Optimization of Material Removal Rate and Surface Roughness in Turning of Aluminum, Copper and Gunmetal Materials using RSM

Abstract

Surface roughness and material removal rate play a major role in the process of machining. The surface roughness plays vital role in appearance, touch and feel of the component while material removal rate influences the surface finish as well as cost and economics of machining. Therefore study of surface roughness and material removal rate has acquired major attention. The present study aims to investigate the effect of spindle speed, feed rate and depth of cut on material removal rate (MRR) and Surface roughness, in turning of aluminium, copper and gunmetal using Tungsten carbide tip on CNC Lathe machine. The effect of cutting parameter on MRR and surface roughness were studied and analyzed. Experiments were conducted based on the Taguchi design of experiments (DOE) with orthogonal L9 array, and then followed by optimization of the results using Analysis of Variance (ANOVA) to find the optimum MRR and surface roughness. The optimum values were obtained when setting the cutting parameter at high values. RSM technique was used to validate the results with experiments. The results obtained for MRR and surface roughness using RSM technique were in a good agreement with the experiments.