Optimization of machining parameters in turning using Design of Experiments (DOE) and Analysis of Variance (ANOVA)

Abstract

Metal cutting process is one of the complex process which has numerous factors contributing towards the quality of the finished product. CNC turning is one among the metal cutting process in which quality of the finished product depends mainly upon the machining parameters such as feed, speed, depth of cut, type of coolant used, types of inserts used etc. Similarly the work piece material plays an important role in metal cutting process. While machining, optimized machining parameters results in good surface finish, low tool wear, etc. This study involves in identifying the optimized parameters in CNC turning. Based on the performance of test results of various sets of experiments performed for analyzing the influence of different machining parameters on the cutting force in the machining of mild steel using HSS cutting tool, Factorial 3k design of experiment (DOE), Analysis of variance (ANOVA), F-test values. The experimental results show that the cutting force and feed force are low at low feed and depth of cut and comparatively high at high feed and high depth of cut. The greater the feed and depth of cut , larger the cross sectional area of the uncut chip, the volume of the deformed metal and consequently the greater is the resistance of the material to chip formation and larger is the force Pz will be in turning operation