In this paper, the influence of machining parameters, Cutting Speed, Feed Rate, and Depth of cut, on surface finish during dry orthogonal turning of Al 6061 – T6 alloy, is studied using the response surface methodology (RSM). This paper proposes a unique way to predict the surface finish in turning, using the effective plastic strain (PEEQ) values obtained from the simulations. A comprehensive finite element model was proposed to predict the surface finish accurately, by correlating the variance of the PEEQ. The Johnson-Cook damage model is used to define the damage criteria and Johnson-Cook material model is used to explain the material constitutive behavior. A dynamic, explicit method is used along with the Adaptive Lagrangian-Eulerian (ALE) method to predict material flow accurately. The influence of machining parameters was studied by assuming Central Composite Design (CCD). The output response, PEEQ, was fitted into analytical quadratic polynomial models using regression analysis, which shows that feed rate was the most dominant factor for PEEQ than the other parameters considered in this study. Using the individual desirability function method, the objective, optimal setting of the machining parameters was obtained for better surface finish.

No abstract

No abstract

No abstract

Turning is one of the most used metal removal operations in the industry. It can remove material faster, giving reasonably good surface quality apart from geometrical requirements. Conformity of geometry is one of the most significant requirements of turned components to perform their intended functions. Apart from dimensional requirements, the important geometrical necessities are Circularity, Straightness, Cylindricity, Perpendicularity, etc. Since they have a direct influence on the functioning of the components, the effect of the cutting parameters on them has greater significance. In this paper experiments are carried out to examine the effect of turning parameters such as cutting speed, feed rate, and depth of cut on responses like; straightness, roundness, surface roughness, and material removal rate during turning of AISI 4340 steel. Analysis of Variance (ANOVA) is performed and the influence of parameters on each response is studied. The optimal values of parameters obtained from the study are further confirmed by conducting experiments.