OPTIMUM FLANK WEAR OF TiAlN-COATED TOOL: TOWARD PRODUCTIVE ROUGH CUTTING OF INCONEL 625

Abstract

Long tool life and high material removal rate (MRR) are the two essential requirements in rough cutting of materials. The rapid rate of the flank wear propagation in machining of nickel-based superalloys has induced the utilization of low cutting parameters when the goal was set to maximize the tool life based on the machining time or cutting length. However, this method may not provide an effective rate for the material being cut. This work presents two mathematical models to find the optimum cutting parameters results for the minimum flank wear and maximum MRR. Experimental tests were carried out based on the central composite design (CCD) in rough cutting of Inconel 625 by using TiAlN-coated insert. Maximum flank wear was measured to determine the tool wear propagation. The wear mechanisms which contribute in the tool wear were analyzed by using scanning electron microscope (SEM) to evaluate the effects of cutting parameters on the flank wear propagation. The results showed that cutting speed and depth of cut had the most significant effect on the tool wear. However, optimum cutting condition was achieved by reducing the cutting speed when feed rate and depth of cut maintained at the highest level. This was associated to the interaction of cutting speed and depth of cut, and predominant of abrasion and notching at their highest levels, respectively.