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

ABSTRACT

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.

KEYWORDS:

• Modelling
• optimisation
• boring operation
• response surface methodology
• 3-level full factorial DOE

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Christopher Okechukwu Izelu

Dr Christopher Okechukwu Izelu started his academic carrier in Mechanical Engineering at the Nigerian Defence Academy Kaduna, Kaduna State, Nigeria, and now a Professor of Design Production and Materials Engineering at the University of Petroleum Effurun, Delta State Nigeria. He obtained BEng degree in Mechanical and Production Engineering at Anambra State University of Technology Enugu, Old Anambra State; MSc degree in Mechanical (Design and production) Engineering at University of Lagos Akoka, Lagos State; and PhD degree in Mechanical (Materials) Engineering. His research interests are in the area of design and development of mechanical systems, components and processes; machining, metal forming process mechanics and analysis; materials development and applications; and of renewable and alternative energy.

Emmanson Itoro Essien

Mr Emmanson Itoro Essien is a graduate of the Department of Mechanical Engineering at the Federal University of Petroleum Resources Effurun, Delta State, Nigeria. He obtained BEng degree in mechanical Engineering, and currently, working as research assistant in the same department

Modestus Okechukwu Okwu

Dr Modestus Okechukwu Okwu is a Lecturer and Research fellow at the Federal University of Petroleum Resources Effurun, Delta State Nigeria and has previously worked as a Lecturer in the Department of Mechanical Engineering at the Federal University Oye-Ekiti, Mechanical and Mechatronics Engineering Department. He obtained PhD and BEng in Mechanical (Industrial) Engineering, Federal University of Technology Owerri and MSc in Industrial Engineering from the University of Ibadan. His research interests include: Algorithms, Combinatorics and Optimization; operations research and modeling; supply chain design, processes and engineering; renewable and alternative energy; industrial safety; IoT; machine learning; artificial intelligence and robotics.

Danladi King Garba

Dr Danladi King Garba served as Captain in the Nigerian Army. His academic carrier began as lecturer in the Department of Mechanical Engineering at the Nigerian Defence Academy Kaduna, Kaduna State, Nigeria. Now he is an Associate Professor of Production Engineering. He holds MEng degree of Abubakar Tafawa Balewa University, Bauchi, Bauchi State, Nigeria in Mechanical Engineering, and PhD degree of Nigerian Defence Academy Kaduna, Kaduna State, Nigeria, in Production Engineering. His research interests are in the area of Materials, Design and Development of Mechanical Systems and Equipment for Civilian and Military Application, and of Materials Development and Military Engineering

Christopher Nonye Agunobi-Ozoekwe

Dr Christopher Nonye Agunobi-Ozoekwe served as Wing Commander in the Nigerian Airforce. His academic carrier has been as lecturer at the Nigerian Defence Academy Kaduna, Kaduna State, Nigeria. He obtained BEng degree in Mechanical Engineering at University of Nigeria Nsukka, Enugu State Nigeria; MEng degree in Industrial Engineering at University of Benin, Edo State, Nigeria; and PhD degree in Production Engineering at the Nigerian Defence Academy Kaduna, Kaduna State Nigeria. His research interests are in area of Design and development of mechanical systems, components and processes, and in materials and their applications