Modeling and Optimization of Tool Wear in a Passively Damped Boring process using Response Surface Methodology

Regenerative chatter in machining process is a root cause for tool wear and poor surface finish resulting in low production rate. Hence research has to be focused to identify an opportunity to suppress these chatters. This investigation is attempted to reduce the tool wear in boring process by incorporation of shape memory alloy (SMA) mass dampers in boring tool. The copper and Zinc based SMA mass dampers were placed at various position of boring bar and the effect of damper position and machining parameters on the tool wear was studied. Boring process was carried out on grey cast iron pipe by varying the damper position (54, 64 and 74 mm), cutting velocity (25, 50 and 75 m/min) and depth of cut (0.2, 0.4 and 0.6 mm). The prediction model was developed to correlate the relationship between machining parameters and tool wear. The optimum damper position and machining parameters to minimize the tool wear was determined using response surface methodology (RSM). The confirmation test on the optimized value has witnessed efficient prediction of the damper position and machining parameters for reduced tool wear in boring process.