An Experimental Study and Parameters Optimization on Duplex Turning of Titanium Alloy

The present article focuses on analyzing the cutting behavior of the duplex turning process for turn-cut machining of aerospace material, especially for titanium alloy. The experiments are conducted on a homemade setup that was mounted on a lathe machine. Each experiment was replicated twice to avoid variability, and a total of 31 experimental data are collected according to the Central Composite Rotating Design matrix. The feed rate, cutting velocity, and depth of cuts (primary and secondary) are taken as control parameters, while the average surface roughness, primary cutting force, and secondary cutting force are taken as response parameters. The experimental data are used to develop an empirical model using Response Surface Methodology (RSM). The developed RSM model has been experimentally tested and used to generate the response surfaces for parametric studies. Finally, the responses are optimized using D-optimality criteria, and the optimal results are experimentally validated. The result shows that RSM models are well fitted with experimental values with percentage errors of 5.03, 4.77, and 4.87 % for the Fp, Fs, and Ra, respectively. Furthermore, the optimal cutting condition shows significant improvement in the responses, i.e., 4.22, 3.72, and 2.85 % for the Fp, Fs, and Ra, respectively.