Title: Application of response surface methodology to evaluate the effect of cutting tool inserts on machining of aluminium 7075 alloy on CNC turning centre

Authors: Atul Choudhary; Sant Ram Chauhan

Addresses: Department of Mechanical Engineering, NIT, Hamirpur HP, 177005, India ' Department of Mechanical Engineering, NIT, Hamirpur HP, 177005, India

Abstract: In this paper, the main emphasis is on the study of machinability of aluminium alloy 7075 with the prime objective to ascertain the minimum tangential force and fine surface roughness. Series of tests were conducted in order to investigate the machinability with the objective to study the performance of different tool materials PCD and carbide. The utmost attention was taken in selecting the test material, tool geometry and cutting parameters for turning of material. The main factors deciding the above objective are cutting speed, feed rate, depth of cut and approach angle. Here, an attempt had been made to model the machinability evaluation through face centred CCD of Response surface method. The experimental results indicate that the proposed mathematical model suggested could adequately describe the performance of the factors that are being investigated. The results indicate that the polycrystalline diamond tool provide satisfactory results with better tool life than carbide tool at high speed turning. Moreover, the cost of (PCD) tools could be absolved by using dry cutting at high turning parameters. Optimum cutting conditions produced from DOE are verified with the experimental measurement.

Keywords: surface roughness; response surface methodology; central composite design; CCD; RSM; cutting tool inserts; aluminium alloys; CNC turning; turning centres; machinability; surface quality; cutting speed; feed rate; depth of cut; approach angle; mathematical modelling; polycrystalline diamond; tool life; carbide tools; PCD tools; dry cutting.

DOI: 10.1504/IJMMM.2013.051906

International Journal of Machining and Machinability of Materials, 2013 Vol.13 No.1, pp.17 - 33

Received: 11 May 2011
Accepted: 08 Nov 2011

Published online: 26 Dec 2013 *

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