Lathe boring operation on ASTM A304 steel parameter optimization using response surface methodology

This paper presents the outcome of a study on the effect of the machining conditions on some performance parameters during dry and hard boring of ASTM A304 low alloy steel round bar with tungsten-carbide insert using a 3-level factorial design of experiment-based response surface methodology. It involved modelling, prediction and optimisation of the performance parameters subject to constraints on variation of the machining conditions. Within the limits defined by levels of the machining, the performance parameters were randomly determined in 27 runs of boring experiments. These experiments, which were performed on a D360 x 1000HS excel lathe machine, serial no J320581, involved dry and hard boring of 27 ASTM A304 low alloy steel specimen work-pieces using tungsten-carbide inserts at different levels of low, medium and high as specified for the machining conditions. The data analysis was performed using Design Expert software version 9.0.6.2 to model, predict, and to obtain the optimal machining conditions, and the corresponding performance parameters. The study revealed the control factors to have varying effects on the response variables of which the prime factor is the cutting speed, for the tool wear and cutting temperature, and depth of cut, for the material removal rate. Hence, it is recommended that the obtained values of these factors should be adopted for optimal machining of the aforementioned material.