Optimization of Polygonal Shaft Machining Parameters for Surface Roughness, Dimensional Error, and Cycle Time using Response Surface Methodology

Umi Hanifah; Novrinaldi; Moeso Andrianto; Satya Andika Putra; Aidil Haryanto; Andi Taufan; Maulana Furqon; Eko Kuncoro Pramono; Yusnan Hasani Siregar; Diang Sagita; Ma'muri; Muizuddin Azka; Nur Arifudin Rofik; Syahrul Rhamadhan

doi:10.15282/ijame.22.4.2025.8.0985

Authors

U. Hanifah Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
Novrinaldi Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
M. Andrianto Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
S. A. Putra Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
A. Haryanto Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
A. Taufan Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
M. Furqon Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
E. K. Pramono Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
Y. H. Siregar Research Center for Smart Mechatronics, National Research and Innovation Agency, 40135, Bandung, Indonesia
D. Sagita Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
Ma'muri Research Center for Equipment Manufacturing Technology, National Research and Innovation Agency, 15314, Tangerang Selatan, Indonesia
M. Azka Research Center for Manufacturing Technology of Production Machinery, 15314, Tangerang Selatan, Indonesia
N. A. Rofik National Research and Innovation Agency, 15314, Tangerang Selatan, Banten, Indonesia
S. Rhamadhan Faculty of Engineering, Lampung University, 35141, Bandar Lampung, Indonesia

DOI:

https://doi.org/10.15282/ijame.22.4.2025.8.0985

Keywords:

Response surface methodology, Turn-milling, Polygonal shaft, Dimension error, Time cycle, Surface roughness

Abstract

In power transmission, the shaft is a crucial component. During development, the cross-sectional features of the shaft are defined using specific geometric shapes, such as polygonal profiles, which require precision machining. This study examines the effects of machining parameters on surface roughness, dimensional accuracy, and machining time during the manufacture of polygonal shaft models made from AISI 304 and AISI 1020 materials. An experimental design, analysis, and optimization were employed using response surface methodology (RSM). Input parameters include cutting depth and cutting speed, while response parameters include surface roughness, dimensional error, and cycle time. Additionally, analysis of variance is used to determine the significance of input variables on response variables. The experiment began with a machining simulation in Esprit CAM software, followed by machining on a CNC Turn-mill machine. The workpiece was inspected using a surface roughness tester and a Coordinate Measuring Machine (CMM). The shortest machining time with the best machining quality per polygonal shaft standard was selected. Analysis of variance revealed that the input variables had a significant impact on surface roughness and cycle time (p-value < 0.0001). However, they did not significantly affect dimensional error. The most influential parameter on the response of both materials was the depth of cut. AISI 304 material yields the best surface roughness value of 0.3637µm at a cutting speed of 48 SPM and a depth of cut of 0.6 mm, while 1020 material yields 0.4045 µm at a cutting speed and depth of cut of 48 SPM and 0.6 mm. In contrast, 3.96 minutes and 5 minutes are the ideal machining times found for each material.

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