Tool life prediction by RSM for cryogenic milling of inconel 718

Abstract

PurposeThe purpose of this study is to present the tool life optimization of carbide-coated ball nose milling inserts when high-speed milling of Inconel 718 under cryogenic CO2 condition. The main aims are to analyze the influence level of each cutting parameter on the tool life and to identify the optimum parameters that can lengthen the tool life to the maximum.Design/methodology/approachThe experimental layout was designed using Box–Behnken RSM where all parameters were arranged without combining their highest and lowest values of each factor at the same time. A total of 29 milling experiments were conducted. Then, a statistical analysis using ANOVA was conducted to identify the relationship between the controlled factors on tool life. After that, a predictive model was developed to predict the variation of tool life within the predetermined parameters.FindingsResults from the experimental found that the longest tool life of 22.77 min was achieved at Vc: 120 m/min, fz: 0.2 mm/tooth, ap: 0.5 mm and ae: 0.2 mm. ANOVA suggests the tool life of 23.4 min can be reached at Vc: 120.06 m/min, fz: 0.15 mm/tooth, ap: 0.66 mm and ae: 0.53 mm. All four controlled factors have influenced the tool life with the feed rate and radial depth of cut (DOC) as the major contributors. The developed mathematical model accurately represented the tool life at an average error of 8.2 per cent when compared to the actual and predicted tool life.Originality/valueThese experimental and statistical studies were conducted using Box–Behnken RSM method under cryogenic CO2 condition. It is a proven well-known method. However, the cooling method used in this study is a new technique and its effects on metal cutting, especially in the milling process of Inconel 718, has not yet been explored.