This paper investigates the effect of cutting parameters on the surface roughness and cutting force of titanium alloy Ti-6Al-4V ELI when turning using PVD TiAlN coated tool in dry environment. Taguchi L9 orthogonal array design of experiment was used for the turning experiment 2 factors and 3 levels. Turning parameters studied were cutting speed (50, 65, 80 m/min), feed rate (0.08, 0.15, 0.2 mm/rev) and depth of cut 0.5 mm constant. Linear and second order model of the surface roughness and cutting force has been developed in terms of cutting speed and feed. The results show that the feed rate was the most impact factor controlling the cutting force and surface roughness produced. MINITAB 17software was used to develop a linear and second order model of surface roughness and cutting force. Optimum condition was at 66.97 m/min of cutting speed, 0.08 mm/rev of feed rate. Surface roughness 0.57?m and cutting force 54.02 N were obtained at the optimum condition. A good agreement between the experimental and predicted surface roughness and cutting force were observed.

Nickel based super alloys are excellent for several applications and mainly in structural components submitted to high temperatures owing to their high strength to weight ratio, good corrosion resistance and metallurgical stability such as in cases of jet engine and gas turbine components. The current work presents the experimental investigations of the cutting parameters effects (cutting speed, depth of cut and feed rate) on the surface roughness, cutting force components, productivity and power consumption during dry conditions in straight turning using coated carbide tool. The mathematical models for output parameters have been developed using Box-Behnken design with 15 runs and Box-Cox transformation was used for improving normality. The results of the analysis have shown that the surface finish was statistically sensitive to the feed rate and cutting speed with the contribution of 43.58% and 23.85% respectively, while depth of cut had the greatest effect on the evolution of cutting force components with the contribution of 79.87% for feed force, 66.92% for radial force and 66.26% for tangential force. Multi-objective optimization procedure allowed minimizing roughness Ra, cutting forces and power consumption and maximizing material removal rate using desirability approach.

This paper presents an experimental study on rough cut, trim cut using distilled water as a dielectric fluid and Al & Si metal powders in dielectric fluid for WEDM of Nimonic-90. First, the influence of discharge energy (DE) in rough cut is evaluated for machining rate (MR) and surface roughness (SR) and compared with trim cut without any metal powder additives in dielectric fluid. The effect of Al and Si metal powders (varying concentration of 1g/L, 2g/L and 3g/L) in dielectric fluid is studied separately and comparison is also made for MR, SR, recast layer and micro hardness of machined Nimonic-90. From the results it is observed that using trim cut, a fine and uniform surface texture is obtained irrespective of the high discharge energy of rough cut. Al and Si powders additives show a significant reduction in MR for trim cutting operation whereas a remarkable modification is obtained in surface textures after trim cut using metals powder mixed dielectric. SR improves with a concentration of 1g/L and shows a little increase with high concentration of both metals powder. Using metals powder in dielectric fluid, the recast layer becomes smooth and denser and thus, micro hardness increases.

Powder mixed electro discharge machining (PMEDM) is a hybrid machining process where the electrically conductive powder is mixed into the dielectric fluid to enhance the machining efficiency. In this investigation, PMEDM is performed for the machining of AISI 304 stainless steel when silicon carbide powder is mixed into the kerosene dielectric. Peak current, pulse on time, gap voltage, duty cycle and powder concentration are considered as process parameter while material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) are considered as response. A face centered central composite design (FCCCD) based response surface methodology (RSM) is applied to design the experiment. A hybrid optimization technique like desirability coupled with fuzzy-logic method is performed to get the optimum level of the multiple performance characteristics. Analysis of variance (ANOVA) is performed for the statistical analysis. The result shows that peak current is the most significant parameter for MRR, TWR and Ra. The optimal setting for maximum MRR, minimum TWR and Ra have been obtained by desirability coupled with fuzzy-logic method.

Powder mixed electro discharge machining (PMEDM) is a hybrid machining process where electrically conductive powder is suspended into a dielectric medium, for enhancing the material removal as well as the surface finish. In this investigation, electro discharge machining (EDM) has been performed for the machining of AISI 304 stainless steel by using the tungsten carbide electrode, when silicon carbide (SiC) powder is suspended into kerosene dielectric medium. Peak current, pulse on time, gap voltage, duty cycle and powder concentration are considered as process parameter while the surface roughness (Ra) is the only response. The effect of significant process parameters on the response has been studied. A regression analysis has been performed to describe the correlation of data between the machining parameter, and the response. Microstructural analysis has been done for the PMEDMed surface. The result shows that peak current is the most influential parameter for surface roughness. Surface roughness decreases with the increase of powder concentration.

This paper demonstrates an experimental scrutiny into turning process of hot work tool steel AISI H21 under dry machining plight. In this paper, face centered central composite design concealed by response surface methodology is practiced and analysis of variance is implemented to analyze the eloquent benefaction of machining parameters on responses. To access accommodate between the surface roughness and the MRR, an approach for concurrent optimization of multi-objective characteristics based on comprehensive desirability function is employed. The multi objective optimization concludes a spindle speed of 1599.568 rpm, feed rate of 0.262 mm/rev and depth of cut of 2 mm.

Electrical Discharge Machining (EDM) is one of the most basic non-conventional machining processes for production of complex geometries and process of hard materials, which are difficult to machine by conventional process. It is capable of machining geometrically complex or hard material components, that are precise and difficult-to-machine such as heat-treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. The present study is focusing on the die sinking electric discharge machining (EDM) of AISI H 13, W.-Nr. 1.2344 Grade: Ovar Supreme for finding out the effect of machining parameters such as discharge current (GI), pulse on time (POT), pulse off time (POF) and spark gap (SG) on performance response like Material removal rate (MRR), Surface Roughness (Ra) & Overcut (OC) using Square-shaped Cu tool with Lateral flushing. A well-designed experimental scheme is used to reduce the total number of experiments. Parts of the experiment are conducted with the L9 orthogonal array based on the Taguchi methodology and significant process parameters are identified using Analysis of Variance (ANOVA). It is found that MRR is affected by gap current & Ra is affected by pulse on time. Moreover, the signal-to-noise ratios associated with the observed values in the experiments are determined by which factor is most affected by the responses of MRR, Ra and OC. These experimental data are further investigated using Grey Relational Analysis to optimize multiple performances in which different levels combination of the factors are ranked based on grey relational grade. The analysis reveals that substantial improvement in machining performance takes place following this technique.

This paper focuses on the exploitation of the response surface methodology (RSM) to determine optimum cutting conditions leading to minimum surface roughness and cutting force components. The technique of RSM helps to create an efficient statistical model for studying the evolution of surface roughness and cutting forces according to cutting parameters: cutting speed, feed rate and depth of cut. For this purpose, turning tests of hardened steel alloy (AISI 4140) (56 HRC) were carried out using PVD – coated ceramic insert under different cutting conditions. The equations of surface roughness and cutting forces were achieved by using the experimental data and the technique of the analysis of variance (ANOVA). The obtained results are presented in terms of mean values and confidence levels. It is shown that feed rate and depth of cut are the most influential factors on surface roughness and cutting forces, respectively. In addition, it is underlined that the surface roughness is mainly related to the cutting speed, whereas depth of cut has the greatest effect on the evolution of cutting forces. The optimal machining parameters obtained in this study represent reductions about 6.88%, 3.65%, 19.05% in cutting force components (Fa, Fr, Ft), respectively. The latters are compared with the results of initial cutting parameters for machining AISI 4140 steel in the hard turning process.

Surface roughness and cutting forces are considered as important factors to determine machinability rate and the quality of product. A number of factors like cutting speed, feed rate, depth of cutting and tool noise radius influence the surface roughness and cutting forces in turning process. In this paper, an Artificial Neural Network (ANN) model was used to forecast surface roughness and cutting forces with related inputs, including cutting speed, feed rate, depth of cut and tool noise radius. The machined surface roughness and cutting force parameters related to input parameters are the outputs of the ANN model. In this work, 24 samples of experimental data were used to train the network. Moreover, eight other experimental tests were implemented to test the network. The study concludes that ANN was a reliable and accurate method for predicting machining parameters in CNC turning operation.

Machining of hardened work materials with appropriate levels of process parameters is still a burning issue in manufacturing sectors and challenging. It is because of pressing demand of surface quality which adversely affected by evolution of tool wear. Therefore the present investigation is undertaken to make a decision on parametric optimization of multi-responses such as flank wear and surface roughness during machining hardened AISI 52100 steel (55±1) steel using mixed ceramic insert under dry environment through grey relational analysis combined with Taguchi approach. Also predicted mathematical models of 1st and 2nd order have been developed for responses and checked for its accuracy. Second order mathematical model presented higher R2 value and represents best fit of the model and adequate compared to first order model. Model indicates good correlations between the experimental and predicted results. The proposed grey-based Taguchi methodology has been proved to be efficient for solving multi-attribute decision making problem as a case study in hard machining environment.