Optimal Turning Process Parameters for Finer Surface Finish of AZ31 Mg Alloy Rods for Automotive Products

Abstract

This study focuses on investigating the impact of various cutting parameters on surface roughness during the turning process of AZ31 magnesium alloys. The turning operation involved three key cutting parameters: depth of cut (DC), feed rate (FR) and cutting speed (CS). The experimental design followed modified Taguchi's approach and was executed using a CNC lathe. Quantitative assessment of surface roughness values was conducted through measurements obtained from the experiments. Both Taguchi and analysis of variation (ANOVA) were employed to identify the influence and contributions of the process parameters. A modified Taguchi methodology was adopted in this research to establish empirical relationships between performance characteristics (output responses) and process variables. These relationships were thoroughly validated by comparing them with the generated test data. The proposed approach recommends a limited number of tests based on an orthogonal array, offering comprehensive insights into all conceivable combinations of process variables and levels. Additionally, this approach provides an estimated range for output responses, facilitating the assessment of data scatter prior to experimentation. The optimal cutting parameter for achieving the minimum surface roughness was determined as follows: depth of cut at level 2 (2 mm), feed rate at level 1 (0.2 mm/rev) and cutting speed at level 1 (320 m/min). Empirical relations linking performance indicators to cutting process parameters were successfully formulated. The test data is within the range of expected range.