Application of response surface methodology in describing the performance of mixed ceramic tool when turning AISI 4140 steel

Statistical tools, as well as mathematical ones, have been widely adopted and their performance has been shown in different engineering problems where randomicity usually exists. In the realm of engineering, merging statistical analysis into structural evaluation and assessment will be a tendency in the future. As a combination of mathematical and statistical techniques, response surface methodology has been successfully applied to design optimization, response prediction and model validation. The aim of this study was to evaluate the impact of factors such as cutting speed, feed rate, and depth of cut on cutting force components and surface roughness of a mixed ceramic (CC650) cutting tool during the hard turning process of AISI 4140 steel. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The depth of cut is the most significant factor that influences the cutting force components and the surface roughness. However, there are other factors that provide secondary contributions to the performance indicators. In the case of surface roughness, the feed rate and the interaction of feed rate and depth of cut provide these contributions whilst for forces components, the feed rate, the interaction of feed rate and depth of cut and the cutting speed provide them.