Optimization of Cutting Parameters for Free Cutting Brass (CuZn35Pb3) Using Taguchi Method

Abstract

The need of smooth surface finish produced during machining process plays a greater role to reduce wear of the part and corrosion protection. However, the cost of making good surface finish depends on selection of optimized parameters and use of precision machines. Dry turning operation is very important for saving cost of cutting fluid, contribute to clean environment and good for safety of machinist. Pure copper produces a long tubular or tangled chips which makes machining very difficult because chips are rolled on cutting tool causing tool wear. Machining of high ductility work material like copper can create high frictional forces between chip and cutting tool. This creates high tool wear due to poor chip formation. In this work, cutting parameters like cutting speed, depth of cut and feed are optimized for dry turning process using Taguchi Method. The optimum turning parameters in this study was obtained at higher cutting speed, lower feed and higher depth of cut. The minimum surface roughness at optimum turning parameters was obtained as 1.63 µm. Result of variance indicates the contribution of cutting speed, feed and depth of cut were 88.74%, 1.13% and 6.46% respectively. Among which cutting speed was the most significant factor for improving surface roughness.