Optimization of Sustainable Production Processes in C45 Steel Machining Using a Confocal Chromatic Sensor

Metal machining production faces a myriad of demands encompassing ecology, automation, product control, and cost reduction. Within this framework, an exploration into employing a direct inspection of the machined area within the work zone of a given machine through a confocal chromatic sensor was undertaken. In the turning process, parameters including cutting speed (A), feed (B), depth of cut (C), workpiece length from clamping (D), and cutting edge radius (E) were designated as input variables. Roundness deviation (Rd) and tool face wear (KM) parameters were identified as output factors for assessing process performance. The experimental phase adhered to the Taguchi Orthogonal Array L27. Confirmatory tests revealed that optimizing process parameters according to the Taguchi method could enhance the turning performance of C45 steel. ANOVA results underscored the significant impact of cutting speed (A), feed (B), depth of cut (C), and workpiece length from clamping (D) on turning performance concerning Rd and KM. Furthermore, initial regression models were formulated to forecast roundness variation and tool face wear. The proposed parameters were found to not only influence the machined surface but also affect confocal sensor measurements. Consequently, we advocate for the adoption of these optimal cutting conditions in product production to bolster turning performance when machining C45 steel.