Optimization of Cutting Parameters Based on Surface Roughness and Cutting Force During End Milling of Nimonic C-263 Alloy

The surface integrity of machined surfaces greatly influences the functional properties of the components such as fatigue life, etc. Nickel-based superalloy such as Nimonic C-263 is termed as difficult to machine material due to its unique properties as well as high strength at elevated temperatures...

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Bibliographic Details
Published in:IOP conference series. Materials Science and Engineering 2020-08, Vol.912 (3), p.32020
Main Authors: Giridhar Reddy, P, Gowthaman, S, Jagadeesha, T
Format: Article
Language:English
Subjects:
Carbide tools
Cutting force
Cutting parameters
Cutting speed
End milling cutters
Experimentation
Fatigue life
Feed rate
High temperature
Machine tools
Machining centres
Morphology
Nickel base alloys
Optimization
Orthogonal arrays
Process parameters
Signal to noise ratio
Superalloys
Surface finish
Surface roughness
Tungsten carbide
Variance analysis
Vertical milling machines
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Summary:The surface integrity of machined surfaces greatly influences the functional properties of the components such as fatigue life, etc. Nickel-based superalloy such as Nimonic C-263 is termed as difficult to machine material due to its unique properties as well as high strength at elevated temperatures. This study intends to optimize the cutting parameters (cutting speed, feed, depth of cut) during the end milling of Nimonic C-263 and the machining has been carried out using solid tungsten carbide tool coated with TiAlN and Vertical Machining Center. Experimentation is carried out using Taguchi L9 orthogonal array technique and based on signal to noise ratio data, optimum machining parameters were achieved for preferred observable characteristics such as cutting force and surface roughness. Additionally, Multi-purpose optimization (Grey analysis) of the observable characteristics was conducted to predict the optimum machining parameters combination which offers better producible surface finish and lowest cutting force requirement. Further, the analysis of variance (ANOVA) reveals that the feed rate is the farthest influencing factor followed by the depth of cut, cutting speed, and the variations in cutting force and surface roughness are confirmed through chip morphology using Scanning electron microscopy.
ISSN:1757-8981
1757-899X
DOI:10.1088/1757-899X/912/3/032020