Mathematical models of material removal rate and power consumption for dry turning of ferrous material using dimensional analysis in indian prospective

Material removal rate (mrr) & power consumption (pc) prediction models using dimensional analysis (da) have been developed to examine the effects of machining field parameters. en1a,en8 and s.s.304 were considered as a ferrous material for the dry turning process. the da models of mrr & pc have been developed with machining field parameters. the parameters were the operator performing the turning operation,the cutting tool used to remove the material,the work piece,the cutting process parameters,such as cutting speed,feed rate,depth of cut etc.,and lathe machining specifications and the turning environmental parameters,such as humidity,atmospheric temperature,air circulation,noise level,and light illumination etc. the experiments were planned according to a random plan of experimentations and the seasonal conditions in india. the mathematical models with few variables can be easily formulated with traditional methods,such as response surface method (rsm). but it is seen that for large numbers of variables the traditional modelling tools could not be unproblematic in very less time. for this,an attempt has been made to formulate the model by using dimensional analysis techniques followed by the analysis,i.e.,optimization and sensitivity analysis. in order to develop da model,the buckingham's pi theorem (bpit) was used to group the variables. the linear programming using ms-solver was used to perform the optimization and the sensitivity analysis for the model developed. the results reveal that the cutting condition and the lathe machine parameters have significant effects on the material removal rate and the power consumption,while the tool and the environment have the least effect. the developed da models can be used for selecting the best set of input parameters which improve mrr and reduce pc. © 2015 jordan journal of mechanical and industrial engineering.