OPTIMIZATION OF MATERIAL REMOVAL RATE, SURFACE ROUGHNESS AND TOOL LIFE ON CONVENTIONAL DRY TURNING OF FCD700

Most of automotive components are manufactured using a conventional machining process, such as turning, drilling, milling, shaping and planning, etc. Ductile cast iron (FCD) is widely used for producing automotive components by turning process. This study aims to investigate the effect of the cutting speed, feed rate and depth of cut on material removal rate (MRR), surface roughness, and tool life in conventional turning of ductile cast iron FCD700 grade using TiN coated cutting tool in dry condition. The machining condition parameters were the cutting speed of 220, 300 and 360 m/min, feed rate of 0.2, 0.3 and 0.5 mm/rev, while the depth of cut (DOC) was kept constant at 2 mm. The effect of cutting condition (cutting speed and feed rate) on MRR, surface roughness, and tool life were studied and analyzed. Experiments were conducted based on the Taguchi design of experiments (DOE) with orthogonal L9 array, and then followed by optimization of the results using Analysis of Variance (ANOVA) to find the maximum MRR, minimum surface roughness, and maximum tool life. The optimum MRR was obtained when setting the cutting speed and feed rate at high values, but the optimum tool life was reached when the cutting speed and feed rate were set as low as possible. Low surface finish was obtained at high cutting speed and low feed rate. Therefore time and cost saving are significant especially is real industry application, and yet reliable prediction is obtained by conducting machining simulation using FEM software Deform 3D. The results obtained for MRR using the proposed simulation model were in a good agreement with the experiments.

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