Optimization of Machining Forces during High-Speed Turning of Graycast Iron with CBN Tools Based on Response Surface Methodology

Abstract

To improve tool performance and productivity, high-speed machining of gray cast iron with cutting tools made of cubic boron nitride (CBN) has garnered considerable interest. The influence of cutting parameters, such as cutting speed, feed rate, and depth of cut, on the cutting force, feed force, and thrust force during CNC turning of gray cast iron was systematically investigated in this study. Response Surface Methodology (RSM) was used to organize and execute experiments to develop mathematical models that explain the relationship between the machining parameters and force components. Analysis of variance (ANOVA) was used to determine the significance of the individual and interaction effects of the process aspects. The findings show that the most important element influencing all force components is the feed rate, followed by the depth of cut. In high-speed situations, the cutting speed has a relatively small impact. The RSM-developed quadratic regression models showed a strong agreement with the experimental data. An ideal set of machining settings was obtained by performing multi-objective optimization to simultaneously decrease the cutting, feed, and thrust forces. Confirmation trials demonstrated a strong connection between the predicted and experimental values, confirming the efficacy of the proposed models. The findings of this study provide valuable insights for optimizing the high-speed machining of gray cast iron using CBN tools, leading to improved machining performance and reduced cutting forces.