Optimization of flank wear using Zirconia Toughened Alumina (ZTA) cutting tool: Taguchi method and Regression analysis

In this study, Taguchi method and Regression analysis have been applied to assess machinability of AISI 4340 steel with newly developed Zirconia Toughened Alumina (ZTA) ceramic inserts. Several experiments have been carried out based on an orthogonal array L-9 with three parameters (depth of cut feed rate, cutting speed) at three levels (low, medium and high). Based on the mean response and signal to noise ratio (SNR), the best optimal cutting condition has been arrived at A(2)B(1)C(1) i.e. cutting speed is 280 m/min, depth of cut is 0.5 mm and feed rate is 0.12 mm/rev considering the condition smaller is the better approach. Analysis of Variance (ANOVA) is applied to find out the significance and percentage contribution of each parameter. It has been observed that depth of cut has maximum contribution on tool wear. The mathematical model of flank wear has been developed using regression analysis as a function of the above mentioned independent variables. The predicted value from the developed model and experimental values are found to be very close to each other justifying the significance of the model. A confirmation run has been carried out with 95% confidence level to verify the optimized result and the values obtained are within the prescribed limit. (C) 2011 Elsevier Ltd. All rights reserved.