Development and Application of Turning Tool Inserts Using ToolTectic 6HSS and EWAC 78 Advanced Materials by Hardfacing Techniques

Abstract

The current study involves the development and application of turning tool inserts using advanced materials (ToolTectic 6HSS/Fe-based and EWAC 78/Ni-based) with the help of hardfacing techniques. Hardfaced turning tool inserts were prepared using wire electrical discharge machining (WEDM) of hardfaced deposits.The parametric study and optimisation of WEDM process variables have been performed for the development of turning tool inserts at high productivity with superior surface finish. It was very beneficial to use grey relational analysis (GRA), technique for order of preference by similarity to ideal solution (TOPSIS), multi-objective genetic algorithm (GA) and combined compromise solution (CoCoSo)for the development of turning tool inserts.The turning of A36 steel has been carried out using Fe-based hardfaced inserts. The increase in machining speed has enhanced the quality of the machined surface, although it has an adverse effect on the tool wear.Chipping, abrasion and adhesion have been identified as the dominant mechanism of tool wear. However, the machining of hardened AISI 1040 steel has been performed using Ni-based turning tool inserts. The high-speed and low-feed machining has resulted in a significant reduction in surface roughness by 47.34% when compared to the low-speed and high-feed machining. On the other hand, multi-objective particle swarm optimisation (MOPSO) and TOPSIS have been coupled to develop a hybrid optimisation technique for the machining of C30 steel using hardfaced Ni-based cutting tool inserts. The hybrid approach has provided the ideal machining condition at the combination of 415 rpm speed, 0.06 mm/rev feed and 0.5 mm depth of cut with marginal error of 2.496% and 3.352%, for material removal rate and surface roughness, respectively. newlineKeywords: Hardfacing; Machining;WEDM; Turning; Surface Roughness; Material Removal Rate; MOPSO, GA; TOPSIS; GRA; CoCoSo newline