Experimental and RSM-Based Process-Parameters Optimisation for Turning Operation of EN36B Steel

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes

Background:

• Machining operations like turning are crucial for metal component fabrication.
• Tool wear, specifically flank wear, significantly impacts machining efficiency and surface quality.
• EN36B steel is a widely used alloy in demanding engineering applications.

Purpose of the Study:

• To determine optimal cutting parameters for turning EN36B steel using tungsten carbide tools.
• To analyze the influence of cutting parameters on tool flank wear.
• To validate experimental findings through simulation and comparison.

Main Methods:

• Experimental turning tests were conducted on EN36B steel with tungsten carbide tools.
• Response Surface Methodology (RSM) was employed for the optimization of cutting parameters.
• Analysis of variance (ANOVA) and graphical plots (main effect, contour, surface) were used to study flank wear and cutting forces (Fx, Fy, Fz).

Main Results:

• Cutting parameters significantly affect tool flank wear.
• Flank wear exhibited a generally linear increase with cutting speed, depth of cut, and feed rate.
• RSM successfully optimized parameters to minimize flank wear, with predicted values closely matching measured results (96.33%–98.92% accuracy).

Conclusions:

• Depth of cut is a key factor influencing tool flank wear.
• Optimized cutting parameters derived from RSM can effectively reduce flank wear in EN36B steel turning.
• The study demonstrates a reliable methodology for optimizing machining processes and predicting tool performance.