Experimental analysis and mathematical modeling of optimized cutting parameters in microturning

Abstract

In the present study, an attempt has been made to investigate the effect of process parameters cutting speed, feed rate and depth of cut on tool wear and surface roughness in micro-turning of titanium alloy using Cermet insert. The experiments are carried out based on response surface methodology and sequential approach using rotatable second-order Box-Behnken design. Mathematical model is developed and used to evaluate the minimum tool wear and surface roughness under optimum micro-turning conditions. Analytical and graphical optimization techniques have been carried out to find out the optimum process parameters. Direct and interaction effects of the process parameters are analyzed, and the major parameter influencing tool wear and surface roughness is found to be feed rate, followed by the cutting speed and depth of cut. The following cutting conditions result in minimum tool wear and surface roughness: 3180 rpm cutting speed, 8 µm/rev feed rate and 15 µm depth of cut, which improve the productivity and surface quality with minimum machining cost.