Investigations on surface quality characteristics with multi-response parametric optimization and correlations

Abstract

This paper presents the parametric optimization on surface quality characteristics (Ra, Rz and Rt) in hard turning of EN31 steel using multilayer coated carbide insert (TiN/TiCN/Al2O3) and also finds correlations. The experiments have been conducted based on Taguchi’s L9 orthogonal array. Multiple linear regression analysis has been utilized to find the correlations. The integrated multi-response optimization approach using CQL concept in WPCA coupled with Taguchi technique has been implemented. Based on the S/N ratio, the optimal process parameters for surface roughness i.e. Ra and Rz are the depth of cut at level 3 (0.5 mm), the cutting speed at level 3 (140 m/min), and the feed at level 1 (0.04 mm/rev). The optimal process parameters for Rt are found to be the depth of cut at level 3 (0.5 mm), the cutting speed at level 2 (100 m/min), and the feed at level 1 (0.04 mm/rev). Feed and depth of cut are found to be the significant cutting parameters affecting the responses at 95% confidence limit from ANOVA study. The first order model presented high correlation coefficient between the experimental and predicted values. The optimal parametric combination for multi-response (Ra, Rz and Rt) becomes d3–v3–f1 and is greatly improved.

Keywords

• Hard machining
• Multi-response optimization
• Multiple linear regression
• Weighted principal component analysis
• Taguchi method