Optimization of surface roughness via the Taguchi method and investigation of energy consumption when milling spheroidal graphite cast iron materials

Abstract

Abstract Due to its excellent casting ability, spheroidal graphite cast iron is widely used in the production of complex automotive and machine products. In this study, the milling of spheroidal cast iron was carried out at different parameters. First, using the Taguchi statistical method, the parameters affecting surface roughness values were determined to b e cutting tool (65.54 %), then feed rate (19.65 %), and finally, with a minimum effect, cutting speed (7.31 %). Second, the amount of power consumed during chip removal was observed as being larger than the amount consumed when the machine was operating without a cutting load. Increases in the power index (PI) were measured by an amperemeter and it was determined that, as cutting speed was augmented, the amount of total power (Ptotal) consumed decreased, while, as feed rate was augmented, total power consumption increased. Total cutting energy (Pcutting) was increased by stepping up cutting speed. The PI was increased as a result of stepping up cutting speed and feed rate. On the basis of the cutting parameters, the Pcutting, Ptotal, spindle torque (%) and specific energy consumption (SEC) value changes were calculated.