A hybrid approach of Taguchi-Response Surface Methodology for modeling and optimization of Duplex Turning process

Productivity is always an important factor related to the industries for achieving higher production rate with better quality at low cost. In this respect, an effort has been made to improve the productivity of turning process with application of two cutting tools in place of single cutting tool and such developed process is named as Duplex Turning. Due to simultaneous application of two cutting tools on a shared rotating surface, the Duplex Turning process becomes more complex. Due to complexity, the selection of suitable combination of the process parameters becomes a difficult task for manufacturer. The aims of present paper are to develop a mathematical model and optimize the parameters for Duplex Turning during turning of alloy steel (AISI 1040) with single point cutting tools Made of high speed steel. The experiments were performed on Center Lathe Machine, which is equipped with Duplex Turning setup. The effect of cutting velocity, feed rate, primary depth-of-cut and secondary depth-of-cut has been analyzed on average surface roughness. The hybrid approach of Taguchi Methbdology-Response Surface Methodology (TM-RSM) has been applied due to their potential for modeling and optimization of complex machining process. The optimum condition obtained from TM has been used as central value in RSM for the modeling and optimization. The result shows the significant improvement in surface finish with hybrid approach as compared to the Taguchi analysis. (C) 2016 Elsevier Ltd. All rights reserved.