Optimizing flank wear and surface roughness during hard turning of AISI D3 steel by Taguchi and RSM methods

Abstract

The study attempts to investigate tool wear (flank wear) and surface roughness during finish hard turning of AISI D3 steel (58HRC) with coated carbide (TiSiN-TiAlN coated) cutting tool. Taguchi L9 (3)3 orthogonal array has been applied for experimental design. S/N ratio and ANOVA analyses were performed to identify significant parameters influencing tool wear and surface roughness. The cutting speed and feed were the most significant factors influencing tool wear (flank wear), and feed is the most significant factor influencing surface roughness (Ra). Mathematical models for both response parameters i.e. tool wear and surface roughness were obtained through regression analysis. The confirmation experiments carried out at optimal combination of parameters given by Taguchi’s analysis, predicted the response factors with less than 5% error. In addition, Desirability function module in RSM was applied to arrive at the optimal setting of input parameters to minimize tool wear and surface roughness. The optimal solution provided by desirability function optimization was compared with the optimal setting of parameters given by Taguchi analysis. The optimization results provided by both techniques are in close proximity.