Modeling and Optimization of Hard Turning Operation on 41Cr4 Alloy Steel Using Response Surface Methodology
International Journal of Mechanical Engineering and Applications
Volume 4, Issue 2, April 2016, Pages: 88-102
Received: May 3, 2016; Accepted: May 14, 2016; Published: May 30, 2016
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Authors
Christopher Okechukwu Izelu, Department of Mechanical Engineering, Federal University of Petroleum Resources, Effurun, Nigeria
Samuel Chikezie Eze, Samez Engineering and Consultancy Services Limited, Kaduna, Nigeria
Festus Ifeanyi Ashiedu, Department of Mechanical Engineering, Federal University of Petroleum Resources, Effurun, Nigeria
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Abstract
Product quality, productivity and organizational goodwill are often the major concern of every production or manufacturing unit. These criteria, more especially product quality, cannot readily and effectively be met through dependence on the skills of an operator. Hence, the need for optimization in order to identify the best process condition, derived from parametric combinations of process variables, for the manufacturing process. The work presented concerns an aspect of a series of hard turning experiments on 41Cr4 alloy structural steel conducted to model, predict and optimize the machining induced vibration, and the surface roughness as functions of the cutting speed, feed rate, and the tool nose radius. The response surface methodology, based on the central composite design of experiment is employed in the study, and analysis of the generated data performed with the aid of Design expert 9 software. A quadratic regression model was suggested as best fits for both the machining induced vibration and surface roughness data. These were confirmed by analyses of variance, which also revealed the tool nose radius and cutting speed, as well as the feed rate and cutting speed to be important factors that determine changes in the machining induced vibration and surface roughness, respectively. The optimum setting of the tool nose radius at 1.72301 mm, feed rate at 0.15 mm/rev, and the cutting speed at 311.075 rev/min minimized the machining induced vibration to a value of 0.08 mm/min2 and the surface roughness to a value of 4.74 µmm.
Keywords
Tool Nose Radius, Feed Rate, Cutting Speed, Machining Induced Vibration, Surface Roughness, Turning Experiment, Response Surface Methodology
To cite this article
Christopher Okechukwu Izelu, Samuel Chikezie Eze, Festus Ifeanyi Ashiedu, Modeling and Optimization of Hard Turning Operation on 41Cr4 Alloy Steel Using Response Surface Methodology, International Journal of Mechanical Engineering and Applications. Vol. 4, No. 2, 2016, pp. 88-102. doi: 10.11648/j.ijmea.20160402.18
Copyright
Copyright © 2016 Authors retain the copyright of this article.
This article is an open access article distributed under the Creative Commons Attribution License (http://creativecommons.org/licenses/by/4.0/) which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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