Optimization of the Cutting Parameters Affecting the Turning of AISI 52100 Bearing Steel Using the Box-Behnken Experimental Design Method

Abstract

In this study, we aimed to optimize the cutting parameters that affect the minimum temperature and power consumption in the turning of AISI 52100 bearing steel. For this, the Box-Behnken experimental design method, which was used for the lowest number of experiments in the experimental systems created using the response surface method (RSM), was used. The cutting parameters affecting the turning of the AISI 52100 bearing steel were determined as the cutting speed, depth of cut, and feed rate based on a literature research. The temperature and power consumption values were obtained via analyses according to the experimental design method determined by the finite element analysis (FEM) method. The results obtained were analyzed in Design Expert 13 software. According to the analysis results, the parameter values were determined for the minimum temperature and power consumption. The temperature and power consumption variables were affected by all three parameters, namely the cutting speed, depth of cut, and feed rate. For the minimum temperature and power consumption, a cutting speed of 162.427 m/min, depth of cut of 1.395 mm, and feed rate of 0.247 mm/rev, as well as the feed rate parameters, affected both the temperature and power consumption the most. In addition, it was determined that the cutting speed parameter had the least effect on both the temperature and power consumption variables. In addition, validation experiments were carried out in a real experimental environment with optimum values for the cutting parameters. The results showed that the output values obtained within the limits of the study with the obtained equation were quite close (3.3% error for temperature, 6.6% error for power consumption) to the real experimental outputs.