This paper introduces a mathematical investigation of the effect of some turning parameters on surface characteristics of turned work-pieces, particularly surface roughness, and out-of-roundness of mild steel, using Response Surface Methodology (RSM). The turning investigated parameters are, cutting speed, feed rate, tool overhang, depth of cut, and tool nose radius.
Relationships between input parameters and the output responses were presented when two different methods are used to support the workpiece; namely 3-jaw chuck support and between two centers support. Mathematical models correlating these five input parameters to each response are established using RSM. Genetic algorithm (GA) was adopted to obtain the optimal fittness of surface roughness and out of roundness, and additionally the cooresponding best individual turning parameters were obtained. The proposed model has been verified experimentally.
The results of the established models showed that the proposed five turning parameters have a significant effect on the surface roughness and out-of-roundness and that there is an interaction between them on both surface roughness and out-of-roundness. RSM and genetic algorithm proved to be good tools to study the effects of machining conditions on the quality of machined workpieces.
Turning, Cutting conditions, Roughness, Roundness, RSM, GA.