Title: Optimisation and impact of process parameters on tool-chip interaction while turning of A286 iron based nickel superalloy

Authors: M. Venkata Ramana; G. Krishna Mohana Rao; M. Dheeraj Reddy; B.V. Raja Ravi Kumar; P. Ravi Kumar

Addresses: Department of Automobile Engineering, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad – 500090, India ' Department of Mechanical Engineering, JNTUH College of Engineering, Hyderabad – 500085, India ' Department of Mechanical Engineering, JNTUH College of Engineering, Hyderabad – 500085, India ' Department of Mechanical Engineering, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad – 500090, India ' Department of Mechanical Engineering, CMR College of Engineering and Technology, Hyderabad – 501401, India

Abstract: A286 alloy is a superalloy categorised under iron based nickel superalloy and this material is considered to be a difficult-to-machine material. In the present work, the process parameters' impact on tool-chip interaction in turning of A286 alloy is examined with two tool materials viz. uncoated and PVD coated tool inserts with sustainable dry turning process. Optimisation of turning process parameters is carried out with the analysis of mean to minimise the chip compression ratio and friction coefficient. The experimental results for optimisation indicate that the minimum chip compression ratio is 2.75 and the coefficient of friction is 0.366 attained with PVD coated insert tool. Results specify that PVD coated cutting insert is a superior tool material in turning of A286 alloy to decrease the chip compression ratio as well as friction coefficient when compared with uncoated tool material. Analysis of variance results indicate that the depth of cut is a more influencing parameter on the coefficient of friction and chip compression ratio with an uncoated tool, whereas feed rate is influencing high on chip compression ratio and friction coefficient with PVD coated tool. Regression models are developed to predict the chip compression ratio and friction coefficient.

Keywords: A286 alloy; optimisation; Taguchi's methodology; uncoated and PVD coated tools; chip compression ratio; coefficient of friction.

DOI: 10.1504/IJMMM.2022.122783

International Journal of Machining and Machinability of Materials, 2022 Vol.24 No.1/2, pp.48 - 67

Received: 21 Jul 2021
Accepted: 29 Oct 2021
Published online: 10 May 2022 *

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