Optimization of Active Cutting Power Consumption by Taguchi Method for Rough Turning of Alloy Steel

Abstract

 In this study, the active cutting power consumption (ACPC) is optimized as it is usually the major factor of the electricity bills in machining operations. The EN 353 alloy steel is used as workpiece material during rough turning while varying cutting parameters and nose_radius. The experiments were conducted in accordance with the Taguchi’s L-27 standard arrangement and the interactions between parameters were also considered with tungsten carbide inserts. The optimum value of ACPC achieved is 0.191kW at a speed of 1200 RPM, feed of 0.25 mm/rev., depth of cut 1 mm and nose_radius of 1.2 mm. ANOVA results reveal that the depth of cut with an involvement of 44.66% for rough turning operation comes out to be most significant variable for ACPC. The feed rate does not contribute significantly for ACPC as well as the interactions between variables. At the optimum levels of rough turning variables, there is an improvement of 51.03% in ACPC in contrast to turning variables commonly used in the industries; as a result of this improvement the cost of electricity bills can be diminished.

Keywords: Rough turning operation; active power consumption; Taguchi method; ANOVA, alloy steel.