Effect of Machining Parameters on Surface Roughness and Material Removal Rate in Dry Turning of AISI 1080 Mild Steel Using HSS Tools

Abstract

This study involves the dry turning of mild steel AISI 1080 in the universal lathe machine using high-speed steel (HSS) right-hand cutting tools. The experiments were designed using the Taguchi method and three process parameters, viz., cutting speed, depth of cut, and clearance angle, each with four levels. To obtain the tool angles, the HSS tool blanks were ground to obtain several clearance angles. The design yielded an L9 orthogonal array, which led to nine experimental trials. After the experiments, the samples were investigated for average surface roughness and the material removal rate. The average surface roughness was measured using the T200 handheld surface roughness tester, while the material removal rate was computed from the mass of chips and turning time. The responses were evaluated using the Taguchi analysis and the analysis of variance (ANOVA). From the Taguchi analysis, the signal-to-noise ratios were obtained. From the ratios, the minimum average surface roughness was obtained as 0.906 µm, as well as the maximum material removal rate of 0.1888 kg/min. These values represented the optimal responses. For the minimum average surface roughness, the optimal parameters were clearance angle of 22.65°, 755 rpm cutting speed and 0.7 mm depth of cut. Consequently, for the maximum material removal rate, the optimal parameters were a clearance angle of 22.65°, a cutting speed of 755 rpm and a depth of cut of 0.5 mm. From the ANOVA, the clearance angle was identified as the most significant factor contributing to surface roughness. Moreover, the depth of cut was identified as the largest contributor to the material removal rate.