Optimize the effects of cutting parameters on average surface roughness during turning of Al6061 metal matrix composite

Abstract

Machining parameter play a very important role in estimating the performance of machining operations. It can be achieved by mathematical modeling of performance as a function of machining conditions using design of experiments (DOE). The Design of experiments based on two level factorial design with three numeric factors (cutting speed, feed rate and depth of cut) and one category factor (nose radius) have been used to develop relationships for surface roughness, aerial removal rate and resultant cutting forces.Model adequacy tests were conducted using ANOVA table and the effects of various parameters were investigated and presented in the form of contour plots and 3D surface graphs. Numerical optimization was carried out considering all the input parameters within range so as to minimize the surface roughness, resultant cutting force and maximize material removal rate. Keywords:Feed, Speed, Depth of Cut, Nose Radius (Category), DOE, Factorial Design ANOVA