Experimental Investigation and Parametric Optimization of EN-8 Steel using Dry Turning for Enhanced Surface Finish

Abstract

In Machining Parts, It Is Most Important To Determine The Optimal Machining Parameters To Achieve The Desired Product Quality. Therefore, It Is Essential To Investigate The Effect Of Cutting Parameters On Surface Roughness In A Machining Operation To Accomplish The Desired Quality Of An Item. The Thesis Focuses On Optimizing The Cutting Parameters Such As Cutting Speed, Feed Rate, And Depth Of Cut On Surface Roughness. The Cutting Parameters Were Optimized By Turning Process Using The Response Surface Methodology Method. The Surface Roughness Is Selected As Response VariablesAnd The Workpiece Is Estimated By Using A Surface Roughness Analyzer (Profilometer). This StudyFocuses On The Development Of Optimization Models To Analyze The Influence Of Machining Parameters On Surface Roughness And To Obtain The Optimal Machining Parameters Leading To Minimum Surface Roughness During The Turning Of En-8 Steel Using Cemented Carbide Cutting Tools.The Outcome Of Data Analysis In The Environment Of The Design-Expert Version 11 And Minitab 19 Software Is Presented And Discussed. The Developed Models Are Compared Using Relative Error AndThe Results Are Validated Using The Experimental Confirmation Tests. The Minimum Surface Roughness At Optimum Tuning Parameters In This Study Was Obtained. The Result Of Variance Indicates That The Contribution Of Cutting Speed, Feed Rate, And Depth Of Cut Was 3.11%, 7.69%, And 76.36%, Respectively. It Has Been Found That The Predictive Model Provides Optimum Machining Parameters. The Results Of The Proposed Model Provide Improvement In Surface Roughness Over The Best Experimental Run. The 3d Surface And Contour Plots Constructed During The Study Can Be Used For Choosing The Optimal Machining Parameters To Obtain Particular Surface Roughness Values. The Optimal Machining Parameters Indicate That The Depth Of Cut Is The Most Significant Machining Parameter Followed By The Cutting Speed And Feed Rate In Surface Roughness. The Confirmation Experiments Were Performed To Facilitate The Verification Of The Obtained Feasible Optimal Machining Parameters (V = 375 M/Min, F = 0.287 Mm/Rev And D = 1 Mm) For The Surface RoughnessAnd The Optimized Surface Roughness Obtained Is (Ra) 5.113 ??M. The Results Reveal That The Developed Predictive Models Provide A Close Relation Between The Predicted Values And The Experimental Surface Roughness Values.