Optimization of Machining Parameters of Aluminum Alloy BS-1474 2014 A using Response Surface Methodology

Abstract High surface quality, optimum Material Removal Rate (MRR) and Tool-Chip Interface temperature (T c ) have significant importance in machining process. Similarly, dimensional accuracy in machining process also relies heavily on machining parameters. In machining operations, there are a number of parameters which have direct or indirect effect on the Surface Roughness (Ra) and MRR of the product. The surface roughness and MRR in turning process are affected by spindle speed (SS), feed rate (FR) and depth of cut (DOC). The optimization of turning parameters will be very helpful in improving quality of manufacturing and machining cost. In order to have an improved product, extensive research has been carried out to optimize machining process. The current research is focused at Response Surface Methodology (RSM) of turning process of Aluminum alloy (BS-1474 2014 A) by using variable sets of machining parameters i.e., SS, FR and DOC with carbide tipped tool. Multiple experiments were performed on CNC Lathe machine by using different combinations of process parameters. Response surface methodology was applied to reach theoretical values of the responses parameters (i.e, Ra, MRR, T c ) and an agreement was observed between actual machining results and methodology values. Design Expert-7 was used as a statistical tool to come to a conclusion on whether achieved results are optimum for turning process or otherwise. For a close correlation, comparison between hypothetical and investigational data is also the part of this research. Significant agreement between theoretically optimized machining parameters and experimental data has been observed.