Modelling of Machining Process While Turning Tool Steel with CBN Tool

For machining operations during the last few decades, there has been major progress in developing models for industries. This paper aimed to develop mathematical models using Design Expert 7.1 software to study the effect of cutting parameters on main cutting force, surface roughness and stress. Second objective of this research work was to optimize the machining process by finding the best parameters setting with defined goals for the variables. Results reveal that the value of main cutting force decreases with a decrease in the value of cutting speed and depth of cut. The most significant factors in case of surface roughness and stress are feed rate and depth of cut, respectively. Mathematical models have been developed for main cutting force, surface roughness and stress, and average errors of 3.87, 5.41 and 2.96% were observed for the corresponding values and analogous trend lines of the plots, respectively. The optimal set of conditions possessing highest desirability value (0.617) and lowest surface roughness (out of eight solutions having the same desirability of 0.617) is as follows: cutting speed-138.29 m/min; feed rate-0.13mm/rev; depth of cut-0.28mm (input parameters) and main cutting force-219.273 N; surface roughness-0.439 mu m; stress-5128.18 N/mm(2) (responses for input parameters).