Statistical and experimental analysis of machining parameters and tool radius in turning of low carbon steels

Abstract

In this study, the effects of basic machining parameters and insert radius on machinability
during turning of low-carbon steels were investigated using experimental and statistical methods. The
experiments were conducted on AISI 1015 case-hardened steel, and speed, depth, feed, and insert radius
were considered as input parameters. Output parameters were determined as roughness and cutting force.
The full factorial method was used for the experimental design, and the obtained data were evaluated
using ANOVA. The results show that feed and insert radius are particularly decisive on roughness. At
low feed and high cutting speed, a 0.8 mm insert radius provides optimum surface quality. Cutting force
increases in direct proportion to depth of cut and feed, while decreasing with increasing speed. It was also
observed that tools with a 0.4 mm insert radius exhibit lower force values. According to the ANOVA
results, feed was the parameter that most affected surface roughness at a 0.4 mm tip radius, while depth
was the most critical parameter determining force at a 0.8 mm tip radius. Consequently, this study
provides guidance in selecting optimal cutting parameters to achieve high efficiency and desired
tolerances in manufacturing processes.