EXPERIMENTAL INVESTIGATION AND OPTIMIZATION OF MACHINING PARAMETERS DURING DRY AND WET TURNING OF AISI 1050 STEEL USING DOUBLE CUTTING TOOL

Advisor: Endalkachew Mosisa (Ph. D) ABSTRACT Surface roughness is one of the most important machining requirements that determine product quality. Cutting parameters are the main factors that affects the surface roughness of mechanical parts. One of the methods used to control these parameters was optimizing them in order to minimize surface roughness of mechanical parts. In the present study, an attempt was made to optimize the cutting parameters of AISI 1050 steel material turning during dry and wet condition on conventional lathe machine by double cutting tool mounted on front tool post in one jig that developed for this purpose. Taguchi L9 orthogonal array design of experiments and variance analysis (ANOVA) was delivered by MINITAB 17 was used for data analysis. profilometer and thermocouple was used for measuring surface roughness and tooltip temperature. Material removal rate and surface roughness was analyzed for both conditions, but tooltip temperature and tool wear were analyzed for dry turning condition. The result obtained shows for dry turning, cutting speed (160m/min), feed (0.2mm/rev), depth of cut-1 (0.33), and depth of cut-2(0.50mm) and for wet turning cutting speed (160m/min), feed (0.1mm/rev), depth of cut-1(0.66mm) and depth of cut-2 (0.50mm) were the optimum parameters to achieve high surface finish. Cutting speed was the most significant parameter for surface roughness followed by feed rate for both dry and wet cutting conditions. The highest surface finish attained for optimum cutting parameter was 1.05µm and 0.84µm for dry and wet turning respectively. The results obtained maximum material removal rate of 806.185mm3/min. The less tool wear was obtained at cutting speed of 160 m/min, feed 0.2mm/rev, depth of cut-1 0.33mm and depth of cut-2 of 0.75mm for both tools. Keywords: Cutting speed, Feed rate, Depth of cut, ANOVA, Taguchi method, Surface roughness.