An experimental study on boring of Inconel 718 and multi response optimization of machining parameters using Response Surface Methodology

Abstract

The main objective of the manufacturing processes is to reduce the production cost and make it environmental friendly. The manufactures focus on elimination or reduction of cutting fluids, and they achieved making dry cuttings using multi layered carbide cutting tools. In aeronautical applications, Nickel based super alloys are widely used and it is still considered to be difficult to machine materials. In this work, an attempt has been made to investigate machining parameters effect on surface roughness, tool wear, cutting forces on cutting tool and work piece vibration during dry boring of Inconel 718 with TiCN-Al2O3-TiN coated inserts using Response surface methodology (RSM). Piezo-electric dynamometer and laser doppler vibrometer was used for online data acquisition of cutting force and the work piece vibration. According to design of experiments, 18 experiments were performed and experimental results are analyzed with RSM to find out significant parameters that are affecting surface roughness (Ra), Flank wear (VB), cutting forces (Fx) and work piece vibration amplitude (VA). A Multi response optimization technique was used to identify optimum machining parameters for minimization of responses.