Modeling and optimization of duplex turning of titanium alloy (grade 5) using Taguchi methodology-response surface methodology (TM-RSM)

Duplex turning is an innovative idea of metal cutting that shows potential to improve the productivity with better quality. In duplex turning, two cutting tools are used as parallel to each other and perpendicular to the workpiece axes for getting the desired surface quality in single pass turning operation. The use of two cutting tools makes the process very complex which requires optimal parameters to enhance the productivity with quality. In present work, the parameters are optimised by applying a Taguchi methodology (TM) and optimised parameters are utilised as central values for further analysis. The central data are used to collect the experimental results for response surface methodology (RSM) for modelling and optimisation of control parameters such as cutting speed, feed rate, primary depth-of-cut (DOC) and secondary-DOC to optimise responses as primary-cutting force, secondary-cutting force and average surface roughness using TM-RSM techniques. The result shows the significant improvement in the responses with TM-RSM approach as primary-cutting force = 18.67%, secondary-cutting force = 15.80% and surface finish = 13.30% than the TM optimised values.