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Analysis of Surface Roughness, Sound Level and Machine Current in the Turning of Hardened AISI S1 Steel

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Abstract

In this study, surface roughness values, sound levels and instantaneous current values were measured with calibrated devices in accordance with the experimental parameters. In this study, turning tests were carried out on AISI S1 steel material workpieces at three different depth of cuts, three different feed rates and 3 different cutting speeds without coolant. A full factorial experimental design method was used. Three different cutting speeds (135, 155, 175 m/min), feed rates (0.045, 0.090, 0.135 mm/rev) and depth of cuts (0.04, 0.08, 0.12 mm) as control factors have been selected. The effect levels on the surface roughness of the control factors with analysis of variance (ANOVA) performed using the experimental results were determined. Finally, the confirmation tests were performed and showed that the analysis is successfully implemented. As a result of analysis, the most effective cutting parameter on all the output parameters was found to be the feed rate. Its influence on the sound level was found to be 60.26%. The feed rate was followed by the cutting speed (22.87%) and the depth of cut (6.58%), respectively. The motor current values were influenced by feed rate, cutting speed and depth of cut by 52.71%, 18.73% and 23.88%, respectively.

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Abbreviations

R a (µm):

Surface roughness value

a (mm):

Depth of cut

V (m/min):

Cutting speed

f (mm/rev):

Feed rate

R 2 :

Accuracy value

Pred. R 2 :

Predicted R2

Adj. R 2 :

Adjusted R2

Seq SS:

Sequential sum of squares

Adj. SS:

Adjusted sum of squares

Adj MS:

Adjusted mean squares

DF :

The total degrees of freedom

F :

An F-value appears for each term in the analysis of variance table

P :

The P-value is a probability

S.L. (dB):

Sound Level

I corr (µAcm−2):

Corrosion current

E corr(mV):

Corrosion electrode

R p :

Corrosion resistance

Β a (mV):

The proportionality constant of anodic

Β c (mV):

The proportionality constant of cathodic

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  1. Department of Machinery and Metal Technologies, Aydin Vocational School, Adnan Menderes University, 09100, Aydin, Turkey

    A. K. Cakir

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Cakir, A.K. Analysis of Surface Roughness, Sound Level and Machine Current in the Turning of Hardened AISI S1 Steel. Trans Indian Inst Met 74, 691–703 (2021). https://doi.org/10.1007/s12666-021-02196-8

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