Optimization of Machining Parameters for C45 Steel in Vertical Machining Centers Using Response Surface Methodology: A Study on Surface Roughness and Material Removal Rate

Achieving optimal machining performance is crucial for maintaining a competitive edge in the manufacturing industry. This study addresses the challenge of optimizing machining parameters for C45 steel in a vertical machining center using Response Surface Methodology (RSM). The focus is on identifying the optimal spindle speed, feed rate, and depth of cut to enhance surface roughness and material removal rate (MRR). An analysis of variance (ANOVA) revealed that surface roughness is primarily influenced by the depth of cut (54.51%), followed by spindle speed (28.48%) and feed rate (15.82%). Conversely, MRR is predominantly affected by the feed rate (65.85%), followed by the depth of cut (29.27%) and spindle speed (2.44%). The study identified different optimized parameters for optimal surface roughness and MRR results. To minimize surface roughness, the optimal parameters were a spindle speed of 829.55 RPM, a feed rate of 165.91 mm/rev, and a depth of cut of 0.16 mm, resulting in a surface roughness value of 0.14 µm. To maximize MRR, the optimal parameters were a feed rate of 334.08 mm/rev and a depth of cut of 1.84 mm, yielding an MRR of 7379.87 mm³/min, with spindle speed having a negligible effect. These findings provide valuable insights for manufacturers aiming to optimize machining processes for C45 steel alloy. By strategically applying these optimized parameters, manufacturers can significantly improve surface quality and material removal efficiency, enhancing overall productivity in machining operations. EFDRE : Federal Democratic Republic of Ethiopia