Effect of Cutting Parameters of Turning Process on Cutting Tool vibrations and surface roughness of stainless steel using Taguchi Method

In actual cutting conditions various forces and unseen factors arise which cause vibrations. If vibrations occur between the tool and the job, then naturally the dimensional accuracy cannot be maintained and the performance of the machine tool will not be satisfactory. Also the machine tool vibration has detrimental effect on tool life and thus the cost of the production is increased and productivity lowered. In any machining operation, minimizing the vibration of the tool is a very important requirement for any turned work piece. Thus the choice of optimized cutting parameter is very important for minimizing the vibration of the cutting tool. The focus of this study is the collection of tool vibration data generated by the lathe dry turning of SS304 samples of diameter 31 mm using ISO 6R 1212 as the cutting tool at different levels of speed (130, 180, 340rpm), feed (0.1, 0.20, 0.22mm/rev) and depth of cut (0.4, 0.5, 0.6mm) and then analyzing the obtained data using taguchi analysis to show how tool vibration varies within a given range of speed, feed & depth of cut. The vibration here is represented by its peak acceleration. The analysis revealed that for the specified range of speed, feed and depth of cut, any change in the depth of cut causes a large change in the tool vibration while change in the cutting speed causes comparatively lowest change in tool vibration. This study highlights the use of Taguchi design to optimize the multi response in turning operation. For this purpose Taguchi design of experiment was carried out to collect the data for tool vibration and cutting forces. The result shows the optimum values of the input parameters and a confirmatory test is held to confirm the result. Although a high roughness value is often undesirable, it can be difficult and expensive to control in manufacturing. Decreasing the roughness of a surface will usually increase its manufacturing costs. This often results in a trade-off between the manufacturing cost of a component and its performance in application. Roughness can be measured by manual comparison against a "surface roughness comparator", a sample of known surface roughness, but more generally a Surface profile measurement is made with a profile meter that can be contact (typically a diamond styles) or optical (e.g. a white light interferometer).