Taguchi optimization of surface roughness and flank wear during the turning of DIN 1.2344 tool steel

Abstract In this study, a turning operation was applied to DIN 1.2344 hot work tool steel under dry machining conditions. The optimum machining conditions were determined by investigating the surface roughness (Ra) and the flank wear (Vb) depending on the machining parameters. Experiments were performed according to the Taguchi L 9 orthogonal array and signal/noise (S/N) ratios were used in the evaluation of the test results. Optimum Ra and Vb values were determined by Taguchi optimization. The effects of the machining parameters on Ra and Vb were found with the help of analysis of variance (ANOVA). According to the ANOVA results, the most important parameter affecting Ra and Vb was feed rate. Two different multiple regression analyses (linear and quadratic) were conducted for the experimental results. A higher correlation coefficient (R 2 ) was obtained with the quadratic regression model, which showed a value of 0.99 for both Ra and Vb. Finally, confirmation tests were performed and showed that the optimization has been successfully implemented. By the Taguchi analysis the optimum results for both surface roughness and flank wear were found to be a cutting speed of 120 m × min −1 , a feed rate of 0.15 mm × rev −1 and a depth of cut of 0.5 mm. The results of the calculations and the confirmation tests for Ra were 0.84 μm and 0.80 μm, and for Vb, 0.0892 mm and 0.0824 mm, respectively.