Machining Parameters Optimization in Wet Turning of EN31 Material Using Box-Behnken Approach of RSM

Abstract

Manufacturing sectors are always challenged to enhance surface quality and tool life while reducing machining costs and setup times in hard-turning operations. In line with this, the current study focused on surface roughness optimization employing machining parameters such as cutting speed: ν (160-260 m/min), feed: f (0.1-0.2 mm/rev), depth of cut: d (0.05-0.15 mm), and tool nose radius: re (0.4-1.2 mm) as functions. The experiment was designed by using Box-Behnken approach of RSM and carried out on a commercial CNC machine using EN31 material at 47 HRC. The research found that machining parameters have a considerable effect on surface roughness, as do stresses, vibrations, heat generation, and increased material per pass. The experimental surface roughness observed in between 1.34-2.81 μm whereas estimated surface roughness have R2=0.9976. The Anova design model showed face value of 356.21 which indicates the developed model is noteworthy. The significant and marginal effect of machining parameters are evaluated by considering p-value and overcall error observed within the range of 1.613-1.974%.