Dry Machining Conditions Research Articles

An Investigation of the Effects of Cutting Edge Geometry and Cooling/Lubrication on Surface Integrity in Machining of Ti-6Al-4V Alloy

This investigation sought to characterize the combined influence of cutting-edge microgeometry and cooling/lubricating strategies on process thermo-mechanics and the resultant surface integrity in orthogonal machining of the Ti-6Al-4V alloy. Reverse waterfall cutting inserts were prepared with varying cutting-edge geometries, and machining experiments were conducted under cryogenic cooling with liquid nitrogen (LN2), minimum quantity lubrication (MQL), and dry machining conditions, using constant machining parameters. The induced surface integrity was characterized in terms of the developed cutting forces and through-thickness microhardness, grain morphology, dislocation generation, and residual stress formation. The experimental results revealed that the governing process physics are strongly influenced by variation in the implemented machining parameters. As a greater proportion of the cutting edge is distributed on the flank face, competing mechanical ploughing and thermal-based frictional effects both become more pronounced. Utilization of advanced cooling strategies to control cutting interface thermal gradients thus provides a processing route to generate tailored microstructures and surface integrity during the machining of this alloy.

Examination of Surface Hardness and Roughness of AISI 1050 Steel Material in Milling Based on Surface Processing Conditions

It is known that material hardness and surface conditions have a significant impact on the operating life of machine elements working with each other. In this study, Surface roughness values obtained depending on processing conditions and hardness changes on the machined surfaces during milling of AISI 1050 steel were examined. In experimental studies, ideal machining conditions were determined by taking into account surface roughness values and hardness changes using the Taguchi L18 experimental design method. In all experiments, it was observed that the lowest surface hardness was achieved under dry conditions when 6500 1/min speed, 4000 mm/min feed rate, and 0.4 mm cutting depth values were applied. When the speed increased from 5500 1/min to 6000 1/min and the feed rate increased from 4500 mm/min to 5000 mm/min, improvements in surface quality were observed in both machining conditions. In conclusion; In experiments where coolant was applied at high cutting speeds, it was determined that surface hardness and surface roughness values were higher than in dry machining conditions.

Surface topography and corrosion resistance of AISI 630 stainless steel after finish turning under different cooling methods

AISI 630 stainless steel (SS) is widely used for medical devices. This paper describes the effects of dry, flood and minimum quantity lubrication (MQL) machining conditions on the surface topography and corrosion resistance (CR) of AISI 630 SS after finish turning. Small areas of valleys and large areas of peaks were observed on the surfaces with minimum surface roughness (SRmin) after dry machining at the feed rate (f) of 0.1 mm/rev and at the f = 0.14 mm/rev using the MQL method. Only small areas of peaks were observed after flood machining at the f = 0.1 mm/rev. Regardless of cooling methods, regularly distributed deep valleys and high peaks were observed on the surfaces with maximum surface roughness (SRmax) machined at the f = 0.35 mm/rev. Surfaces of the samples with SRmin and SRmax under flood machining and with SRmax under MQL machining had high oxygen content in the range of ∼ (20−30) %wt. during 7–72 days of the sample storage in SBF. Such an oxygen content is observed on the machined surfaces for which maximum peak height Sp parameters were in the range of ∼ (10–16) μm and maximum valley height Sv – ∼ (8–10) μm. Compared to SRmin, high ion diffusion was observed on surfaces with SRmax. This means that surfaces with regular deep valleys and high peaks provide high ion mobility between them. In addition, compared to dry and MQL machining, higher resistivity was obtained for the samples under flood machining. Depending on the industrial application requirements, the passivity and CR of AISI 630 SS can be modulated by selecting machining conditions and surface topography. It has been established that in order to achieve favorable CR of the AISI 630 SS surface after finish turning, the flood method is recommended.

Comparative Study of Machining Parameters of Single and Double Cutting Tools During Turning of AISI 1045 Steel

Background:: The patent of cutting operations is carried out with a cutting tool that is fed parallel to or at right angles to the work axis. The main objective of this study is to minimize surface roughness and MRR. Objective:: The effect of cutting parameters on surface roughness and material removal rate is investigated using AISI 1045 steel as a workpiece material, and single and double carbide cutting tools are used under dry machining conditions. Methods:: The cutting speed, feed rate, and depth of cut are considered input parameters for experimental purposes. Taguchi L9 orthogonal array design of experiments is used for designing the experiments. Parameters are optimized using Taguchi L9 orthogonal design of experiments and Analysis of Variance (ANOVA). MINITAB 17 software is used to solve the coefficients of the regression model. Results:: The result indicates that the cutting speed was the most significant influencing factor that affects the surface roughness, followed by feed rate and depth of cut for both single and doublecutting tools. Conclusion:: The minimum surface finish for the best cutting parameter was 0.95 μm for a single and 0.92 μm for a double-turning tool. The highest material removal rates for single and double turning were 6456 mm3/min and 6603 mm3/min. The result shows that while using double tools, the rate of material removal rate increased and the machining time decreased.

Machinability investigation of grinding 2.5D-SiCf/SiC composites under nanofluid minimum quantity lubrication

SiCf/SiC composites are now the preferred option for the thermal structures of next-generation advanced aero-engines, owing to their high-temperature strength, and creep resistance. Grinding is currently a highly reliable and mature method for SiCf/SiC processing. However, the harsh, dry machining conditions lead to degradation of surface quality, and the dust generated can harm both humans and the environment. Nanofluid Minimum Quantity Lubrication (NMQL) maximizes heat transfer and lubrication in grinding and is environmentally and human-friendly. Based on this, this study thoroughly investigates the effects of dry, flood grinding, minimum quantity lubrication, and different nanofluids (MoS2 and carbon nanotubes (CNTs)) on grinding performance at different grinding depths. Compared with dry grinding, the results show that the normal grinding component force Fn is reduced by 56.9 %, 56.8 %, and 71.6 %, and the tangential grinding component force Ft is reduced by 48.4 %, 50.5 %, and 57.5 % for NMQL-CNTs lubrication condition at grinding depths of 0.2 mm, 0.4 mm, and 0.6 mm, respectively. Meanwhile, NMQL-CNTs can significantly improve the surface quality and help to obtain a surface morphology with fewer surface defects, and the stabilized lubricant film formed by NMQL-CNTs can significantly reduce the specific grinding energy. Although brittle removal was observed in different lubrication methods, NMQL-CNTs could significantly reduce surface damage due to their filling and friction reduction effects. Due to the high viscosity of NMQL-CNTs and the low intermolecular forces, they have strong lubrication stability and wear resistance. This study provides theoretical guidance for the green processing of SiCf/SiC composites.

Evaluation of the turning parameters of AISI 5115 steel in dry and MQL cutting environments with the use of a coated carbide cutting insert: An Experimental Study

This study investigates the effects of cutting parameters on turning AISI 5115 steel in both dry and MQL environments using a coated carbide insert. The cutting parameters are determined using a full factorial design. A comprehensive full factorial experimental design was executed in order to investigate the effect of cutting parameters, including cutting speed, feed rate, and depth of cut, on surface roughness, cutting force and cutting temperature. Following the completion of the turning trials, surface roughness measurements were meticulously recorded. Also cutting force and cutting temperature were measured. The results of the study indicated that the most significant influence on surface roughness is exerted by the feed rate. Moreover, the impact of the depth of cut became more significant as the cutting speed decreased. While the surface roughness increased by 23% in the dry environment due to the increased feed rate at low cutting speed, the increase in the MQL environment was 32%. The cutting temperature is influenced by a number of factors, including the cutting parameters and the material properties. The maximum temperature for turning in the MQL environment was 381°C compared with an average cutting temperature of 430°C in dry machining conditions. The application of high-speed cutting in a dry cutting environment was found to result in a 10% increase in cutting temperature. The influence of cutting speed on the outcome was less pronounced in the MQL environment. At high cutting speeds and low parameter values in the MQL environment, the cutting force decreased by 75% in contrast to the low cutting speeds and high cutting parameters in the dry environment. The optimal cutting conditions for minimising cutting force were identified in the MQL environment, characterised by high cutting speeds and low feed rates.

Internally cooled tools as an innovative solution for sustainable machining: Temperature investigation using Inconel 718 superalloy

Machining is a process that involves intense heat generation at localized points within the tool-chip interface. This leads to elevated temperatures, which can be detrimental to cutting tools. This issue becomes even more crucial when dealing with superalloys like Inconel 718, as they exhibit high shear strength and good creep resistance. Consequently, a significant amount of energy is expended, increasing the cutting temperature. Until now, the primary technique employed to address this issue has been using Cutting Fluids (CFs). In machining, a portion of costs is attributed to fluid handling. It also contains harmful elements that can pose health risks, potentially leading to conditions such as cancer. Moreover, the toxic components can contribute to environmental degradation when improperly disposed of. Therefore, this study proposes an innovative cooling technique called Internally Cooled Tools (ICTs). The ICTs employ an internally circulating coolant fluid through closed cooling channels within the cutting tools, eliminating fluid dispersion into the atmosphere. The main objective was to compare the performance of ICTs in controlling the tool-chip interface temperature during Inconel 718 turning using hard metal tools. For this purpose, a complete factorial experimental design (25) was utilized, with the response variable being the temperature measured by the tool-work thermocouples technique. Beyond that, a sustainable assessment was performed using the Pugh Matrix method. Many key sustainable factors were evaluated related to three atmospheres, cutting fluids in abundance – CFA, dry machining, and ICT. The data base used was a depth literature investigation together with results found in this work. The main findings of this entire work demonstrated that an increase in cutting parameters corresponded to an increase in temperature, as anticipated. TiNAl coating reduced the temperature by up to 10% compared to uncoated tools. Similarly, applying ICTs led to temperature reductions of up to 17% compared to dry machining conditions. The Pugh Matrix made considering 12 factors showed that ICT (14 points) was the most sustainable lubri-cooling method in comparison to CFA (3) and DM (5). Ultimately, ICTs showed to be a promising eco-friendly method. It outperformed conventional methods, showcasing a remarkable heat dissipation capacity. As a result, further studies are warranted to delve deeper into this promising approach.

Enhancing machining performance of EN24 steel with CVD diamond coated tool and minimal quantity lubrication

The research aims to investigate the effect of chemical vapour deposition (CVD) diamond coatings on cemented tungsten carbide (WC-Co) inserts when machining EN24 steel. In addition to the diamond coating, the research also incorporates the use of minimal quantity lubrication (MQL) technique during the machining process. The research involves experimental studies to evaluate the machinability characteristics of EN24 steel using tungsten carbide cutting inserts with diamond coatings and MQL. Diamond-coated tools are extremely effective in machining EN24 steel, particularly in applications requiring high precision, wear resistance, and long tool life. They are commonly used in industries such as aerospace, automotive, and manufacturing, where quality and durability of the machined components are critical. L12 orthogonal array was used to design experiments with the type of cutting insert used, test condition and cutting speed as control factors. Various parameters such as tool wear, cutting temperature and surface roughness were measured and compared with conventional machining techniques. The results reveal that average flank wear of cutting inserts decreased by 67.4% as a result of MQL when compared with dry machining conditions. Average flank wear decreased by 77.6% after diamond coating were applied compared with uncoated inserts. Diamond coated inserts subjected to MQL exhibit largest percentage reduction of 74.11% for surface roughness when compared to uncoated inserts. The average cutting temperature decreased by 53.09% due to MQL compared to dry machining.

Impact of cryogenic treatment on the performance of coated tungsten carbide inserts during machining of EN24 grade alloy steel

AbstractToday's industries need to be more productive, especially those that shape and machine materials. As a result, engineers and scientists are seeking for cutting tool materials and technologies that have high hot hardness, chemical stability, wear resistance, and toughness while also improving tool life or contact time. Cryogenic treatment of cutting tools has been proven to be a good way for increasing the contact time of any cutting tool material. This study presents the results of turning alloy steel (EN24 grade) using P20 grade carbide inserts under various conditions under continuous machining. Cutting speeds varied from 100 to 500 m/min (in increments of 100 m/min), with feed rates ranging from 0.1 to 0.4 mm/rev in stages of 0.1 mm/rev and a constant radial depth of cut of 1.5 mm were considered under dry machining conditions. Cryogenic treated/coated inserts are better than other inserts in terms of tool life for optimized parameters such as cutting speed 100 m/min, feed rate 0.1 mm/rev, and depth of cut 1.5 mm, according to the study's findings. Under similar conditions of cutting speed, feed rate, and depth of cut, coated/cryotreated inserts had a tool life increase of about 97.5% over uncoated/untreated inserts, a 50.58% increase over uncoated/crytreated inserts, and a 23.89% increase over coated and untreated inserts, respectively.

Assessment of Machinability of Ti6Al4V Alloy Under Dry Conditions

Titanium alloys pose significant challenges during machining, necessitates a thorough investigation into the impact of process parameters on machining Ti6Al4V alloy. This study investigates into the machinability of Ti6Al4V alloy under dry machining conditions using uncoated tools. The experimental design studiedthe effect of process parameters on the cutting power, surface roughness and material removal rate during dry machining of Ti6Al4V alloy. Utilizing Taguchi design of experiments, unified cutting experiments were conducted under dry conditions employing uncoated tools. The study findings revealed that optimal cutting parameters lead to improved cutting energy consumption, reduced tool wear, and enhanced surface finish and material rates. Analysis of Variance (ANOVA) and regression modelling were employed to obtain an objective function capable of predicting the best cutting conditions. ANOVA showed that cutting speed is the main factor for an increase in the cutting power with major contribution of 73 % whereas feed rate is the key factor for surface roughness with the contribution of 80 %. These results help to gain the advantages of dry machining under optimal conditions, facilitating clean production with minimal energy consumption and improved surface quality.

Investigating the supremacy of PVD S3p deposition over HiPIMS for AlTiN coating

Dry machining of Duplex Stainless Steel 2205 (DSS2205) is a challenging task due to difficulties including high cutting temperatures, work hardening tendency and Built-up Layer (BUL) formation. Moreover, the high demand for DSS stresses improving machining productivity and quality. This study focuses on inspecting the supremacy of the PVD Scalable Pulse Power Plasma (S3p) coating deposition technique, which is rarely used for dry machining DSS, over High Pulse Impulse Magnetron Sputtering (HiPIMS) to deposit AlTiN coatings. A combination of evaporation and sputtering used for S3p dominated over HiPIMS. After a machining length of 6240 mm, the AlTiN (HiPIMS) coatings were unable to sustain the dry machining conditions, exhibiting faster tool wear rates than the AlTiN (S3p) coatings. As a result, AlTiN (S3p) exhibited a tool life of 8840 mm, 1.6 times higher than the AlTiN (HiPIMS) coating. The effect of decreasing tool life at any selected cutting speed was more severe at higher feed rates (0.19 mm/rev). The tool life decreased by 56%, 32% and 23% for the uncoated, AlTiN (HiPIMS) and AlTiN (S3p) tools, respectively. The surface roughness and cutting force were found to decrease by a notable 13% and 10%, respectively, due to the excellent properties of AlTiN (S3p) coatings compared to AlTiN (HiPIMS) coatings.

Influence of laser parameters on the machining performance of textured cutting tools

Over the past three decades, surface texturing has garnered significant interest as a method of controlling friction and wear in tribological systems. Surface textures play a significant role in reducing friction under dry machining conditions by lowering adhesion, decreasing the effective area of contact, and collecting wear particles. However, the effect of various laser parameters on the machining performance of textured tools is still unclear. In this research study, linear textures have been fabricated on the rake surface of uncoated carbide tools using the Nd:YAG laser by varying the laser parameters. The effect of the laser parameters, such as fluence and the average number of pulses per surface spot has been evaluated in terms of depth of textures, resolidified layer, and change in substrate hardness. The textured tools have been further used for turning the pH 13–8 Mo SS (UNS S13800) alloy under dry and wet conditions. The machining outcome results obtained with the textured tools have been compared with the plain tool. The turning experiments showed that textured tools helped in improving the machining performance by reducing the cutting forces, cutting temperature, surface roughness, and tool wear. In this research work, the textured tools fabricated with the combination of fluence = 31.4 J/cm2 and pulses per surface spot = 5 pulses/surface spot have outperformed the other textured tools fabricated with the combination of different laser parameters in terms of machining performance.

The Effect of the Surface Topography of High-Speed Steel Cutting Blades Made Using Various Methods on Their Technological and Functional Properties.

Indication of the proper scope of application of high-speed steels (HSS) produced by conventional methods and powder metallurgy for cutting tool blades requires a thorough assessment of their properties in various cutting conditions. According to common knowledge, the properties of tools made of both types of steel are largely determined by the arrangement of carbide phases. It turns out, however, that the surface morphology of the cutting blades is at least as important for their operational properties. This was already indicated by the preliminary research of the authors of the article, in which it was found that the surface topography significantly affects their durability depending on the applied value of the cutting speed in dry machining conditions and in the presence of a cooling lubricant. As it turned out, contrary to the literature data, blades made of sintered HSS do not have better service properties in all cutting conditions than blades made by conventional methods (e.g., in forging and hot rolling processes). Hence, it was necessary to determine the justified range of use of both types of steel for cutting blades. Cutting blades with a similar chemical composition from conventional high-speed steel and those produced in the powder metallurgy process were tested. Wear curves were determined on the basis of the tests. On this basis, for the assumed value of the blunting index, the tool life of the cutting edges was determined during the cutting of selected structural steel, commonly used for high-strength machine parts. Tests of the cutting ability of the blades were carried out without and with the use of a cooling--lubricating liquid. In order to correctly interpret the obtained results of the wear and durability tests of the cutting edges, verification tests were carried out. A detailed analysis of the research material made it possible to determine the recommended range of applicability of conventional and sintered HSS for the tested case.

Investigation of Surface Roughness Changes in The Machining of Carbon Steel Under Sustainable Conditions

In this study, surface roughness analysis was performed in the turning of C45 steel underMinimum Quantity Lubrication (MQL) and dry machining conditions. For this purpose, turningexperiments were carried out using two different cutting speeds and feed parameters. In order to improvethe machinability of C45 steel, which is one of the most used industrial materials, a graphical and statisticalevaluation was made as well as the optimization approach. With three different evaluations, both thepositive effect of MQL on the roughness in the turning process has been explained and differentperspectives have been created for C45 steel in terms of surface roughness. The optimum values of the bestsurface roughness were determined and the cutting conditions was revealed as the most important parametereffecting the roughness by analysis of variance.

Effect of casting modification materials on cutting forces of an Al12Si alloy used in aircraft technology

Abstract In this study, the effect of modification Al-12Si (Etial 140) casting alloy with Al10Sr, CuSn5, and Al10Sr + CuSn5 master alloys has been investigated with respect to the cutting forces. In order to characterize the morphology of materials used in this study, metallography, hardness, density tests, and chemical analysis were performed. An optical microscope was used to examine the microstructure of the samples. Machinability tests were performed with the turning method by using a titanium diboride-coated cementite carbide cutting tool. All experiments were carried out under dry machining conditions with three different cutting speeds and feed rates with a constant cut depth. After the turning test, scanning electron microscope (SEM) images were used to examine the build-up edge (BUE) formation on the cutting tool. It was determined that the modification process has a positive effect on increasing the density and hardness. According to the results, it was observed that cutting (Fc), feed (Ff), and tangential (Fr) forces decreased for all material groups with increasing cutting speed V. Furthermore, Fc, Ff, and Fr forces increased for all material groups with increasing feed rate f. Finally, the highest cutting forces were observed on the Etial 140 c + Al10Sr master alloy.

Investigation on Machinability Characteristics of Inconel 718 Alloy in Cryogenic Machining Processes

In this innovative work, Inconel 718 alloy turning simulation models under dry and cryogenic machining (Cryo) conditions are developed. The machinability characteristics of the aforementioned alloy were assessed with relation to cutting temperature (Tct) and cutting force (Fcf). The comparison of the Tct and Fcf results from simulation with those obtained under the identical experimental conditions served as additional evidence of the effectiveness of the suggested simulation model. By varying the cutting speed, the reduction in Tct under Cryo conditions was 9.36% to 11.98% compared to dry cutting. Regarding the force comparison under experiment and simulation, the average difference between the simulation and experimental values for the main cutting force (Fc) was 13.73%, whereas the average deviation for the feed force (Ff) was 14.63%. Response surface methodology (RSM) was employed to build the forecasting models for Tct and Fcf in cryogenic settings. These mathematical models showed excellent predictive performance and were able to estimate the Tct and Fcf under machining operations settings, according to the present research. When compared to dry cutting, Cryo reduced the cutting temperature, which had a positive impact on the alloy’s machinability.

A Comparative Machinability Study of SS 304 in Turning under Dry, New Micro-Jet, and Flood Cooling Lubrication Conditions

The main objective of this experimental investigation is to examine favourable machining conditions by utilising fewer resources of machining industries for the techno-economical and ecological benefits. The machining operations are performed in turning SS 304 using coated carbide tool inserts under dry, water-soluble cutting fluid solution in the form of flood cooling and small-quantity lubrication (SQL) conditions by employing a newly formed micro-jet for a comparative classical chips study and analysis. The machining experiments are conducted in turning by a 25 kW precision CNC lathe with a special arrangement of micro-jets into the machining zone. Machining speeds and feed rates are varied under dry, micro-jet, and flood cooling conditions and their effects are studied on the type of chips and their morphology, chip reduction coefficient (ξ), and chip shear plane distance (d). The effect of machining environments on tool health conditions (such as BUEs, tool-edge chipping, and edge breaking) is examined for the inferences. In the range of low-speed machining (less than 600 m/min), metal cutting seems easier in flood cooling conditions, but it imposes more unfavourable effects (such as edge chipping and edge breaking) on the ceramic cutting tool’s health. On the other hand, the dry machining condition shows a favourable performance for a ceramic cutting tool. The optimum machining condition is found in the micro-jet SQL by the analysis of experimental data and observation results for the tool and work combination. The analysis of the results is carried out by the response surface methodology (RSM) and artificial neural network (ANN). The ANN model is found to be more accurate than RSM. The aspects of effective green machining are emphasised.

Environmental, economical, and machinability based sustainability assessment in hybrid machining process employing tool textures and solid lubricant

Different techniques can be employed to improve the sustainability and machinability characteristics of a machining process. The sustainability assessment analyzes different aspects and indicators of an operation, including environment (energy consumption and carbon emission), economy (cost and production rate), and social (operator health and safety). The comparison of machining techniques based on sustainability assessment requires quantitative evaluation of indicators and sustainability index (SI) based on machining characteristics.Current research employs two main techniques of tool textures (on dual tool faces) and solid lubricant during the external grooving operation to make a sustainable hybrid process. Tool textures include pit-shape and linear patterns fabricated on rake and clearance faces.Results showed that in the case of energy consumption, the linear textured tool with solid lubricant consumed the minimum value by about 10.7 kJ. In the case of carbon emission, linear textured tool in dry machining conditions emitted about 0.008 kg-CO2 which was the minimum value. In the case of cost, a linear textured tool in dry machining conditions required 0.118 $ which was the cheapest process. In the case of production rate, the linear textured tool with solid lubricant presented the highest production rate by about 1773 parts/shift. On average, textures achieved about 23 higher SI values whereas solid lubricant reduced SI by about 13. Finally, linear texture in the dry condition achieved the most considerable value of the SI (52.5) and was selected as the best sustainable machining operation.

Experimental Study of MQL Performance on the Titanium Material Drilling Process

This titanium material is very difficult to machine due to its low thermal conductivity resulting in heat generated when machining accumulates in the cutting zone. This causes the thermal effect to be absorbed in the drill tool so that the tool wears out quickly which affects the quality of the hole. This study aims to examine the effect of tool wear on the cutting force of hole quality under dry machining conditions and machining using the MQL method. The cutting force resulting from the process of drilling holes using MQL is smaller than drilling in dry conditions. The larger the feed (f), the greater the cutting force (N) that is generated during the drilling process in dry conditions and MQL conditions. The greater the cutting speed (v) used during the drilling process, the lower the cutting force generated

High-speed face milling of AZ91 Mg alloy: Surface integrity investigations

Magnesium (Mg) alloys are popular in the aerospace and automotive sector owing to their light-weight aspects. Amongst various Mg alloys, AZ91 alloy behaviour under machining has been trending and needs to be completely explored. The selection of optimal machining parameters is an important decision making process to achieve highest quality along with reduced cost and time. In this regard, this article describes experimental investigations to evaluate the performance of face milling operations on the surface characteristics of AZ91 magnesium alloy. The experiments were carried out with uncoated and PVD (Physical Vapour Deposition) coated carbide inserts at three levels of cutting speed (500, 700 and 900 m/min), feed rate (0.1, 0.2 and 0.3 mm/teeth) and depth of cut (0.5, 1.0 and 1.5 mm) under dry machining conditions. Major surface integrity indicators, such as roughness, hardness, residual stresses and microstructure are analysed. Chip morphology is also analysed and the correlation between chips and machined surface roughness is established. Face milling operation significantly improved surface roughness and microhardness of this alloy. Roughness improvement up to 85% (0.067 μm) and hardness improvement up to 33% (91.8 HV) is observed from the use of uncoated carbide inserts. Whereas, from PVD coated inserts, roughness improvement up to 81% (0.083 μm) and hardness improvement up to 60% (111.2 HV) is achieved. A similarity in behaviour between the two types of insert conditions are observed with increase in roughness from feed increase and decrease in hardness from cutting speed increase. Microstructural analysis showed PVD coated insert conditions producing surface with no defects, when compared to the crack observed in the surface from the use of uncoated carbide inserts. Marginally higher compressive residual stresses are detected at the surfaces from use of the uncoated inserts. Overall, due to no surface defect and the significant improvement in hardness and roughness from the PVD coated inserts, they are recommended for use in face milling operation for the cutting conditions investigated in this study.