Optimization of Dry Turning Parameters for AISI 1026 Steel Using Taguchi Design and ANOVA

Abstract

Despite its widespread use in hydraulic and automotive components, AISI 1026 steel has been understudied in dry turning, with contradictory findings on the dominant machining factors and limited multi-response optimization research. This study addresses this gap by experimentally investigates the optimization of cutting parameters (spindle speed, feed rate, and depth of cut) for surface roughness, material removal rate (MRR), tool tip temperature, machining time, and tool wear, during dry turning of AISI 1026 steel using a carbide tool. The experiments were designed using a Taguchi L9 orthogonal array, and results were analyzed using analysis of variance (ANOVA). The optimal cutting conditions were identified as a spindle speed of 1100 rpm, feed rate of 0.05 mm/rev, and depth of cut of 0.2 mm, producing a surface roughness of 1.063 μm, MRR of 4148.63 mm³/min, tool tip temperature of 57.6 °C, and machining time of 0.717 minutes. The findings show that tool tip temperature rises with spindle speed and feed rate, machining time is mainly influenced by feed rate (64.82%) and spindle speed (29.62%), and tool wear increases with higher tool tip temperatures This research contributes a high-precision optimization framework for AISI 1026, establishing a technical basis for enhancing productivity and surface integrity in sustainable as well as coolant-free manufacturing environments.