APPLICATIONS OF TAGUCHI AND DESIGN OF EXPERIMENTS METHODS IN OPTIMIZATION OF SURFACE ROUGHNESS AND MATERIAL REMOVAL RATE IN DRY TURNING OF CARBON STEEL AISI 1045

Abstract: Now a day’s achieving a low surface roughness to obtain better surface finish and higher of material removal rate for better productivity are the main challenge in the metal cutting industry in dry turning processes. This paper presents an experimental investigation focused on identifying the effects of cutting conditions on the surface roughness and material removal rate in dry turning of AISI1045 carbon steel bars at 58 HRC. Machining experiments were carried out at the lathe using reinforced ceramic cutting tool (CC670). Three levels for depth of cut, feed rate and cutting speed) were chosen as cutting variables. The Taguchi method L9 (34) orthogonal array was applied to design of experiment. By the help of signal-to-noise ratio (S/N ratio) and analysis of variance. Optimum levels of the cutting conditions were determined using the signal-to-noise ratio, which was calculated for machining output variables surface roughness and material removal rate according to the smaller-the-better (SB) and larger-the-better (LB) approaches, respectively. The best optimal cutting condition for surface roughness (Ra) is D3E1F1 and material removal rate (MRR) is D3E3F3. It was concluded that the depth of cut and the feed rate are the most significant factors on surface roughness and material removal rate, with contributions of (71.30% and 63.49%) respectively. In the regression model, the values of R2 for material removal rate and 0.98 for surface roughness indicate that 100% and 98.4% of the total variations are explained by the models, respectively. It indicates that the developed models can be effectively used to predict the surface roughness and material removal rate with 95% confidence intervals.Finally, confirmation experiments were conducted to verify the effectiveness and efficiency of the Taguchi method in optimizing the cutting parameters for surface roughness and material removal rate.