Implementation of Box–Behnken design to study the factors interaction impacts and modelling of the surface roughness of AL 6063 alloys during turning operations

This study focuses on the experimental investigation of the relationships between cutting parameters and their effects on surface roughness during the turning process of aluminum alloy 6063 when dry machining is used. In order to construct a model utilizing Box–Behnken Design and analyze the surface quality of the three machining variables, experiments were conducted. The factors employed in this study are input factors Spindle speed depth of cut and feed rate, in order to predict surface roughness. The experiment was designed by using Box–Behnken Design in which 17 samples were machined in a lathes machine. Each of the experimental results was measured using an SRT-6210S surface roughness tester. After achieving the data the Box–Behnken Design was used to predict the surface roughness. The ANOVA shows the significant factors and their interaction effects on the surface roughness and the model developed shows an accuracy of 95% which is realistically reliable for surface roughness prediction. With the obtained optimum input factors of 165 rev/min, depth of cut 1 mm, and feed rate 0. 5 mm/rev achieved predicted surface roughness of 9 μm. Therefore, the optimum input factors will greatly reduce the surface roughness and it will have improved manufacturing operations.