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This paper presents an experimental investigation focused on identifying the effects of cutting conditions and tool construction on the surface roughness and natural frequency in turning of AISI1045 steel. Machining experiments were carried out at the lathe using carbide cutting insert coated with TiC and two forms of cutting tools made of AISI 5140 steel. Three levels for spindle speed, depth of cut, feed rate and tool overhang were chosen as cutting variables. The Taguchi method L9 orthogonal array was applied to design of experiment. By the help of signal-to-noise ratio and analysis of variance, it was concluded that spindle speed has the significant effect on the surface roughness, while tool overhang is the dominant factor affecting natural frequency for both cutting tools. In addition, the optimum cutting conditions for surface roughness and natural frequency were found at different levels. Finally, confirmation experiments were conducted to verify the effectiveness and efficiency of the Taguchi method in optimizing the cutting parameters for surface roughness and natural frequency.

The Effect of Tool Construction and Cutting Parameters on Surface Roughness and Vibration in Turning of AISI 1045 Steel Using Taguchi Method