Optimization of Residual Stresses, Tool Wear, and Material Removal Rate of Tempered EN-36C Alloy Steel in CNC Turning Using Response Surface Methodology

In the manufacturing industry, it is a great challenge to achieve residual stress-free products from hard metals and alloys. Optimum selection of process parameters and cutting conditions in the turning of hard metals plays a significant role in minimization of residual stress and tool wear as well as maximizing the material removal rate (MRR). The primary aim of the present study is to optimize process parameters such as cutting speed (Vc), feed rate (f), and depth of cut (d) to minimize tool wear as well as residual stresses and maximize material removal rate in turning tempered EN-36C alloy steel with the use of a tungsten carbide cutting insert (CNMG-120408-TMH-F) in a dry environment. Tests were carried out using response surface methodology (RSM) to develop statistical models for tool wear, residual stress, and MRR. Analysis of variance (ANOVA) revealed that more contribution toward cutting speed and feed rate was observed than depth of cut for minimum residual stress and tool wear, while more contribution toward cutting speed and depth of cut was observed as compared to feed rate for maximization of MRR. The predicted model and confirmatory experiment results show good unanimity with the developed statistical model at 95