Parametric optimization of dry turning for improved machining of duplex stainless steel (DSS2205) using response surface methodology (RSM) and design of experiments (DOE)

• Published in: Sadhana (Bangalore) Vol. 50; no. 1
• Main Authors: Thakur, Rahul, Sahu, Neelesh Kumar, Shukla, Rajendra Kumar
• Format: Journal Article
• Language: English
• Published: New Delhi Springer India 19.12.2024; Springer Nature B.V
• Subjects: Austenitic stainless steels; Composition effects; Cutting parameters; Cutting wear; Design of experiments; Duplex stainless steels; Engineering; Feed rate; Ferritic stainless steels; Optimization; Parameter identification; Response surface methodology; Stainless steel; Turning (machining); material removal rate; duplex stainless steel; dry turning; RSM; surface roughness; cutting tool wear
• DOI: 10.1007/s12046-024-02649-y
• ISSN: 0973-7677; 0256-2499

Duplex materials, which have a unique combination of characteristics derived from austenitic and ferritic steel, show excellent hardness and toughness. However, this particular composition also makes machining difficult. This study aims at conducting a detailed parametric investigation on dry turning operations using CNC for duplex stainless steel (DSS 2205). Specifically, it focuses on critical cutting variables like machining velocity, feed rate and depth of cut. Response surface method (RSM) is utilized by the researchers to optimize these variables while taking into account important factors like MRR, wear of tool and roughness of surface. Through a carefully planned series of dry turning experiments involving different cutting parameters on DSS 2205, this work identifies optimum values for specific responses during machining processes. The optimized cutting conditions include a cutting velocity of 100 m/min or spindle speed of 1178 rpm, feed rate of 282.72 mm/min (or 0.24 mm/revolution) and depth of cut (DOC) of 1.5 mm. This optimization approach significantly contributes towards enhancing overall performance by addressing the intrinsic challenges associated with its unique composition that make it difficult to machine effectively.