Effects of insert geometry and feed rate on quality characteristics of turned parts

This paper investigates experimentally and analytically the influence of insert geometry and feed rate on the quality characteristics of turned parts under the dry cutting condition. A three-level, three-parameter experiment was planned using the design of experiment methodology. The three levels of independent input parameters were: insert shape - rhombus, triangle, and square; nose radius 0.4, 0.8, and 1.2 mm; and feed rate - 0.11, 0.22 and 0.33 mm/rev. The measured output parameters were the three most widely used quality characteristics of turned parts-diameter error, circularity and surface finish (arithmetic average). The results were analyzed using three methods: traditional analysis, Pareto analysis of variation and Taguchi method. The results reveal that two of the selected tool geometry parameters, insert shape and nose radius, influence diameter error considerably (total contribution 66.97%) and have minor effects on circularity (total contribution 3.67%) and surface finish (total contribution 11.60%). Feed rate is the major contributor to surface finish (76.42% contribution), whereas circularity is dominated by interaction effects such as insert shape-feed rate interaction (31.44% contribution). © 2015 World Scientific Publishing Company