EXPERIMENTAL STUDY ON THE SURFACE ROUGHNESS AND OPTIMIZATION OF CUTTING PARAMETERS IN THE HARD TURNING USING BIOCOMPATIBLE TiAlN-COATED AND UNCOATED CARBIDE INSERTS

Abstract

Machining of difficult-to-cut materials has always been a focus of research. In terms of surface roughness, it is one of the most important machinability indicators used to evaluate the performance of machining processes. This research aims to investigate the effect of biocompatible TiAlN-coated and uncoated carbide inserts, as well as the effect of cutting parameters such as feed, rotational speed, and depth of cut on surface roughness in the hard turning of M2 tool steel at 64 HRC. The central composite design is used to create the experimental layout. Surface roughness values are measured using separate experiments for coated and uncoated inserts. A quadratic model is selected, and an analysis of variance (ANOVA) is performed to test the adequacy of the developed model. From the ANOVA, it is found that feed and rotational speed are the most significant parameter while hard turning with TiAlN-coated and uncoated inserts, respectively. Cutting parameters are ranked according to their importance using the Pareto chart. The composite desirability function is employed to determine the optimal setting of cutting parameters to minimize the surface roughness and a confirmation experiment is conducted to validate the optimization results. Confirmation results are very close to the predicted value and the error between experimental and predicted results are 7.93% and 9.36% with TiAlN-coated and uncoated carbide inserts, respectively. TiAlN-coated carbide insert gives better surface roughness compared to an uncoated carbide insert.