ABSTRACT
This paper investigated the influence of some of the main turning parameters in surface finish and roughness of turning samples. The 0.45%C (SAE 1045) steel bars samples, turned on a CNC turning machine, were analyzed using Design of experiments (DOE) approach to produce a total of thirty-two parameters combination, analyze its interactions and influences in each sample’s surface finish. Machining parameters investigated were: (1) feed rate, (2) cutting speed, (3) nose radius, (4) rake angle and (5) region of roughness measurement. Two factorial analyses were conducted through the DOE data. The first one evaluated the influence of those five parameters in the average roughness, represented by Ra, and the second one evaluated the accuracy of each parameters combination to achieve the expected surface finish. For this measurement, an index was created to compare the theoretical surface roughness of each process with the surface roughness measured by rugosimeter. Results showed that parameters as feed rate and nose radius have strong standardized effect in both factorial analysis. Results shown that reduction of the feed rate (or increase in nose radius) was able to produce lower roughness average (Ra) but, on the other hand, it also contribute to generate a surface roughness significant higher than theoretical roughness. The increase in cutting speed was beneficial to both, achieving a lower roughness average and improving process accuracy. The region of roughness measurement was found not significant to influence the roughness average, Ra.
Keywords
Finish; roughness; turning; SAE 1045
