Optimization of controllable turning parameters for high speed dry machining of a super alloy

Abstract

Turning operations were performed on Inconel 718, a Nickel based super alloy under dry cutting conditions using PVD coated carbide cutting tool. An optimized set of input parameters have be presented for obtaining the best combination of Tool wear, Temperature, surface roughness and Material removal Rate. The control factors that were investigated were Cutting speed, feed and Depth of cut. The chosen response factors are Flank Wear, Tool Tip Temperature, Surface roughness and Material removal rate. For each control factor 3 levels were selected, conducting 27 experiments in total according to full factorial design of experiments. Regression was carried out for the experimental results, where the mathematical model was found to be adequate enough. The mathematical models obtained for both the responses were used for formulating a multi objective optimization which was solved using Genetic Algorithm for optimized control factor values. The optimized solutions were confirmed with experimental results. In addition, tool life was also calculated for optimized solution. A user friendly application program was developed to suit the industry needs.