Analysis of effect of cutting parameters on surface roughness and cutting force during turning of aluminum alloy (AlSi5Cu3)

Abstract

The aim of this research work is focused on analysis of process parameters during turning of aluminium alloy (AlSi₅Cu₃). A study of effect of cutting parameters in turning of Aluminum Alloy (AlSi₅Cu₃) on the cutting force generated and machined surface roughness is carried out. In the experiment conducted, six values of feed rate, three values of depth of cut, and two values of cutting speed respectively, are used. The test pieces were turned on a centre lathe machine with different levels of cutting parameters by using full factorial design of experiment orthogonal array. The surface roughness of the machined surface was measured using surface measurement tester. Taguchi methodology was used to optimize process parameters. The results were analyzed by using Analysis of variance. From result analysis, it was found that, feed rate played a major role in producing lower surface roughness followed by cutting speed whereas depth of cut has least significance in producing lower surface roughness. To achieve better machining performance, the optimum condition parameters for surface roughness and cutting force, are as feed rate (FR = 0.045 m/min.), the cutting speed (CS = 90 m/min.), depth of cut (DOC = 0.5 mm). From analysis it is also seen that the cutting force equation and surface roughness equations are appropriate for accurate prediction. Thus, with proper selection of cutting parameters, it is possible to achieve good surface roughness, reduce tool wear while maintaining the cutting forces and temperatures at reasonable levels.