AISI 1045 has been widely used in many industrial applications requiring good wear resistance and strength. Surface roughness of\nproduced components is a vital quality measure. A suitable combination of machining process parameters must be selected to\nguarantee the required roughness values. The appropriate parameters are generally defined based on ideal lab conditions since\nmost of the researchers conduct their experiments in closed labs and ideal conditions. However, when repeating these experiments\nin industrial workshops, different results are obtained. Imperfect conditions such as the absence of a turning tool with definite\nspecifications as shown in know-how â??tool nose radius 0.4 mmâ? and its replacement with the closest existence tool â??tool nose\nradius 0.8mmâ? as well as the interruption of cutting fluid during work as a result of sudden failure in the coolant pump lead to the\nmentioned different lab-industrial conditions. These complications are common among normal problems that happened during\nthe metal cutting process in realistic conditions and are called noise factors. In this paper, Taguchi robust design is used to select\nthe optimum combination of the cutting speed, depth of cut, and feed rate to enhance the surface roughness of turned AISI 1045\nsteel bars while minimizing the effects of the two noise factors. The optimum parameters predicted by the developed model\nshowed good agreement with the experimental results.
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