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Metal cutting is a common operation in modern manufacturing. Integrating high-precision machines like NC machines has reduced downtime and human intervention while improving product quality. However, balancing quality, productivity, and sustainability in the machining industry remains a significant challenge. While metal cutting fluids can improve productivity and quality, they also increase machining costs and reduce sustainability. AISI 1060 is a high-carbon steel commonly used in automotive components such as clutch discs, shafts, and axles. Dry turning this steel generates excessive heat, requiring high cutting forces and compromising surface integrity. This study investigates how dry-turning parameters, such as feed rate, depth of cut, and cutting speed, affect productivity metrics, including surface roughness, cutting temperature, and material removal rate (MRR), when CNC turning AISI 1060 steel. The experiments are designed using Central Composite Design (CCD) from Design-Expert software (version 13.0.5.0), and the settings are optimized for improved performance using desirability function analysis (DFA). To ascertain the significance level of factors on outcomes, an ANOVA was performed using the Response Surface Methodology (RSM) research type. With percentage contribution values of 40.6 and 54.4 for surface roughness and cutting zone temperature, respectively, the ANOVA highlighted cutting speed as the significant parameter. Multi-objective optimization using DFA showed that a cutting speed of 128.928 m/min, feed rate of 0.150 mm/rev, and depth of cut of 1.137 mm were the optimal conditions, yielding the lowest roughness of 3.966 μm, cutting temperature of 64.9 °C, and maximum MRR of 21919.191 mm3/min with a 0.586 desirability value.
| Topic Area | Design Optimization, Additive Manufacturing Technologies & Applications |
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