Optimizing Turning Parameters Using Taguchi Method to Maximize Tool Life and Minimize Wear and Vibration

Turning is an essential machining process utilized across various industrial sectors, including aerospace, automotive, and engineering. Optimizing parameters such as cutting speed, feed rate, and depth of cut is crucial for extending tool life, reducing vibrations, and enhancing machining efficiency. This study examines the effects of these parameters on EN31 high-carbon chromium steel through the Taguchi method and ANOVA. EN31 is chosen for its superior mechanical properties, rendering it suitable for high-wear applications. A total of 27 experiments were performed using an orthogonal array (L27) to evaluate tool wear and vibrations, with S/N ratio calculations employed to identify optimal conditions. Findings indicate that feed rate is the predominant factor influencing tool wear (61.11%), while cutting speed significantly affects vibrations (76.30%). This analysis provides valuable insights for minimizing tool wear and improving machining accuracy in practical manufacturing contexts. Major Findings: Feed rate had the greatest influence on tool wear (61.11%), followed by cutting speed (25.07%) and cut depth (9.61%). Cutting speed had a substantial impact on vibration (76.30%), whereas cut depth and feed rate contributed 15.99% and 5.58%, respectively. The ideal machining settings reduced tool wear and vibration, as shown by S/N ratio and ANOVA studies.