Title: Multiple-response modelling and optimisation of micro-turning machining parameters using response surface method

Authors: S. Palani; U. Natarajan; M. Chellamalai

Addresses: Department of Mechanical Engineering, Mount Zion College of Engineering and Technology, Pudukkottai-622507, Tamilnadu (State), India. ' Department of Mechanical Engineering, A.C. College of Engineering and Technology, Karaikkudi-630004, Tamilnadu (State), India. ' Department of Micro and Precision Machining, Central Manufacturing Technology Institute, Bangalore-560022, India

Abstract: Response surface methodology (RSM) helps the engineers to raise a mathematical model to represent the behaviour of system as a convincing function of process parameters. This paper investigated the influence of three micro-turning process parameters, which were cutting speed (A), feed rate (B) and depth of cut (C). The response variables were average surface roughness (R_a), tool wear ratio (TWR) and metal removal rate (MRR). Statistical models of these output responses were developed using three-level full factorial design of experiment. The developed models were used for multi-response optimisation by desirability function approach to obtain minimum R_a, TWR and maximum MRR. Maximum desirability was found to be 86.63%. The optimised values of R_a, TWR and MRR were 0.0295 ?m, 0.0272, 0.098 mg/min respectively for 1101.94 rpm cutting speed, 10 ?m/sec feed rate, 0.20 ?m depth of cut. Optimised machining parameters were used in verification experiments, where the responses were found very close to the predicted values.

Keywords: micro turning; response surface methodology; RSM; surface roughness; tool wear ratio; TWR; metal removal rate; MRR; micromachining; surface quality.

DOI: 10.1504/IJMATEI.2011.042883

International Journal of Materials Engineering Innovation, 2011 Vol.2 No.3/4, pp.288 - 309

Published online: 26 Mar 2015 *

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