MULTI-OBJECTIVE OPTIMIZATION OF CUTTING PARAMETERS TO MINIMIZE ENERGY CONSUMPTION IN DRY TURNING OF AISI 4140 ALLOY STEEL by Avilash Sharma
Abstract
Manufacturing processes consume huge amounts of energy and hence have significant impact on environment because most of electricity is still produced by burning fossil fuels which liberates carbon dioxide and other greenhouse gases. Therefore, reduction of energy consumption of manufacturing processes can considerably reduce environmental or ecological impact of energy generation but also can benefits manufacturer economically. Machining is one of major manufacturing process, so it is important to optimize the energy consumption of machining while considering other parameters like surface finish and tool wear. So in this work Response Surface Methodology (RSM) has been utilized to optimize and study the effect of cutting parameters (cutting speed, feed rate and depth of cut) on Specific Energy Consumption (SEC), surface finish and tool wear during dry turning of AISI 4140 alloy steel. And multi-objective optimization method of RSM was used to find optimum setting of cutting parameters which would simultaneously minimize SEC, tool wear and surface roughness. From the analysis of results it was found that minimum SEC was achieved at higher levels of all cutting parameters. Feed rate was found to be only significant parameter for surface finish. In case of tool wear, minimum tool wear was achieved at lower levels of cutting parameters. The most optimal solution for SEC, surface finish and tool wear were achieved at cutting speed equal 136.715 m/min, feed rate equal to 0.160 mm/rev and depth of cut equal to 1.168 mm
