Experimental Investigation and Parametric Optimization of Double Cutting Tool Turning During Dry Condition for AISI 1050 Steel

Abstract

Optimizing the machining parameters during the machining process is important to achieve a certain desired machined surface quality. Failure of engineering materials starts at the surface. This implies the optimization of cutting parameters to get a high surface finish that reduces mechanical failures caused by wear and corrosion and increases the productivity of mechanical parts could be adapted. In this research, an experimental test was conducted using double tool turning with an auxiliary ceramic inserted cutting tool on AISI 1050 steel material. And also, this paper is intended to study and optimize cutting parameters to achieve a better surface finish, minimum cutting temperature, and optimize material removal rate. Investigation of chip morphology was conducted for each experiment in dry turning operation. Each experiment was repeated two times and each test used a new cutting insert to ensure accurate readings of the surface roughness. Besides, the cutting temperature in both the tooltip was recorded using a contact digital thermometer, and data is observed during each run. Taguchi L16 orthogonal array has been selected for the design of the experiments, signal to-noise, regression analysis for each response, and grey relational analysis-based optimization were used. Analysis of variance (ANOVA) was used to determine the influences of cutting parameters and a mathematical model was done using regression analysis on each response. The results of variance presented influence of cutting speed, feed rate, first depth of cut, and second depth of cut were 5.83 %, 8.92 %,15.41%, and 64.99% respectively on surface roughness. The minimum surface roughness attained for the optimum cutting parameter was 1.12µm. The minimum tooltip temperatures of 41.5 0C and 40.2 0C were measured for both primary and secondary tool turning respectively. The material removal rate is about 112 mm 3 /sec which is too high due to the double tool turning operation used.