IJSART - Volume 3 Issue 5 – MAY 2017 ISSN [ONLINE]: 2395-1052 Page | 293 www.ijsart.com Optimization of Machining Parameters in A Turning Operation of AISI 202 Austenitic Stainless Steel to Minimize Tool Wears Chandan Kumar 1 , Mohammad Nehal Akhtar 2 , Priti Singh 3 1, 2, 3 Department of Mechanical Engineering 1, 2, 3 AIET Lucknow, UP, India Abstract- The present work concerned an experimental study of turning on Austenitic Stainless steel of grade AISI 202 by a TiAlN coated carbide insert tool. The primary objective of the ensuing study was to use the Response Surface Methodology in order to determine the effect of machining parameters viz. cutting speed, feed, and depth of cut, on the tool wear of the machined material. The objective was to find the optimum machining parameters so as to minimize the tool wear for the selected tool and work materials in the chosen domain of the experiment. The experiment was conducted in an experiment matrix of 20 runs designed using a full-factorial Central Composite Design (CCD). Tool wears are measured with the help of a Toolmaker’s microscope. The data was compiled into MINITAB ® 17 for analysis. The relationship between the machining parameters and the response variable ( tool wear) were modeled and analysed using the Response Surface Methodology (RSM). Analysis of Variance (ANOVA) was used to investigate the significance of these parameters on the response variables, and to determine a regression equation for the response variables with the machining parameters as the independent variables, with the help of a quadratic model. Main effects and interaction plots from the ANOVA were obtained and studied along with contour and 3-D surface plots. Keywords- Turning, RSM, Cutting Speed, Depth of Cut, Tool Wear, CCD, ANOVA, etc. I. INTRODUCTION The work piece used for the concluded experiment was AISI 202 grade Austenitic stainless steel. There are two series of Austenitic stainless steels – 300-series and 200- series. 300 series steels find most wide use around the world but 200 series have become very popular in the Asian subcontinent as an alternative to the 300 series to counter the increase in prices of Nickel. Grade 202 steel can be made into plates, sheets and coils and finds extensive use in restaurant equipment, cooking utensils, sinks, automotive trims, architectural applications such as doors and windows, railways cars, trailers, horse clamps etc. The turning operation is a basic metal machining operation that is used widely in industries dealing with metal cutting. In a turning operation, a high-precision single point cutting tool is rigidly held in a tool post and is fed past a rotating work piece in a direction parallel to the axis of rotation of the work piece, at a constant rate, and unwanted material is removed in the form of chips giving rise to a cylindrical or more complex profile. This operation is carried out in a Lathe Machine either manually under an operator’s supervision, or by a controlling computer program. Tool wear is an inherent occurrence in every conventional machining process. Bin Halim said that the tool wear is analogous to the gradual wear of the tip of a pencil [1]. It is the gradual failure of cutting tools due to regular operation. The tool wear rate is dependent on the tool material itself, the tool shape and geometry, work piece material etc. The foremost important factors affecting the tool wear which can be easily controlled are process parameters. A key factor in the rate of tool wear of materials is the temperature achieved during machining. The general idea is that energy expended in cutting is converted into heat and that a large fraction of it is taken away in the chip. This results in about 20% of the heat generated going into the cutting tool. The following types of tool wear modes can be observed [2]: a) Flank b) Notch c) Crater d) Edge rounding e) Edge chipping f) Edge cracking g) Catastrophic failure