studies show that process performance can be improved considerably by proper selection of machining parameters. The challenge of modern machining industries is mainly focused on the achievement of high quality, in terms of work piece dimensional accuracy, lower surface roughness, high production rate, less tool wear on the cutting tools, economy of machining in terms of cost saving and increase the performance of the product with reduced environmental impact.This particular phenomenon can affect the efficiency and quality of the process. The performance was assessed in terms of different parameters such as depth of cut, material removal rate, cutting efficiency. Experimental investigations were conducted to study the effect of different cutting speed , feed rate and depth of cut on material removal rate (MRR) and surface roughness in CNC machine. Taguchi's design of experiments and analysis of variance were used to determine the effect of machining parameters on Ra and MRR.
IRJET, 2020
Nowadays, surface finish has become an important indicator of quality and precision in manufacturing processes and it is considered one of the most significant parameter in industry. In this present study, the influence of different machining parameter surface roughness has been analyzed through experiments. For this experiment the material used is stainless steel420. Stainless steel420 is one of the highly used materials in thermodynamic steam trap and manufacturing industries. Most of the metal parts are manufactured by machining resulting in one of the most vital characteristics of all metal parts which is the surface roughness of the machined surfaces. Moreover, DOE techniques have been used to predict the surface quality and to select the optimal turning conditions. In this study an experimental investigation of cutting parameters (spindle speed, feed and depth of cut) in turning operation of stainless steel420 was done and influence of cutting parameters on surface roughness, tool wear, material removal rate was studied. The machining was performed using tool such as tungsten carbide tool (0.4). Taguchi method is used to find optimum result. Orthogonal array, signal to noise ratio and used to study the performance characteristics in turning operation Keywords: SR, TWR, MRR, ANOVA, S/N-RATIO, Turning is an important and widely used manufacturing process in engineering industries. The study of metal removal focuses on the features of tools, input work materials, and machine parameter settings. The technology of metal removal using turning operations has grown substantially over the past decades and several branches of engineering have contributed to this to achieve the various objectives of the process. Selection of optimal machining conditions is a key factor in achieving these objectives. There are large numbers of variables involved in the turning process. These can be categorized as input variables and output variables. Various input variables involved in the turning process are: cutting speed, feed, depth of cut, number of passes, work material and its properties, tool material and tool geometry, cutting fluid properties and characteristics, etc. Similarly, the output variables associated with the turning process are: production cost, production time, tool life, dimensional accuracy, surface roughness, cutting forces, cutting temperature, and power consumption, etc. For optimization purposes, each output variable is taken as a function of a set of input variables. To achieve several conflicting objectives of the process, optimum setting of the input variables is very essential, and should not be decided randomly on a trial basis or by using the skill of the operator. Use of appropriate optimization techniques is needed to obtain the optimum parameter settings for the process. Bhosale et al. [1], discusses on the parameter optimization of CNC lathe machining for surface roughness using the Taguchi method, where surface roughness generated during machining. In the parameter optimization, the parameters are cutting speed, feed, and depth of cut. After selecting parameters turning on CNC lathe is to be done and selected orthogonal array and parameters used for the optimum set of combined controlled parameters for surface roughness. Into this combination of parameters selected for minimum surface roughness value and for the optimum combination of parameters by Taguchi design. Taguchi orthogonal array L9 for three parameters cutting speed, feed rate, and depth of cut with its combination surface roughness measured. Material-Mild Steel Result-cutting speed-1800rpm, feed rate-0.1mm/min, depth of cut-0.4mm, surface roughness-1.27µ. Davis et al. [2], The present experimental study is concerned with the optimization of cutting parameters (depth of cut, feed rate, spindle speed) in wet turning of EN24 steel (0.4% C) with hardness 40+2 HRC. In the present work, turning operations were carried out on EN24 steel by carbide P-30 cutting tool in wet condition and the combination of the optimal levels of the parameters was obtained. The Analysis of Variance (ANOVA) and Signal-to-Noise ratio were used to study the performance characteristics in turning operation. The results of the analysis show that none of the factors was