Optimization of machining parameters for fine turning operations based on the response surface method

Richard Horvath, Gyula Matyasi, Agota Dregelyi-Kiss


Machining of aluminium parts has become particularly important in recent years. Surface roughness measurements are essential in the characterization of the surface integrity of a machined surface. To examine the effect of cutting parameters on surface roughness thoroughly, a huge number of experiments are needed, depending on the number of parameters. By utilizing the method of design of experiments, the number of experiments is reduced, as determined by the effects of the parameters. If linear effects of cutting parameters are considered, then fractional factorial design is sufficient, but to take into consideration the interactions between the factors and the quadratic terms, the response surface method has to be utilized. The machinability of two AlSi alloys with diamond tools is examined using the response surface method. During the experiments the cutting parameters (cutting speed, feed rate, depth of cut) were changed systematically and the surface roughness was measured as an output parameter. The significant factors are determined by statistical analysis, and a mathematical model is developed to describe the relationship between the surface roughness and the cutting parameters. Optimization determines the appropriate manufacturing parameters for the manufacturing process planning.

  • A. Dregelyi-Kiss, R. Horvath and B. Miko. Design of experiments DOE in investigation of cutting technologies. Scientific Research Reports vol. 3. Krakow University, 2012.
  • H. Aouici, M. A. Yallese, K. Chaoui, T. Mabrouki and J.-F. Rigal. Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization. Measurement, 45:344–353, 2012. doi:10.1016/j.measurement.2011.11.011
  • M. Y. Noordin, D. Kurniawan, Y. C. Tang and K. Muniswaran. Feasibility of mild hard turning of stainless steel using coated carbide tool. Int. J. Adv. Manuf. Tech., 60:853–863, 2012. doi:10.1007/s00170-011-3656-0
  • I. Asilturk and S. Neseli. Multi response optimisation of CNC turning parameters via Taguchi method-based response surface analysis. Measurement, 45:785–794, 2012. doi:10.1016/j.measurement.2011.12.004
  • Y. K. Hwang and C. M. Lee. Surface roughness and cutting force prediction in MQL and wet turning process of AISI 1045 using design of experiments. J. Mech. Sci. Technol., 24:1669–1677, 2010. doi:10.1007/s12206-010-0522-1
  • M. Harnicarova, J. Valicek, M. Kusnerova, R. Grznarik, J. Petru and L. Cepova. A new method for the prediction of laser cut surface topography. Meas. Sci. Rev., 12:195–204, 2012. doi:10.2478/v10048-012-0030-9
  • D. Lazarevic, M. Madic, P. Jankovic and A. Lazarevic. Surface roughness minimization of polyamide pa-6 turning by Taguchi method. J. Prod. Engineer., 15:29–32, 2012. http://www.jpe.ftn.uns.ac.rs/papers/2012/no1/7-Lazarevic.pdf
  • R. Horvath and A. Dregelyi-Kiss. Analysis of surface roughness parameters in aluminium fine turning with diamond tool. Measurement 2013 Conference, Smolenice, Slovakia, 275–278, 2013. http://www.measurement.sk/M2013/
  • R. Horvath, A. Dregelyi-Kiss and Gy. Matyasi. Application of RSM method for the examination of diamond tools. Acta Polytech. Hung., 11:137–147, 2014. doi:10.12700/APH.11.02.2014.02.8
  • TiroTool Werkzeugsysteme Gmbh. http://www.tirotool.com/


fine turning, surface roughness measurement, design of experiments, RSM method, statistical analysis, numerical optimization

Full Text:


DOI: http://dx.doi.org/10.21914/anziamj.v55i0.7865

Remember, for most actions you have to record/upload into this online system
and then inform the editor/author via clicking on an email icon or Completion button.
ANZIAM Journal, ISSN 1446-8735, copyright Australian Mathematical Society.