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Surface Roughness Prediction Model using Zirconia Toughened Alumina (ZTA) Turning Inserts: Taguchi Method and Regression Analysis

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Abstract

In the present study, an attempt has been made to apply the Taguchi parameter design method and regression analysis for optimizing the cutting conditions on surface finish while machining AISI 4340 steel with the help of the newly developed yttria based Zirconia Toughened Alumina (ZTA) inserts. These inserts are prepared through wet chemical co-precipitation route followed by powder metallurgy process. Experiments have been carried out based on an orthogonal array L9 with three parameters (cutting speed, depth of cut and feed rate) at three levels (low, medium and high). Based on the mean response and signal to noise ratio (SNR), the best optimal cutting condition has been arrived at A3B1C1 i.e. cutting speed is 420 m/min, depth of cut is 0.5 mm and feed rate is 0.12 m/min considering the condition smaller is the better approach. Analysis of Variance (ANOVA) is applied to find out the significance and percentage contribution of each parameter. The mathematical model of surface roughness has been developed using regression analysis as a function of the above mentioned independent variables. The predicted values from the developed model and experimental values are found to be very close to each other justifying the significance of the model. A confirmation run has been carried out with 95 % confidence level to verify the optimized result and the values obtained are within the prescribed limit.

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Acknowledgments

The authors are thankful to CSIR-Central Mechanical Engineering Research Institute, Durgapur, India for constant support in completing this research work. The authors, also acknowledge, with thanks, the Science and Engineering Research Board, Department of Science and Technology, New Delhi, India for providing financial support (SERB sanction order no. SB/S3/MMER/0035/2014 dated 22-05-2014) to carry out this work.

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Authors and Affiliations

  1. Centre for Advanced Materials Processing, CSIR - Central Mechanical Engineering Research Institute, Durgapur, West Bengal, 713209, India

    Nilrudra Mandal & Biswanath Mondal

  2. Production Engineering Department, Jadavpur University, Kolkata, 700032, India

    Biswanath Doloi

Authors
  1. Nilrudra Mandal
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  2. Biswanath Doloi
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  3. Biswanath Mondal
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Correspondence to Nilrudra Mandal.

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Mandal, N., Doloi, B. & Mondal, B. Surface Roughness Prediction Model using Zirconia Toughened Alumina (ZTA) Turning Inserts: Taguchi Method and Regression Analysis. J. Inst. Eng. India Ser. C 97, 77–84 (2016). https://doi.org/10.1007/s40032-015-0189-6

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  • DOI: https://doi.org/10.1007/s40032-015-0189-6

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