Optimization of Surface Roughness and Material Removal Rate in Turning of AISI D3 Steel with Coated Carbide Inserts

Abstract

The aim of this paper is to optimize the metal removal rate and surface roughness through turning on AISI D3 Steel with coated carbide inserts. As per the current market scenario, for the metal cutting industries the most important challenge in the turning process is to satisfy both requirements quality as well as high productivity in less time in order to remain competitive. Among all the different cutting processes, the turning process is one of the most applied and fundamental metal removal operations in the real manufacturing environment. This work examines the impact of machining factors like speed, depth of cut & feed on roughness and MRR of AISI D3 steel which have a hardness value of 60 HRC with coated carbide inserts. At high speed and feed rate optimum MRR was achieved and opposite to that at low feed and depth of cut optimum surface roughness was obtained. Taguchi L9 (3)3 OA has been applied for experimental design. ANOVA analysis is performed just after DOE to identify the significant factor which influences MRR and surface roughness. Among the three machining factors, depth of cut and speed has more influencing effect on roughness and the feed influences MRR. Effort was made to find optimum solution to minimize the roughness and maximize the MRR by Taguchi and ANOVA technique.