Optimization of cutting forces and surface roughness in dry turning of AM magnesium alloy using Taguchi method Uday Kiran Kolluru ⇑ , Suresh Kumar Reddy Narala, Sunil Dutta Department of Mechanical Engineering, BITS-Pilani Hyderabad Campus, Hyderabad, Telangana 500078, India article info Article history: Received 1 May 2020 Received in revised form 20 August 2020 Accepted 29 August 2020 Available online xxxx Keywords: Turning operation Cutting forces Surface roughness Taguchi method Magnesium alloy abstract This study aimed to analyze the feed force, cutting force, and surface roughness deviations through CNC lathe turning operation of AM series magnesium alloy. Machining operations were performed using Tungsten Carbide insert with nose radius of 0.8 mm and by varying the basic cutting parameters like feed, cutting speed, and depth of cut. Throughout the experiments, the geometry of the tool was not changed and the cutting fluids are not used in turning operation. The investigation is performed only on the tung- sten carbide inserts, and these were changed continuously to prevent the tool wear. The experiments are carried out as per Taguchi’s L27 orthogonal array for cutting force, feed force, and surface roughness under dry cutting conditions. The results prove that the depth of cut and feed mainly influences the Cutting force and feed force. For Surface roughness, the feed and depth of cut are perceived as the influ- encing controlling factors. Finally, the optimum results are verified by the experimentation. Ó 2020 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by- nc-nd/4.0) Selection and Peer-review under responsibility of the scientific committee of the International Conference & Exposition on Mechanical, Material and Manufacturing Technology. 1. Introduction In modern times, magnesium has become an excellent choice due to its significant mechanical properties. It has high level of strength-to-weight and stiffness-to-weight ratios, and environ- mentally friendly, etc. most importantly being the lightest metal of all it is extensively used in automotive, communication, auto- motive, military, and medical [1–3]. Tonshoff, through his study, stated that there was excessive tool wear and FBU was formed when machining magnesium alloy at high cutting speeds under the dry condition with non-coated cemented carbide insert. He deliberated the effects of the interac- tion between the tool material and its coating under machining [4]. Carou conducted a turning test on magnesium alloy by chang- ing the cutting conditions to evaluate the significant factor of sur- face roughness, and he noticed that at low speed machining there was an increased deviation in surface roughness [5]. Surface qual- ity shows a direct impact on functional characteristics. The corrosion resistance and fatigue strength of the material has been improved substantially, with a high-quality finish [6]. Yalcin performed turning operation on AZ91 alloy using a sin- tered carbide tool. He noticed that the depth of cut and feed affects significantly on the machining forces [7]. Guo performed dry turn- ing operation using kentanium cutting tool on magnesium alloy. It was found that there was a peel off on the workpiece due to diffu- sive and abrasive cutting conditions [8]. Venkatesan observed that feed rate affects the surface integrity significantly; he then suggested the optimal process parameters. For better surface finish out of cutting speed and feed he suggested the point angle as the most influencing factor in milling. He sug- gested that by high speed, depth of cut and low feed rate we can improve surface finish [9]. Shi employed Taguchi approach combined with grey relational analysis and by performing ANOVA on the experimental data drawn by dry milling on alloy and found out that feed rate has more influence on the surface roughness and the micro hardness. By means of ANOVA, they could conclude that surface integrity is greatly affected by feed rate [10]. Baris investigated the optimiza- tion of cutting forces and surface roughness by Taguchi approach followed by Grey Rational Analysis in the oblique turning of https://doi.org/10.1016/j.matpr.2020.08.774 2214-7853/Ó 2020 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Selection and Peer-review under responsibility of the scientific committee of the International Conference & Exposition on Mechanical, Material and Manufacturing Technology. ⇑ Corresponding author. E-mail addresses: f20150416h@alumni.bits-pilani.ac.in (U.K. Kolluru), nskred- dy@hyderabad.bits-pilani.ac.in (S.K.R. Narala), p20170301@hyderabad.bits-pilani. ac.in (S. Dutta). Materials Today: Proceedings xxx (xxxx) xxx Contents lists available at ScienceDirect Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr Please cite this article as: Uday Kiran Kolluru, Suresh Kumar Reddy Narala and S. Dutta, Optimization of cutting forces and surface roughness in dry turning of AM magnesium alloy using Taguchi method, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.08.774