Effects of Cutting Conditions on Tool Temperature and Material Removal Rate in Turning Operations

Abstract

Cutting conditions in manufacturing processes have effects on tool temperature and material removal rate. The objective of this study was to investigate the effects of cutting conditions namely spindle speed, feed rate, depth of cut and tool nose radius on tool temperature and material removal rate in turning operations. A total of 81 experiments were conducted to measure tool temperature and material removal rate in order to determine the effects of cutting conditions on tool temperature and material removal rate using ANOVA and regression analysis. The results show that tool nose radius, depth of cut, and spindle speed are significant to tool temperature, whereas feed rate is insignificant to tool temperature. Tool nose radius has the highest contribution to tool temperature with 44.43%, followed by spindle speed with 6.96%, depth of cut with 6.52%, and then feed rate with 0.08%, all with an error of 42.01%. In addition, spindle speed, feed rate, and depth of cut are significant to material removal rate while the tool nose radius is insignificant to material removal rate. The most important factor is feed rate, which contributes to 39.8%, followed by the depth of cut with 21%, spindle speed with 4.86%, and tool nose radius with 0.71% and an overall 33.64% contribution to the error. The findings conclude that tool nose radius may be closely controlled for generation of lower tool temperature while feed rate and depth of cut need to be thoroughly monitored to take advantage of higher productivity.