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AISI 1040 steel is widely used for production of various parts. This material has been studied by many researchers. In this work, turning tests were carried out on AISI 1040 steel workpieces at five different depth of cuts, four different feed rates and 4 different cutting speeds without coolant. The influence of the cutting parameters on turned part surface roughness, vibration, sound level and machine tool motor current were examined. A full factorial experimental design method was used. The Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) were used to determine the effects of input parameters on the resultant surface roughness, vibration, sound level, current. The experimental results showed that increasing feed rate increased the surface roughness, vibration, sound level and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate. Furthermore as feed rate and depth of cut increased, the current value and sound level also increased. [ABSTRACT FROM AUTHOR]

In this research, AISI 1040 steel whose hardness is 46 HRc was processed in CNC lathe. Taguchi L16 experiment design was created based on cutting speed, feed rate and depth of cut of which is consisted of four levels. As a result of these experiments, average surface roughness (Ra) values were measured. Multiple regression models for measured Ra values were created by using MINITAB 14 program. The closest results to the experiment results in regression models created for Ra were obtained with the quadratic regression model with the 99.8% coefficient of determination. With the regression models created, it was determined that the most effective parameters are the feed rate parameters. From mathematical equations created in the result of the experiments carried out, it was determined that the quadratic regression equation is approximately 90% correct. [ABSTRACT FROM AUTHOR]