Optimization of turning process parameters of stainless-steel using Box-Behnken method

• Main Author: Ahmad Rozelan, Aina Dalila
• Format: Thesis
• Language: English; English
• Published: 2023
• Online Access: http://eprints.utem.edu.my/id/eprint/27150/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=123109

This project focuses on the simulation of the turning process by using the finite element analysis (FEA) processing Deform 3D software based on the Box-Behnken of Response Surface Method (RSM) experimental matrix. Based on the Box-Behnken design matrix, 15 simulation runs were performed with a centre point to analyse the influence of cutting parameters on the turning process output responses such as cutting temperature, effective stress and material removal rate. The cutting parameters chosen in this turning simulation of 7075 stainless steel were cutting speed (100 m/min - 140 m/min), feed rate (0.5 mm/rev - 1.5 mm/rev) and depth of cut (0.5 mm - 2.0 mm). Analysis of variance (ANOVA) was used to determine the most influential cutting parameters on the results. The Box-Behnken response surface method was used to investigate the interactions between the cutting parameters on the initial responses and to optimise the setting of the cutting parameters for the turning process. From the results, the feed rate is the most influential cutting parameter on the cutting temperature. Meanwhile, the depth of cut is the most important cutting parameter for the effective stress. For the metal removal rate, the cutting speed is the most influential cutting parameter. Furthermore, the interaction between cutting speed and feed rate is the predominant interaction that has a significant effect on the cutting temperature, which shows that the downward saddle shape. Meanwhile, the relationship between cutting speed and depth of cut is the main relationship that has the greatest influence on the effective stress, when shows the upward saddle shape. The interaction between cutting speed and feed rate, which shows that the upward saddle shape. Additionally, the cutting temperature yields a minimum value of 926°C. Furthermore, the minimum value of 577.5 MPa is provided by the effective stress. The maximum value for the material removal rate is 2.45 m3/s. Overall, this project was effective in achieving all of its objectives. As a result, the defect of the wear on the cutting tool can be minimised by a decrease in both the cutting temperature and effective stress with an increase in material removal rate.