Optimisation of machining parameters for turning operations based on response surface methodology

Design of experiments has been used to study the effect of the main turning parameters such as feed rate, tool nose radius, cutting speed and depth of cut on the surface roughness of AISI 410 steel. A mathematical prediction model of the surface roughness has been developed in terms of above parameters. The effect of these parameters on the surface roughness has been investigated by using Response Surface Methodology (RSM). Response surface contours were constructed for determining the optimum conditions for a required surface roughness. The developed prediction equation shows that the feed rate is the main factor followed by tool nose radius influences the surface roughness. The surface roughness was found to increase with the increase in the feed and it decreased with increase in the tool nose radius. The verification experiment is carried out to check the validity of the developed model that predicted surface roughness within 6% error.

► We model AISI 410 steel for optimisation of turning operations based on RSM.
► We examine surface roughness as an index of product quality with the help of 34 full factorial design.
► Feed is the main factor followed by tool nose radius and cutting velocity for the predicted models.
► Depth of cut has no significant effect on the surface roughness.
► 3D surface counter plots are useful in determining the optimum condition.