Experimental Investigation of Turning AISI 1045 Steel for Surface Roughness in Double Cutting Tool Using Taguchi Method

Abstract

The surface finish quality in turning is an important requirement to produce mechanical parts. Failure of engineering materials starts at the surface. Optimizing cutting parameters is very important to get high surface finish that reduce mechanical failures caused by wear, corrosion and increasing productivity of mechanical parts. In this research double tool turning on AISI 1045 steel material was conducted. Ceramic inserted cutting tool was used and comparison of dry and wet machining were investigated showing wet machining was effective to reduce surface roughness. In both cases investigation on surface finish and material removal rate was analyzed in detail. Tooltip temperature also analyzed during dry machining. Taguchi L9 orthogonal array design of the experiments was used to optimize cutting parameter. For both machining condition Analysis of Variance (AVOVA) was applied. Among cutting parameters; cutting speed was the most significant factor for improving surface roughness in both cutting conditions. The minimum surface roughness attained for optimum cutting parameter was 1.02µm in dry turning conditions and 0.81µm for wet turning conditions. The results showed that in wet machining, a maximum of 38.1 %, and a minimum 3.9 % reductions were investigated in surface roughness when compared with dry machining. This reveals that wet machining improved the surface finish during double tool turning operations. Material removal rate was high due to double tool turning implemented. It was obtained maximum material removal rate of 93.75mm3 /sec.