Experimental Study on Tool Wear and Cutting Temperature during Machining of Nimonic C-263 and Waspaloy Based on Taguchi Method and Response Surface Methodology

Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys studied experimentally based on Taguchi method and response surface methodology. Taguchi’s L₁₆ orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al₂O₃/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses are studied using analysis of variance, empirical models, and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied. The results show that progress of flank wear associated with Waspaloy is faster that of Nimonic C-263 due to high cutting temperature for Waspaloy that of Nimonic C-263. Abrasion is active wear mechanism for both the alloys with the investigated cutting parameters. Also, plastic deformation and mechanical fracture are observed for both inserts on turning of two alloys. In overall, PVD tool brings down the cutting temperature (10% for Nimonic C-263 and 4% for waspaloy), and flank wear land (31% for Nimonic C-263 and 41% for waspaloy) than that of CVD tool due to its superior tribological properties.