Surface Roughness Case Study

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Abstract- AISI1040 has a high quality, unalloyed medium carbon steel usually good ductility with resistance to wear. Tool wear (TW) and surface roughness (SR) are mostly considered as demanding phases, and thus causing poor results in machining. Optimal setting of machining parameter is more important for getting high quality products. Taguchi method, a powerful tool can only be used to optimize the single-response problem; it cannot be used to optimize the multi-response problem. In this study single and multi response problem were performed in computer numerically controlled (CNC) turning on AISI1040 with TiCN/TiN coated cutting tool during dry condition using Taguchi Techniques and Grey relational analysis (GRA). Analysis of variance (ANOVA)…show more content…
For that purpose, the CNC machine tools with automated and flexible manufacturing systems have been implemented. In the manufacturing industries, various manufacturing processes are adopted to remove the material from the work piece. Out of these, turning is the first most common method for metal cutting because of its ability to remove materials faster with a reasonable good surface quality [1, 2]. Surface roughness (SR) is one of the most important quality characteristics in manufacturing industries which influences the performance of mechanical parts as well as production cost. SR of a machined product could affect several of the product’s functional attributes such as contact causing surface friction, wearing, light reflection, heat transmission, ability of distributing and holding a lubricant, coating and resisting fatigue. Therefore, SR is one of the important quality aspects in facing operations [3]. TW which results in tool substitution is one of the most important economical penalties, so it is very important to minimize TW, and optimizing all the cutting parameters [4, 5]. In actual practice, there are many factors which affect surface roughness and tool wear, e.g., cutting conditions, tool variables and work piece variables. Cutting conditions include…show more content…
Taguchi approach can economically satisfy the need of problem solving and product/process design optimization projects in the manufacturing industries [8]. Taguchi suggests signal to noise ratio (S/N) as the objective function for matrix experiments. The S/N ratio is used to measure the quality characteristics and is also used to measure the significant machining parameters through the ANOVA [9]. Taguchi classifies objective function into three categories, such as smaller the better type, larger the better type, nominal the best type [10]. The main objective of this paper is to study the different process parameters during turning of AISI1040 steel using robust design methodology. This paper attempts to introduce how Taguchi parameter design could be used in identifying the significant processing parameters and optimizing the SR and TW of turning operations. Since the quality characteristic is to be minimized, the-lower-the-better category is used to calculate the S/N ratio for SR and

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