Title: Robust design optimisation of cutting force and material removal rate in thread turning process

Authors: Suraj Rane; Amar Dalvi; Sujay Kharat; Raheel Ahmed Kittur

Addresses: Mechanical Engineering Department, Goa College of Engineering, Farmagudi, Goa, 403401, India ' Godrej & Boyce Mfg. Co. Ltd., Mapusa, Goa, 403526, India ' L&T Hydrocarbon Engineering, Mumbai, Maharashtra, 400072, India ' Taj SATS, Dabolim, Goa, 403801, India

Abstract: Thread cutting is the most commonly used method of producing threaded components in small scale industries. Literature review revealed that enough research is not undertaken in optimising thread turning, in spite of it being a widely used method of producing threads. The present work highlights a case from a small scale organisation, manufacturing hexagonal headed bolt with high accuracy in lean environment. The objective was to optimise cutting force and material removal rate, which were indicators of power consumption and productivity, respectively. To obtain optimal levels of input parameters using less number of components, a robust design methodology was used. The input parameters studied are cutting speed, depth of cut and infeed angle, in external thread turning of mild steel. The optimum level of each input variable was found out for minimum cutting forces generated and maximum material removal rate. Significant improvement in power savings and productivity was observed.

Keywords: thread turning; cutting forces; material removal rate; MRR; robust design; Taguchi method; analysis of variance; ANOVA; orthogonal array; signal-to-noise ratio; cutting speed; depth of cut; infeed angle.

DOI: 10.1504/IJISE.2021.120625

International Journal of Industrial and Systems Engineering, 2021 Vol.39 No.4, pp.461 - 475

Received: 02 Feb 2019
Accepted: 16 Dec 2019

Published online: 31 Jan 2022 *

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