In this work experimental investigation is carried out to study the effect of process

parameters such as spindle speed and feed, depth of cut on surface roughness, power
consumption and machining time during the turning of Phosphor Bronze PB2 using PVD
coated carbide insert. Design of experiments adopted and optimize combination of process
parameter chosen using response surface methodology. Optimization of the process parameters
for minimization of surface roughness, power consumption and machining time done with
Genetic Algorithm optimization.
The present work concerned an experimental study of turning on PB2 by a TNMG coated
carbide insert tool. The primary objective of the ensuing study was to use the RSM in order to
determine the effect of machining parameters viz. cutting speed, feed, and depth of cut on the
surface roughness, power consumption and machining time of the machined material. The
experiment was conducted in an experiment matrix of 15 runs designed using a box Behenken of
RSM Design of Experiment. Surface Roughness was measured using a MITUTOYO SJ-210
Surface tester, Power Consumption is found with Power Capacity Analyzer and machining time
with stop watch. The data was compiled into MINITAB for analysis. The relationship between
the machining parameters and the response variables were analyzed using the RSM. Genetic
algorithm was used to investigate the significance of these parameters on the response variables,
and to determine a optimum values for the response variables with the machining parameters as
the independent variables. Contour plots and main effects plots from the RSM were obtained and
studied. The surface finish was improved as cutting speed was increased and deteriorated with
feed rate. The optimum parameter setting for better surface finish is obtained at middle level of
cutting speed, feed rate and depth of cut. When the cutting speed increases with feed rate and
depth of cut, higher power is required for the deformation of material within short period of time.
Machining time varies inversely with feed rate. As feed rate increases time decreases drastically.
As speed increases machining time goes on decreasing. Response surface methodology gives
optimum results with medium speed, high level feed and low level of depth of cut. Genetic
algorithm validate the RSM data and gives optimal solution which is closer to RSM optimum
values.