Evaluation of Machining Parameters Affecting Cutting Forces in Dry Turning of GGG50 Ductile Cast Iron

Abstract

Cutting forces in turning have dramatic impact on the cutting stability, tool wear index and surface quality. Machinability of cast iron is important as per this material is served as the main source in manufacturing specific parts of automotive industry. Also, this special material may require final operation to eliminate the manufacturing related defects and residuals. In this context, this study focuses on the optimization and analysis of cutting forces during dry turning of GGG50 material. Thus, Taguchi based experimental design was applied using three levels of cutting speed, feed rate and cutting depth and totally 9 experiments were performed. The discussions on the cutting forces were made based on statistical analysis, optimization approach and graphical presentations. Accordingly, feed rate is the most influentive parameter on cutting forces with the contribution rate about 71.2 %. Cutting speed and depth of cut follows it with the contributions of 21.7 % and 1.5 %. To achieve the minimized cutting forces the parameter group should be; 0.16 mm, 0.2 mm/rev, 80 m/min. This study is expected to be an auxiliary resource for designers and manufacturers in the field to improve the machinability aspects of casted materials.