Optimisation and effect of tool rake and approach angle on surface roughness and cutting tool vibration

Abstract

Over the years, machining has been one of the pivotal manufacturing processes used in industries to produce superior products where multiple aspects regulate their efficacy. In this work, the motive is to study the effect of tool rake and approach angle in turning of mild steel specimens while varying process parameters such as spindle speed, feed rate and depth of cut. Experiments were designed using Taguchi L9 orthogonal array. For every trail, cutting tool vibrations were recorded using tri-axial accelerometer connected to a fast Fourier transform analyser after which surface roughness tests were conducted. Analysis of variance was performed to obtain significant parameters. Results revealed that spindle speed and feed rate predominantly affect surface roughness with approach angle contributing certain level of influence. Spindle speed highly influences vibrations in the tangential and radial direction while depth of cut and rake angle have significant effect on vibrations in the axial direction.