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Multi-objective Optimization of Parameters in CNC Turning of a Hardened Alloy Steel Roll by Using Response Surface Methodology

  • Research Article-Mechanical Engineering
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Abstract

This study was conducted to optimize the machining parameters of the CNC turning operation of a large-sized, hardened alloy steel roll, at low cutting speed, and under wet machining conditions, which consumed minimum power and minimum specific energy to produce the machined surface with minimum surface roughness. A mixed-level statistical design was developed with four factors including cutting speed, feed, depth of cut, and tool insert type. Response surface methodology was used for the analysis and optimization of experimental results. The full quadratic response model and the main effect plots reported that the cutting speed was the most dominant factor for power consumption and feed for the specific energy consumption, while the most contributing factor for the surface roughness was feed. Cutting tool insert type was also found to be a significant factor. The effectiveness of the CBN and ceramic cutting tool was also compared by using contour plots. Desirability analysis showed that the optimized machining parameters were cutting speed of 41.23 m/min, feed of 0.1333 mm/rev, and depth of cut of 0.49 mm with CBN tool insert. This work compared the effectiveness of CBN and ceramic cutting tool inserts, at low cutting speeds under a wet machining environment. This work has also developed mathematical models for power consumption, specific energy consumption, and surface roughness. This research work also contributes to the practical industrial application of CNC turning in hot rolling mills.

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Data availability

All the data used in this paper can be obtained from the corresponding author upon request.

Abbreviations

V c :

Cutting speed

f :

Feed

d :

Depth of cut

L W :

Length of workpiece

D w :

Diameter of workpiece

E s :

Specific energy consumption

P :

Power consumption in the machining stage

R a :

Surface roughness of a machined surface

Δi :

Individual desirability for ith response

D :

Composite desirability

y i :

iTh response

m :

No. of responses

T :

Target value

U :

Upper bound

r :

Desirability function index

\(\overline{x}\) :

Mean value

DOE:

Design of experiments

e-CDF:

Empirical commutative distribution

S:

Standard deviation

SS:

The sum of squares

DF:

Degree of freedom

MS:

Mean squares

RSM:

Response surface methodology

DOE:

Design of experiments

e-CDF:

Empirical commutative distribution

MRR:

Material removal rate

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Acknowledgements

The authors are grateful for the support of Amreli Steels Limited, Pakistan (Dhabeji Plant), for providing the material (alloy steel roll) and for providing the workshop facility. The authors are also thankful to the Electronics Department of NED University of Engineering & Technology, Pakistan, for providing the Fluke device for recording power consumption data.

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Authors and Affiliations

  1. Department of Mechanical Engineering, NED University of Engineering and Technology, Karachi, Pakistan

    Kashif Noor, Mubashir Ali Siddiqui & Syed Amir Iqbal

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  1. Kashif Noor
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  2. Mubashir Ali Siddiqui
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  3. Syed Amir Iqbal
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Contributions

KN developed and formulated the methodology, performed the experimental work, analyzed the results, and drafted the manuscript. MAS supervised the project, helped in developing experimental plans and samples, reviewed the drafted paper, and addressed revision. SAI co-supervised the project, reviewed the drafted paper, and assisted in experimental plans.

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Correspondence to Kashif Noor.

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Noor, K., Siddiqui, M.A. & Iqbal, S.A. Multi-objective Optimization of Parameters in CNC Turning of a Hardened Alloy Steel Roll by Using Response Surface Methodology. Arab J Sci Eng 48, 3403–3423 (2023). https://doi.org/10.1007/s13369-022-07117-5

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  • DOI: https://doi.org/10.1007/s13369-022-07117-5

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