Title: Experimental investigation on cutting tool performance during turning AA 6063 using uncoated and multilayer coated carbide inserts

Authors: Dipti Kanta Das; Purna Chandra Mishra; Ashok Kumar Sahoo; Dipankar Ghosh

Addresses: School of Mechanical Engineering, KIIT University, Bhubaneswar, Odisha, 751024, India ' School of Mechanical Engineering, KIIT University, Bhubaneswar, Odisha, 751024, India ' School of Mechanical Engineering, KIIT University, Bhubaneswar, Odisha, 751024, India ' School of Mechanical Engineering, KIIT University, Bhubaneswar, Odisha, 751024, India

Abstract: Cutting tool performance based on flank wear and tool life, surface roughness, volume of chip removal and economical feasibility in machining AA 6063 using uncoated and multilayer (TiN/TiCN/Al₂O₃/ZrCN) coated carbide inserts under dry cutting environment was investigated. Experimental results revealed that the tool life of coated carbide insert was approximately 8.75 times higher than that of the uncoated carbide insert under similar cutting conditions. Mechanical abrasion was the dominant wear mechanism for the coated carbide insert and progression of wear was steady; however, the rate of growth of wear for uncoated carbide insert was rapid. From ANOVA, the feed was found as the most significant parameter for the surface quality characteristics (Ra, Rz and Rt), followed by cutting speed. Multi-response optimisation for Ra, Rz and Rt using grey relational analysis revealed that the optimal parametric combination was 0.16 mm, 0.04 mm/rev and 110 m/min for depth of cut, feed and cutting speed respectively.

Keywords: aluminium alloys; turning; uncoated carbide inserts; multilayer coated carbide inserts; grey relational analysis; GRA; cutting tool performance; flank wear; tool life; surface roughness; surface quality; chip removal volume; economical feasibility; dry cutting; dry machining; ANOVA; depth of cut; feed rate; cutting speed.

DOI: 10.1504/IJMMM.2015.071996

International Journal of Machining and Machinability of Materials, 2015 Vol.17 No.3/4, pp.277 - 294

Received: 01 Jul 2014
Accepted: 07 Mar 2015
Published online: 27 Sep 2015 *

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