APPLICATION OF TAGUCHI METHOD TO OPTIMIZE TURNING PROCESS PARAMETERS FOR SURFACE ROUGHNESS AND MATERIAL REMOVAL RATE ON AISI 1045 STEEL: CASE STUDY OF AKAKI BASICMETALS INDUSTRY

Abstract

Optimization of turning process parameters using Taguchi method is essential because of its difficulty in obtaining minimum surface roughness and maximum material removal rate during turning of AISI 1045/C45 due to its ovality of the work piece, mismatch between the sample piece diameter and the tolerance, bend lead screw work piece breakdown, hardness of the piece. This study is mainly focused on the optimization of turning process parameters (spindle speed, feed rate, and depth of cut) for the workpiece material. The experimental analysis was performed by using different softwares: MINITAB 18 is used to analyze Taguchi and DOE, Solid Work is used to design a work piece, and Gwyddion software is used to display roughness profiles. Optimization was performed by lathe turning, using tungsten carbide inserts for each test. Taguchi analysis of the SN ratio and analysis of the variance were used to optimize machining parameters. An analysis of variance (ANOVA) has been used to determine the effect of turning process parameters on surface roughness and material removal rate. The machine tools and inserts based on the ISO measurement and the influence of cutting parameters were also analyzed. The cutting parameters for minimum surface roughness were obtained at a smaller spindle speed (600 rpm), a higher feed rate (0.16 mm/rev), and a higher depth of cut (1.50 mm), while the maximum material removal rate was obtained at a higher spindle speed (1250 rpm), a higher feed rate (0.16 mm/rev), and a medium depth of cut (1.0 mm). According to the ANOVA, all cutting parameters have a significant effect on surface roughness, with the depth of cut having the highest weight percentage (33.051%), the highest feed rate (16.910%), and the fastest spindle speed (14.251%). And for material removal rate, it was found that the spindle speed weight percentage (47.120%), feed rate (10.240%), and depth of cut (7.015%)have a significant influence on material removal rate