Dry machining characteristics of coated inserts and multi response optimization through DEAR‐Taguchi method

Abstract

AbstractThe primary intent of the proposed research work is to investigate the effectiveness of the titanium aluminium nitride/tungsten carbide‐carbide coated insert during dry turning structural stainless steel. The aim of the study is to simultaneously optimise machining variables like spindle speed, depth of cut and feed for several responses like flank wear, material removal rate and surface roughness. Titanium aluminium nitride/tungsten carbide‐carbide is coated on the surface of carbide tool by cathodic arc evaporation method. The characterization studies have been conducted to ensure the existence of coating material. Micro hardness of coated and pure inserts was tested, which confirms that titanium aluminium nitride/tungsten carbide‐carbide coated insert possesses 17.43 % augmented hardness over pure inserts. The machining was performed by adopting Taguchi experimental design. A multi‐response optimization approach was applied in this study that included ranking methodology based on data development analysis and Taguchi's design. The performance index for multiple responses was measured and mathematically analysed for their effect on processing parameters. The combination of parameter such as spindle speed: 2000 min−1; cutting depth: 0.45 mm and feed rate: 0.16 mm rev−1 was experimental as optimal machining parameters.