Green machinability studies on SAE 8822 alloy steel using RSM and taguchi method

The study aims to optimize machining parameters for turning SAE 8822 Alloy steel under green machining (without coolant), using a CNC turning machine with a carbide tool. The controlled factors are spindle speed (A), feed rate (B), and depth of cut (C), with roughness (R_a) as the response variable. The experimental runs are conducted using an L₉ Orthogonal Array (OA). Orthogonal arrays are used to efficiently explore the parameter space with a relatively small number of experimental runs while maintaining statistical validity. The impact of the machining parameters on the roughness is interpreted using Analysis of Variance (ANOVA). ANOVA is a statistical technique that helps identify the significance of each parameter and their interactions on the response variable. The result indicated that variation of A between 1500 rpm to 2000 rpm resulted in a significant increase in R_a. Similarly, the effect of B and C contributed towards huge variations in R_a. The optimal values of 1500 rpm for A, 0.5 mm/rev for B, and 1 mm for C are identified as the most favorable combination for achieving the desired R_a. Achieving a minimum R_a of 0.04 microns indicate a very high-quality surface, which may be desirable in precision engineering applications. The analysis shows that the C and B have the highest influence followed by A on R_a.

Keywords:
Optimization; CNC turning; ANOVA; RSM; Green machining