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In this study, effects of cutting speed (V), feed rate (f), depth of cut (a) and tool tip radius (R) on  surface roughness (Ra, Rz, and Rt) and cutting forces (radial force (Fx), tangential force (Fy), and feed force (Fz)) in hard finish turning processes of hardened 42CrMo4 (52 HRC) material was investigated experimentally. Taguchi’s mixed level parameter design (L18) is used for the experimental design (2x1,3x3). The signal-to-noise ratio (S/N) was used in the evaluation of test results.  By using Taguchi method, cutting parameters giving optimum surface roughness and cutting forces were determined. Regression analyses are applied to predict surface roughness and cutting forces. Analysis of variance (ANOVA) is used to determine the effects of the machining parameters on surface roughness and cutting forces. According to ANOVA analysis, the most important cutting parameters were found to be feed rate for surface roughness and depth of cut among cutting forces.  By conducting validation experiments, optimization was seen to be applied successfully.

In this study, the effect of cutting speed, feed rate, and depth of cut on surface roughness was experimentally examined in the processing of AISI 409 (ferritic chromium stainless steel) material. As cutting parameters, three cutting speeds (200, 300, and 400 m/min), three feed rates (0.1, 0.2, and 0.3 mm/rev), and three depths of cut (1, 2 and 3 mm) were selected. Turning tests in CNC machine were made according to Taguchi L27 orthogonal array and the signal/noise (S/N) ratios were used in the evaluation of the experimental results. By using Taguchi method, cutting parameters giving the optimum surface roughness (Ra and Rz) values were determined. The effect of control factors on the results was found with the help of Analysis of Variance (ANOVA). According to ANOVA results, the most important parameters affecting the surface roughness were determined as feed rate, depth of cut, and cutting speed, respectively. By conducting validation tests, the optimization was observed to be applied successfully.

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