Aluminum alloys are employed in agricultural equipment, aerospace sectors,
medical instruments, machinery, automobiles, etc. due to their physical and
mechanical characteristics. The geometrical shape and size of the parts are
modified in turning operation by using a single-point cutting tool. A356
aluminum alloy is widely used in various engineering sectors, hence there is a
necessity to produce A-356 components with quality. The inappropriate cutting
parameters used in turning operation entail high production costs and reduce
tool life. Box–Behnken design (BBD) based on response surface methodology (RSM)
was used to design the experiments such that the experiment trials were
conducted by varying cutting parameters like N-spindle speed (rpm), f-feed rate
(mm/rev), and d-depth of cut (mm). The multi-objective responses, such as
surface roughness (SR) and metal removal rate (MRR) were analyzed with the
desirability method. The analysis of variance (ANOVA) represents the significant
factor for each response, whereas the desirability approach focuses on a single
optimal cutting parameter setting to achieve both responses with a better level
of accuracy. The most favorable turning parameters N: 713.563 rpm (715 rpm), f:
1 mm/rev, and d: 1 mm was determined in the desirability approach to enhance
results of SF: 2.511 μm and MRR 25.145 gm/min. The validation test was executed
with predicted factors, such that the experiment results form a better agreement
with the predicted results. The determined cutting parameters settings are
advisable to machine the liquid metallurgical A-356 aluminum alloy castings.