Optimization of Initial Cutting Parameters for a Turning Process Based on the Response Surface Methodology

Assessing tool wear is crucial for determining the machinability of cutting operations, with the initial cutting conditions having a significant impact on both tool wear and longevity. This study examines how starting cutting parameters affect tool wear during the machining of TiMMC. Findings indicate a rapid increase in initial wear alongside rises in cutting force and speed. The peak cutting force is reached within approximately 5 s, coinciding with the period where initial wear stabilizes across all tested cutting conditions. Notably, the early stage of tool wear, which unfolds in a brief timeframe, contributes to as much as 39% of total wear across both initial and steady wear phases. The primary mechanisms of wear in this phase are identified as adhesion and diffusion. To optimize the initial cutting conditions with the goal of reducing early tool wear, this research employs response surface methodology (RSM) and central composite design (CCD). Further, an analysis of variance (ANOVA) is utilized to evaluate the regression model of the cutting process, enabling the optimization of cutting parameters through empirical response equations and the development of a 3D model to visualize the effects.