Abstract
The motivation of research in modern manufacturing systems demands the least expensive operations to produce the best quality products. To achieve the same objective, the current study analyses and optimizes the Coated tungsten carbide cutting tool’s performance compared to the uncoated tool. For the study the coating over the cutting tool has been done using the novel Scalable Pulse Power Plasma (S3P) physical vapor deposition. For the experiments, cutting velocity (Vc), feed rate (f) and depth of cut (d) have been considered as the process or independent variable, while surface roughness and material removal rate have been taken as the response. During the study, Taguchi’s L18 orthogonal array is used for the design of experiments, and S/N ratios are used to obtain the impact of process variables on the responses; analysis of variance (ANOVA) is used to get the regression equations used as an objective function for optimization. Grasshopper’s optimization algorithm is used for the optimization. The results show that the individual optimization coated tool is suitable for generating smoother surfaces while for higher material removal rate uncoated tool favours. Multi-objective optimization suggested 0.1 mm depth of cut, 0.812 mm/rev feed rate and 70.45 mm/min cutting speed with a coated tool as the optimum parameters for the machining operation, which produces surface roughness of 4.843 μm and 5.47 cm3/min MRR.
Similar content being viewed by others
Data availability
The data presented in this study are available in the article.
References
Prakash, J., Equbal, A., Ravindrannair, P., Equbal, M.A., Equbal, M.I.: Optimizing the machining parameters during turning of EN 31 steel using TiN + Al2O3 + TiCN coated tungsten carbide tool. Materials Today: Proceedings. May 10. (2023)
Shahensha, S., Saravanan, R.: Tool wear reduction in CNC turning of En31 steel by novel wet machining with waste cooking oil. InAIP Conference Proceedings 2023 Nov 14 (Vol. 2822, No. 1). AIP Publishing
Gangwar, S., Rao, P.S.: Experimental examination of Tool wear during turning of Ti-Grade 2 Alloy in Dry and Minimum Quantity Lubrication (MQL). Int. J. Innovative Technol. Explor. Eng. 8, 4768–4771 (2019)
Said, Z., Gupta, M., Hegab, H., Arora, N., Khan, A.M., Jamil, M., Bellos, E.: A comprehensive review on minimum quantity lubrication (MQL) in machining processes using nano-cutting fluids. Int. J. Adv. Manuf. Technol. 105, 2057–2086 (2019)
Kumar, A., Sharma, A.K., Katiyar, J.K.: State-of-the-art in sustainable machining of different materials using nano minimum quality lubrication (NMQL). Lubricants. 11(2), 64 (2023)
Liu, N., Liu, B., Jiang, H., Wu, S., Yang, C., Chen, Y.: Study on vibration and surface roughness in MQCL turning of stainless steel. J. Manuf. Process. 65, 343–353 (2021)
Kumar, S., Rao, P.S., Goyal, D., Sehgal, S.: Process modelling for machining Inconel 825 using cryogenically treated carbide insert. Met. Powder Rep. 76, S66–74 (2021)
Natrayan, L., Balaji, S., Bharathiraja, G., Kaliappan, S., Veeman, D., Mammo, W.D.: Experimental investigation on mechanical properties of TiAlN thin films deposited by RF magnetron sputtering. J. Nanomaterials. 2021, 1–7 (2021)
Chinnasamy, M., Rathanasamy, R., Palaniappan, S.K., Pal, S.K.: Investigation of TiAlN, AlTiN, and TiAlSiN coated inserts on the machining performance of AISI 420 steel and multi-objective optimization of process parameters. J. Institution Eng. (India): Ser. D. 103(2), 563–573 (2022)
Sonawane, G.D., Sargade, V.G.: Performance evaluation of HiPIMS, S3p and CAE deposited coatings during dry turning of Dss2205. Mach. Sci. Technol. 26(3), 396–427 (2022)
Sonawane, G.D.: Investigating the supremacy of PVD S3p deposition over HiPIMS for AlTiN coating. Mach. Sci. Technol. 2023 Dec. 27:1–29
Mahapatra, S., Das, A., Jena, P.C., Das, S.R.: Turning of hardened AISI H13 steel with recently developed S3P-AlTiSiN coated carbide tool using MWCNT mixed nanofluid under minimum quantity lubrication. Proc. Institution Mech. Eng. Part. C: J. Mech. Eng. Sci. 237(4), 843–864 (2023)
Das, A., Kamal, M., Das, S.R., Patel, S.K., Panda, A., Rafighi, M., Biswal, B.B.: Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning. Proc. Institution Mech. Eng. Part. C: J. Mech. Eng. Sci. 236(6), 3174–3197 (2022)
Mahapatra, S., Das, A., Jena, P.C., Das, S.R.: Turning of hardened AISI H13 steel with recently developed S3P-AlTiSiN coated carbide tool using MWCNT mixed nanofluid under minimum quantity lubrication. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. ;237(4):843 – 64. (2023)
Vetter, J.: Innovative PVD Processes for Advanced Coatings Based on HiPIMS and arc. Scalable Pulsed Power Plasma and High Ionization Triple (2014)
Kumar, P., Sharma, M., Singh, G., Singh, R.P.: Experimental investigations of machining parameters on turning of Ti6Al4V: Optimization using Taguchi method. Int. J. Interact. Des. Manuf. (IJIDeM). 23, 1–1 (2023 May)
Okokpujie, I.P., Tartibu, L.K.: Multi-objective Grasshopper Optimizer for Improved Machining Performance. InModern Optimization Techniques for Advanced Machining: Heuristic and Metaheuristic Techniques 2023 Jul 22 (pp. 123–136). Cham: Springer Nature Switzerland
Abbas, A.T., Al-Abduljabbar, A.A., El Rayes, M.M., Benyahia, F., Abdelgaliel, I.H., Elkaseer, A.: Multi-objective optimization of performance indicators in turning of AISI 1045 under dry cutting conditions. Metals. 13(1), 96 (2023)
Rajeev, D., Singh, S.C.E., Rejilin, D.R.A., Devadhas, G.G., Ajitha, S.: Optimization tool wear on hard turning of AISI4140 steel with coated carbide tool cutting conditions. Int. J. Innov. Technol. Explor. Eng. 9(5), 2051–2054 (2020)
Kumar, V., Mondal, S.C.: Tribomechanical investigation and Parametric optimization of the cutting performance of Ni-based hardfaced turning tool insert. Int. J. Interact. Des. Manuf. (IJIDeM). 30, 1–22 (2023 Jul)
Touggui, Y., Belhadi, S., Mabrouki, T., Temmar, M., Yallese, M.A.: Dry turning optimization of austenitic stainless steel 316L based on Taguchi and TOPSIS approaches. Matériaux Tech. 108(4), 401 (2020)
Singh, P.K., Kumar, K., Saini, P.: Optimization of surface roughness and hole diameter accuracy in drilling of EN-31 alloy steel–A TGRA based analysis. Mater. Today: Proc. 26, 2961–2971 (2020)
Chen, W.H., Uribe, M.C., Kwon, E.E., Lin, K.Y., Park, Y.K., Ding, L., Saw, L.H.: A comprehensive review of thermoelectric generation optimization by statistical approach: Taguchi method, analysis of variance (ANOVA), and response surface methodology (RSM). Renew. Sustain. Energy Rev. 169, 112917 (2022)
Palaniappan, T., Subramaniam, P.: Investigation in optimization of process parameters in turning of Mild Steel using response surface methodology and modified deep neural network. Mater. Today Commun. 19, 108425 (2024 Feb)
Author information
Authors and Affiliations
Contributions
Conceptualization- Sukhdev Gangwar, R K Ghadai, A Kumar, S C Mandal. Formal analysis- Sukhdev Gangwar, R K Ghadai. Investigation- Sukhdev Gangwar, R K Ghadai. Methodology- Sukhdev Gangwar, R K Ghadai, A Kumar, S C Mandal. Writing original draft- Sukhdev Gangwar, R K Ghadai. Writing – review & editing- Sukhdev Gangwar, R K Ghadai, A Kumar, S C Mandal. All authors have read and agreed to the published version of the manuscript.
Corresponding author
Ethics declarations
Ethical approval
Not Applicable.
Conflict of interest
The authors declare no conflict of interest.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
gangwar, S., Mondal, S.C., Kumar, A. et al. Performance analysis and optimization of machining parameters using coated tungsten carbide cutting tool developed by novel S3P coating method. Int J Interact Des Manuf (2024). https://doi.org/10.1007/s12008-024-01852-9
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s12008-024-01852-9