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Dry Machining Performance Studies on TiAlSiN Coated Inserts in Turning of AISI 420 Martensitic Stainless Steel and Multi-Criteria Decision Making Using Taguchi - DEAR Approach

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Abstract

The key objective of this research study is to examine the performance of TiAlSiN coated insert while performing dry machining of AISI 420 martensitic stainless steel on quantified output responses. This paper seeks to optimize process parameters namely speed, feed, and depth of cut during turning process, such as surface roughness, flank wear, and material removal rate simultaneously. TiAlSiN thin film was coated on the carbide tool through high power impulses magnetron sputtering. To confirm the existence of coated elements, SEM and XRD studies were performed. For coated and pure inserts, microhardness was measured, whereas the TiAlSiN coated tool possesses 43.34% higher than pure inserts. The dry machining was performed with three process parameters, each in three phases. The experimentation was performed based on Taguchi’s design of experiments (DoE). In this study, a Multi-Criteria decision making (MCDM) approach encompassing Data Envelopment Analysis based Ranking Methodology (DEAR) with Taguchi’s design was applied. The multi-response performance index (MRPI) was calculated and their impact on the machining parameters was scientifically examined. The parameter combination of cutting speed: 240 m/min; feed rate: 0.20 mm/rev and depth of cut: 0.50 mm was observed to be the optimal input parameters.

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Acknowledgments

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Authors and Affiliations

  1. Department of Mechanical Engineering, Kongu Engineering College, Perundurai, Tamilnadu, India

    C. Moganapriya & R. Rajasekar

  2. Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India

    T. Mohanraj

  3. Department of Mechatronics Engineering, Kongu Engineering College, Perundurai, Tamilnadu, India

    V. K. Gobinath

  4. Department of Mining Engineering, Indian Institute of Technology, Kharagpur, West Bengal, India

    P. Sathish Kumar

  5. Department of Information Technology, Vivekanandha College of Engineering for Women, Elaiyampalayam, Tamilnadu, India

    C. Poongodi

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  1. C. Moganapriya
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  2. R. Rajasekar
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  3. T. Mohanraj
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  4. V. K. Gobinath
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  5. P. Sathish Kumar
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Contributions

All authors discussed the content of the article based on their domain expertise on the subjects presented. C. Moganapriya performed the experiments and analyzed the data through statistical approach. P. Sathish Kumar characterized the coatings through SEM and XRD. T. Mohanraj optimized the results through DEAR approach. V. K. Gobinath and C. Poongodi executed the confirmation experiment. C. Moganapriya drafted the paper and revised the manuscript. R. Rajasekar supervised the study and discussed the results, proofread the manuscript and confirmed its findings. All authors read and approved the final manuscript.

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Correspondence to R. Rajasekar.

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Moganapriya, C., Rajasekar, R., Mohanraj, T. et al. Dry Machining Performance Studies on TiAlSiN Coated Inserts in Turning of AISI 420 Martensitic Stainless Steel and Multi-Criteria Decision Making Using Taguchi - DEAR Approach. Silicon 14, 4183–4196 (2022). https://doi.org/10.1007/s12633-021-01202-4

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