Experimental Investigation and Optimization of End-Milling Parameters in the Machining of Inconel 825 Using Carbide-Coated Tool

Abstract

In order to achieve reduction in machining cost and increase in productivity in machining processes, optimization of cutting conditions involving cutting speed, feed per tooth and radial depth of cut is very critical. In this study, optimization of cutting parameters with various performance characters that rely on the grey relational analysis with Taguchi method is performed in order to obtain minimum surface roughness and maximum material removal rate during dry end-milling process. The experiments were conducted on Inconel 825 material using carbide inserts, with physical vapour deposition and TiAlN coating. Sixteen experiments were conducted, based on the design of experiments with three factors constituting four levels each. The surface measurement was done using Talysurf. The optimal parameters achieved are cutting speed of 55 m/min, feed per tooth of 0.09 mm/tooth and the radial depth of cut, 1.2 mm. The analysis of grey relational grade indicated that the radial depth of cut is the more influential parameter, followed by the feed rate.