Taguchi optimization of process parameters of turning of nickel based super alloy with textured inserts

Subtractive manufacturing techniques like turning, milling, boring on hard to machine metal alloys like Titanium and Inconel not only require advanced tooling but also require optimization of process parameters. Performance comparison of textured and non-textured tools in turning of Inconel was already studied by many researchers previously. The present work is about the optimization of machining parameters in dry turning of Inconel 600 with dimple textured uncoated carbide inserts by considering cutting speed, feed rate and rake angle as process parameters. Surface roughness and Material removal rate were considered as response parameters. Texturing of inserts was done on plain carbide inserts with no chip breakers. Fiber laser was used to create these textures on the rake face as it is proved to create them more efficiently. Taguchi method was used to reduce the number of experiments. The results from the studies indicate that sequence of Cutting speed of 300 m/min, Feed rate of 0.05 mm/rev and Rake angle of -3° was found to achieve minimum surface roughness whereas highest Material removal rate was obtained with a sequence of Cutting speed of 300 m/min, Feed rate of 0.15 mm/rev and Rake angle of -3°. Results from Analysis of Variance indicate that Cutting speed has maximum influence on producing good surface finish with 53% contribution whereas feed rate has maximum influence in increasing the MRR with 80% contribution.