Optimization of process parameters for cutting force minimization in dry turning of aluminium 6063 using taguchi approach

Abstract

This study investigated the turning of 6063 aluminium alloy for minimizing the cutting forces using taguchi method. The turning process is done at low feed rates and depth of cuts for finish turning condition in the present study. Under these cutting conditions, minimum cutting force is produced hence, the objective of the study is to optimize the turning parameters for cutting force minimization with good surface finish. All 27 experiments were performed in dry condition in line with sustainable machining aspects. All responses were optimized individually. Optimal parameter was (v3-f1-d1) for minimizing all the responses. Experiment number 19 produces the optimum value of cutting force (CF) 21 N, feed force (FF) 21.22 N and surface roughness (SR) 0.9546 µm found through taguchi method. The prediction mathematical model was established for all the responses for finding the optimal turning parameter. The R2 value for all the responses in the present study is almost equal to unity which shows the good prediction accuracy. The parameter depth of cut is greatly affecting the cutting force with 54.22 % and feed force with 90.97 % respectively. The variation in the surface roughness was mainly affected by feed rate with 73.04 % contribution. From the multi-response optimization also, the optimum parameter was found as the same as that of (v3-f1-d1). The experimental and predicted results show good agreement hence; there is an enhancement in the quality characteristics of the output values.