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 (Ra), 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 Ra, TWR and maximum MRR. Maximum desirability was found to be 86.63%. The optimised values of Ra, 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: 07 Oct 2011 *

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