Analysis and Optimization of Residual Stresses in Hard Turning of AISI M2 Tool Steel Using Taguchi Technique

Introduction: Residual stresses play a critical role in the performance and durability of machined components, particularly in the hard turning of tool steels. Objective: The main objective of this investigation to optimize the residual stress during hard turning of AISI M2 tool steel. Material and Method: This study investigates the optimization of residual stresses in the turning of AISI M2 tool steel using the Taguchi method. An L27 orthogonal array was employed to analyze the effects of cutting speed, feed rate, and depth of cut on residual stress formation. X-ray diffraction (XRD) was used for stress measurement. Result: Analysis of variance (ANOVA) identified cutting speed as the most significant parameter, followed by feed rate and depth of cut. The residual stress is minimum at level optimal cutting conditions: 100 m/min cutting speed, 0.2 mm/rev feed rate, and 0.4 mm depth of cut. Conclusion: The optimal cutting conditions: 100 m/min cutting speed, 0.2 mm/rev feed rate, and 0.4 mm depth of cut resulted in the lowest residual stress of 230 (compressive) MPa. The cutting speed as the most significant parameter, followed by feed rate and depth of cut. The findings demonstrate the effectiveness of statistical optimization techniques in enhancing machining quality and surface integrity in industrial applications. Application: The application of this project will be in cutting tool industries where AISI M2 tool steel is used as raw material.