Analysis of cutting force, feed force and surface roughness of Cu-Al-Mn shape memory alloys under CNC turning

Abstract

The present investigation into the CNC turning of Cu-Al-Mn SMAs was conducted using a tungsten carbide tip tool as a cutting tool material to determine the effect of machining factors, such as spindle speed, feed rate, and depth of cut, on the response factors such as cutting force (Fc), feed force (Ff), and surface roughness (Ra). Taguchi's L9 orthogonal array (OA) was used to plan the experiment. During the turning operation, the cutting force and feed force values were noted using a tool dynamometer attachment. From ANOVA, it was noticed that cutting speed and depth of cut were the important factors affecting the Fc, Ff, and Ra, followed by feed rate, which was less significant. From the experimental results, it was identified that with an increase in cutting speed at a particular feed rate and depth of cut, the formation of long thin chips and the number of chip curls rises. The C-type of chip was observed at same cutting conditions. The Ra was evaluated using a Mitutoyo equipment to study the effectiveness of machining operations, and it plays a significant role in predicting product quality as well. For a thorough investigation, chip morphology was examined using SEM analysis.