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

Abstract

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. References

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