PROCESS OPTIMIZATION IN DRY TURNING OF STEEL, CAST IRON AND BAKELITE USING LOW COST TOOL MATERIAL

The present work includes a methodical study of the effects of input parameters viz. spindle speed, longitudinal feed and depth of cut on surface roughness (Ra) of machined components and vibration generated during machining. Vibration is an output response produced in metal cutting operation. This vibration acts directly as a response which takes part in roughness formation on work materials. There is an impact on both surface finish and productivity. The design of experiment plan is based on L16 orthogonal array with three factors and four levels for each variable as per Taguchi method. The experiments are conducted on Low Carbon steel, Grey Cast Iron and Bakelite on Centre Lathe using HSS single point turning tool under dry cutting condition. Response variables viz. surface roughness (Ra) and cutting vibration (dB) in the three directions are recorded by using accelerometer placing on the periphery of work holding chuck end bearing housing. An attempt is made to optimize the cutting parameters in respect of multi-response variables viz. surface roughness (Ra) and cutting vibration (dB) in three directions to achieve a breakeven level of both the quality and yield by using low cost tool material. CQL perception in WPCA based Taguchi technique is used to evaluate optimal input parameters.