Experimental investigation and optimization of cutting parameters during dry turning process of copper alloy

Abstract

Increasing the quality and productivity of machined components are the main issues of machining operations in metalworking industries. The copper alloys CuZr and CuCrZr generally find applications for current-carrying structural components, seam welder wheels, shafts, and bearings flash. The manufacturing of these components is still facing challenges in the form of machining process characteristics. One of the most common machining operations for removing material is turning that produces reasonably good surface finish quality, which is influenced by different factors (speed of cut, rate of feed, tool geometry, cutting fluid, cutting tool, etc.). This research has focused on experimental study and optimization of the cutting parameters viz. cutting speed, depth of cut, and feed, for best surface finish, material removal rate, tool tip temperature as well as surface morphology during dry turning of C15000 and C18150 copper alloy using High-Speed Steel (HSS) tool The plan and design of experiment has been performed through orthogonal Taguchi L9. array. The optimum cutting settings were discovered by using the Taguchi technique and using the performance index by applying a Grey Relational Grade (GRG). The best cutting parameters for both materials were a cutting speed 1200 rpm, feed rate 0.06 mm/rev, and depth of cut 1.25 mm. The optimum factors obtained from GRA for all responses (surface roughness, MRR, and tool temperature) at the best level of cutting parameters are the same for both materials. These cutting parameters values yielded the experimental result for each response like surface roughness, MRR, and tool tip temperature (2.5 µm,12,475 mm³/min, and 74 °C) for grade C15000 whereas (2.39 µm, 2590mm³/min and 68 °C) for grade C18150. The optimization of cutting parameters plays a vital role in the improvement of surface finish which minimizes mechanical failures caused by wear, corrosion, and thereby increasing the productivity of the products. This investigation is expected to help all researchers working in this area of applications.