Abstract
Cutting tool performance based on flank wear and tool life, surface roughness, volume of chip removal and economical feasibility in machining AA 6063 using uncoated and multilayer (TiN/TiCN/Al2O3/ZrCN) coated carbide inserts under dry cutting environment was investigated. Experimental results revealed that the tool life of coated carbide insert was approximately 8.75 times higher than that of the uncoated carbide insert under similar cutting conditions. Mechanical abrasion was the dominant wear mechanism for the coated carbide insert and progression of wear was steady; however, the rate of growth of wear for uncoated carbide insert was rapid. From ANOVA, the feed was found as the most significant parameter for the surface quality characteristics (Ra, Rz and Rt), followed by cutting speed. Multi-response optimisation for Ra, Rz and Rt using grey relational analysis revealed that the optimal parametric combination was 0.16 mm, 0.04 mm/rev and 110 m/min for depth of cut, feed and cutting speed respectively.
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