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<p>The turning process plays a crucial role in defining the mechanical properties and surface integrity of manufactured components. This study investigates the influence of turning factors—cutting speed, feed rate, and depth of cut—on the material removal rate (MRR) and surface roughness parameters (Ra and Rz) of material extrusion (MEX)-fabricated parts. A Box-Behnken Design (BBD) was employed to systematically assess the significance of these factors, and analysis of variance (ANOVA) was conducted to quantify their effects. The results revealed that feed rate was the most dominant factor affecting surface roughness, contributing 93.89% to Ra and 87.90% to Rz, while both feed rate and depth of cut significantly influenced MRR. Contour plots were generated to visualize the interactions between process factors and response variables. Regression models were developed to predict the responses, achieving high accuracy with coefficient of determination (<i>R</i><sup>2</sup>) values of 99.3% for MRR, 98.7% for Ra, and 98.8% for Rz, confirming their reliability. The optimization results identified the optimal turning conditions as 150&#xa0;m/min cutting speed, 0.140172&#xa0;mm/rev feed rate, and 1.5&#xa0;mm depth of cut, ensuring enhanced material removal efficiency while maintaining surface quality. These findings provide valuable insights for optimizing the turning process of MEX parts, paving the way for improved manufacturing precision and efficiency.</p>

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Maximizing material removal rate and surface smoothness in MEX parts through turning process optimization using BBD

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年7月11日

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  • Hussein Alzyod,
  • Gabor Konya,
  • Peter Ficzere

摘要

The turning process plays a crucial role in defining the mechanical properties and surface integrity of manufactured components. This study investigates the influence of turning factors—cutting speed, feed rate, and depth of cut—on the material removal rate (MRR) and surface roughness parameters (Ra and Rz) of material extrusion (MEX)-fabricated parts. A Box-Behnken Design (BBD) was employed to systematically assess the significance of these factors, and analysis of variance (ANOVA) was conducted to quantify their effects. The results revealed that feed rate was the most dominant factor affecting surface roughness, contributing 93.89% to Ra and 87.90% to Rz, while both feed rate and depth of cut significantly influenced MRR. Contour plots were generated to visualize the interactions between process factors and response variables. Regression models were developed to predict the responses, achieving high accuracy with coefficient of determination (R2) values of 99.3% for MRR, 98.7% for Ra, and 98.8% for Rz, confirming their reliability. The optimization results identified the optimal turning conditions as 150 m/min cutting speed, 0.140172 mm/rev feed rate, and 1.5 mm depth of cut, ensuring enhanced material removal efficiency while maintaining surface quality. These findings provide valuable insights for optimizing the turning process of MEX parts, paving the way for improved manufacturing precision and efficiency.