Machinability of GG25 gray cast iron using carbide inserts

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This study examined the machinability of GG25 gray cast iron with carbide inserts in the CNC milling process. Cutting parameters were selected as feed rate, cutting speed, and depth of cut, while response variables were chosen as surface roughness, force, and power. The experimental design was made using Taguchi L27 full factorial array. The utilization of response surface methodology and analysis of variance was employed to assess the outcomes. Furthermore, ballbar tests were conducted to optimize the performance of the CNC milling machine without the necessity of chip removal, thereby enhancing the overall efficiency of the machining process. According to the study's findings, surface roughness was measured in the range of 1.29–4.27 µm, cutting force was determined in the range of 14–262 N, and power was calculated from 1116 to 4115 W. Based on the results, the feed rate and depth of cut had the most influence on the output characteristics. The effect of feed rate on the surface roughness, cutting force, and power is 82.37 %, 18.68 %, and 27.24 %, respectively. The impact of cutting depth on the Ra, Force, and Power is 11.15 %, 68.82 %, and 49.34 %, respectively. The experimental data show that power and force increase as the feed rate, depth of cut, and cutting speed rise, while feed rate is the only dominant factor on the surface roughness. The obtained regression equations show that the output parameters could be predicted with at least 91 % accuracy. Based on the response optimizer, the optimum cutting parameters for machining the GG25 gray cast iron with carbide insert are calculated as Vc: 300 m/min, f: 2000 mm/min, and a: 0.1 mm.