Experimental analysis for optimization of process parameters in machining using coated tools

Abstract

Manufacturers are facing challenges in achieving high productivity and quality in manufacturing through machining. PVD-coated tools can control several machining challenges by enhancing hardness and abrasion resistance of the cutting tool. These tools facilitate turning operations in terms of efficiency, accuracy, and productivity by extending cutting performance and tool life. Aluminum bronze, a copper alloy valued for its mechanical, thermal, corrosion, and wear-resistant properties, finds application in diverse industries such as aerospace, automobile, marine, and electrical engineering, as well as in the creation of sculptures, decorative elements, and thermal devices. However, machining aluminum bronze presents common challenges, including achieving a smooth surface finish and minimizing high cutting force due to its inherent strength and abrasiveness. This research aims at identifying the optimal levels of cutting velocity, feed, and depth of cut to minimize surface roughness and cutting force during dry turning of wear-resistant high-strength CuAl10Fe5Ni5-C. PVD AlTiN-coated tools were utilized, which offer many advantages over others. Experiments were conducted through Taguchi’s L27 OA (orthogonal array) of factors. The results indicate that coated tools have superior performance in reducing surface roughness and cutting force. When it comes to designing and optimizing experiments, integrating PCA with Taguchi method is a potent strategy. Again, it was observed that feed is the most influential factor affecting responses.