Abstract
The main aim of this research work is to investigate and optimise the performance of coated and uncoated cemented carbide end mill cutting tool while dry machining high hardness EN-8 grade steel. Three different end mill tools: one uncoated and the other two with 2–4 μm thickness of AlTiN coating and AlCrN coating, respectively, are used to process the EN-8 steel using a three-axis CNC milling machine. The coatings are applied using arc-PVD process. Pocket milling operation is performed on the workpiece. The effect of varying cutting parameters of cutting speed, depth of cut and feed rate, which influence the output parameters of surface roughness, temperature and material removal rate are studied. Optimisation of the output parameters is done using Taguchi Design of Experiments method with L9 orthogonal array of experiments for single-objective function of surface roughness. Fuzzy logic analysis method is used to predict the best optimal solution, and to find out the most influential parameter to determine the output characteristics. SEM and XRD analysis are studied to characterise the coated cutting tool and analyse the workpiece surface finish.
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