Volume 2 Issue 4 pp. 819-830 Fall, 2011


Surface roughness model and parametric optimization in finish turning using coated carbide insert: Response surface methodology and Taguchi approach


Ashok kumar Sahoo and Bidyadhar Sahoo
This paper presents the experimental study, development of mathematical model and parametric optimization for surface roughness in turning D2 steel using TiN coated carbide insert using Taguchi parameter design and response surface methodology. The experimental plan and analysis was based on the Taguchi L27 orthogonal array taking cutting speed (v), feed (f) and depth of cut (d) as important cutting parameters. The influence of the machining parameters on the surface finish has also been investigated and the optimum cutting condition for minimizing the surface roughness is evaluated. The optimal parametric combination for TiN coated cutting insert is found to be v3-f1-d3. The ANOVA result shows that feed the most significant process parameter on surface roughness followed by depth of cut. The cutting speed is found to be insignificant from the study. The RSM model shows good accuracy between predicted values and experimental values with 95% confidence intervals and adequate. It is concluded that the developed RSM model can be effectively utilized to predict the surface roughness in turning D2 steel.


DOI: 10.5267/j.ijiec.2010.06.001

Keywords: Taguchi, Surface roughness, Response surface method optimization, Coated carbide
References

Abdullah, A. (1996). Machining of aluminium based metal matrix composite (MMC), Ph.D Thesis, University of Warwick, Warwick, UK.

Aggarwal, A., Singh, H., Kumar, P., & Singh, M. (2008). Optimizing power consumption for CNC turned parts using response surface methodology and Taguchi’s technique—A comparative analysis. Journal of materials processing technology, 200, 373–384.

Choudhury, I.A., & El-Baradie, M.A. (1997). Surface roughness prediction in the turning of high-strength steel by factorial design of experiments. Journal of Materials Processing Technology, 67, 55-61.

Coldwell, H., Woods, R., Paul, M., Koshy, Ph. Dewes, R., & and Aspinwall, D. (2003). Rapid machining of hardened AISI H13 and D2 moulds, dies and press tools. Journal of Materials Processing Technology, 135, 301–311.

Davim, J.P. (2001). A note on the determination of optimal cutting conditions for surface finish obtained in turning using design of experiment. Journal of Materials Processing Technology, 116, 305-308.

Fisher, A. (1925). Statistical Methods for Research Worker, Oliver & Boyd, London.

Imbeni, V., Martini, C., Lanzoni, E., Poli, G. and Hutchings, I.M. (2001). Tribological behaviour of multi-layered PVD nitride coatings. Wear, 251, 997-1002.

Isakov, E. (2009). Cutting data for turning steel. Industrial press, New York, USA, 104.

Isik, Y. (2007). Investigating the machinability of tool steels in turning operations. Materials and Design, 28, 1417–1424.

Klocke, F., & Krieg, T. (1999). Coated tools for metal cutting-features and applications. Annals of CIRP, 48(2), 1-11.

Lin, V.S., Lee, B.Y., & Wu, C.L. (2001). Modeling the surface roughness and cutting force for turning. Journal of Materials Processing Technology, 108, 286-293.

Montgomery D.C. (1991). Design and analysis of experiments, John Wiley and Sons, NewYork.

Nalbant, M., Gokkaya, H., & Sur, G. (2007). Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning. Materials and Design, 28, 1379-1385.

Nian, C.Y., Yang, W.H., & Tarng, Y.S. (1999). Optimization of turning operations with multiple performance characteristics. Journal of Materials Processing Technology, 95, 90-96.

Noordin, M. Y., Tang, Y. C., & Kurniawan, D. (2007). The use of TiALN coated carbide tool when finish machining hardened stainless steel. International Journal of Precision Technology, 1(1), 21-29.

Phadke, M.S. (1989). Quality engineering using robust design, Englewood Cliffs, NJ:Prentice-Hall.

Ross, P.J. (1996). Taguchi Techniques for Quality Engineering, McGraw-Hill, New York.

Sahin, Y., & Motorcu, R. A. (2005). Surface roughness model for machining mild steel with coated carbide tool. Materials and Design, 26, 321–326.

Singh, H., & Kumar, P. (2007). Mathematical models of tool life &surface roughness for turning operation through response surface methodology. Journal of scientific & industrial research, 66, 220-226.

Stappen, V.M., Stals, L.M., Kerkhofs, M. and Quaeyhaegens, C. (1995). State of the art for the industrial use of ceramic PVD coatings. Surface and Coatings Technology, 74/75, 629-633.

Thomas, M., Beauchamp, Y., Youssef, Y.A., Masounave, J. (1997). An experimental design for surface roughness and built-up-edge formation in lathe dry turning. International Journal of Quality Science, 2 (3), 167-180.

Wallbank, J. (1991). Development in tool materials, advanced machining for quality and productivity, Proceedings of the second international conference on behaviour of materials in Machining. York, UK, Nov 14-15.

Yang, W.H. and Tarng, Y.S. (1998). Design optimization of cutting parameters for turning operations based on Taguchi method. Journal of Materials Processing Technology, 84, 112-129.

YİĞİT, R. FINDIK, F., & ÇELİK, E. (2009). Performance of multilayer coated carbide tools when turning cast iron. Turkish Journal of Engineering Environment Sciences, 33, 147-157.