Cleaner Engineering and Technology (Jun 2021)

Optimization of surface roughness and tool wear in sustainable dry turning of Iron based Nickel A286 alloy using Taguchi’s method

  • M. Venkata Ramana,
  • G. Krishna Mohana Rao,
  • Bidya Sagar,
  • Ravi Kumar Panthangi,
  • B.V. Raja Ravi Kumar

Journal volume & issue
Vol. 2
p. 100034

Abstract

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Superalloys are categorized as difficult-to-cut materials. The machinability of these alloys is poor due to their hardness and non-availability of proper tool materials. The main aim of sustainable machining is to avoid or minimize the usage of cutting fluids to reduce the harmful effects of the cutting fluids and cost of the machining. This work is aimed to investigate the machinability of Iron-based Nickel A286 alloy with uncoated and PVD coated tool materials under sustainable dry machining. The experimental tests are performed by varying the cutting speed, feed rate and depth of cut to analyze the machinability of Iron-based Nickel A286 alloy concerning surface roughness, tool flank wear rate, and chip morphology. The SEM analysis is carried out to analyze the tool wear behavior. Results indicate that cutting tool with PVD coated is the best apt tool material for machining of Iron-based Nickel A286 alloy to reduce the surface roughness and tool flank wear rate when compared to the uncoated tool. From the results of optimization, the minimum surface roughness is 0.87 ​μm and the tool wear rate is 0.07 ​mm obtained with the PVD coated tool, it is also observed that, the PVD coated tool improved the surface roughness by 24% and tool wear rate by 12% as compared to uncoated tool. This is due to the TiAlN/TiN coatings and capable of withstanding high temperature and stresses produced during machining. From the results of AVOVA, the feed rate is contributing high on surface roughness with uncoated, and PVD coated tools. On the other hand, the depth of cut is contributing high on tool flank wear rate with the uncoated tool, cutting speed is influencing high on tool flank wear rate with PVD coated tool. Long continuous chips are produced in turning of Iron-based Nickel A286 alloy and chip thickness rises with an increase in depth of cut is noticed. The experimental results and predicted results with regression analysis using uncoated and PVD coated tools shows fairly good agreement for surface roughness and tool wear rate.

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