Experimental and RSM-based process-parameters optimisation for turning operation of EN36B steel

Abstract

The main objective of this article is to perform the turning operation on an EN36B steel work-billet with a tungsten carbide tool, to study the optimal cutting parameters and carry out an analysis of flank-wear. Experimental and simulation-based research methodology was opted in this study. Experimental results were obtained from the lab setup, and optimisation of parameters was performed using RSM (response surface methodology). Using RSM, cutting-tool flank-wear was optimised, and the cutting parameters which affect the flank wear were determined. In results main effect plot, contour plot, the surface plot for flank-wear and forces (Fx, Fy and Fz) were successfully obtained. It was concluded that tool flank-wear is affected by depth of cut, and that flank-wear generally increases linearly with increasing cutting-speed, depth of cut and feed-rate. To validate the obtained results, predicated and measured values were plotted and were in very close agreement, having an accuracy level of 96.33% to 98.92%.