Application of Response Surface Methodology for Predicting Flank Wear in Turning Operation

Wear has drastic effects on flank wear during the turning process, which affects tool life and the surface roughness of the finished component. The aim of this study was to evaluate the impact of factors such as cutting speed, feed rate, and depth of cut on flank wear of a highspeed steel (HSS) cutting tool during the turning process of a mild steel component. A mathematical model was developed relating flank wear and the main factors such as cutting speed V, feed rate F, and depth of cut T. Response surface methodology (RSM) was used to develop the mathematical model and the model was checked for adequacy by regression analysis. Main and interaction effects of the control factors on flank wear are presented in graphical form, which helps in selecting quickly the process parameters to achieve the desired quality of machining surface by way of controlling the wear of the cutting tool. It is a very important technique to measure the tool wear on-line, so that the tool can be changed when its profile is lost or it produces a poor quality, which is not acceptable.