Investigating the effect of cutting conditions and tool geometry on surface roughness in dry end milling of Inconel 625 using TiAlSiN ultra hard coated solid carbide tool

Abstract

ABSTRACT In aerospace and submarine industries, mechanical parts are designed & developed using nickel-based alloys, such as Inconel 625. In such applications, severe work hardening occurs, leading to poor surface quality. In this context, this study was conducted using an end mill with PVD TiAlSiN coating, under dry conditions, wherein four input variables were considered. Rotatable CCD technique of DoE was used to conduct the experimental plan. RSM was applied to develop a second-order mathematical model, with roughness parameter and process parameters to establish the relationship between them. ANOVA was carried out to test the significance of the model. From the model, it was observed that both the feed per tooth and radial depth of cut have a significant effect on surface roughness. Further, the interaction between the cutting speed and feed per tooth was also found significant. The study also demonstrated that the coated carbide tool has the potential to eliminate the usage of cutting fluid, thus taking care of the environmental concerns, as far as machining operations are concerned.