Modeling of power consumption, cutting force, sound, current, and surface roughness during turning of AISI 4340 steel with different hardness

Up to now, a lot of research has been done on modeling and optimization of parameters like surface roughness, tool life, tool wear, cutting forces, vibration, and material removal rate influencing machining. However, little research has been done to optimize and model power consumption, sound, and current. To this aim, the effects of cutting parameters on power consumption, cutting forces, sound, current, and surface roughness were investigated. The present study focuses to obtain the optimal machining parameters leading to minimum power consumption, cutting forces, sound, current, and surface roughness during turning of AISI 4340 steel with different hardness (30, 35, 40 HRC) using ceramic, carbide, and CBN inserts. Predicted results with developed mathematical models for power consumption, cutting forces, sound, current, and surface roughness have been compared with experimental/calculated values. The results establish that there is a close relationship between the predicted values and experimental/calculated values. As a result of optimization, the most important parameter for power consumption, current, sound was found to be cutting speed. In addition to this, the most effective parameter for surface roughness was determined to be insert. The most effective parameter on radial force (Fx) and tangential force (Fy) is feed rate. And the most effective parameter on feed force (Fz) is depth of cut. Also, it has been observed that there is a strong relationship between the machining parameters and power consumption. In this way, it has been determined that power savings can be achieved by using optimal processing parameters.