DOE based response surface regression methodology of the study of PVD coated cemented carbide tool performance on surface roughness /

Abstract

Now days PVD and CVD coated tools are widely used in different industries to ensure cost effectiveness in terms of tool life and work piece quality. Selection of tool geometry, its material and cutting parameters are very important in machining processes. These stake holders can affect production quality as well as time.. In this research uncoated cemented carbide tools and PVD coated cemented carbide tools are used for the dry machining of aluminum alloy 2024 to evaluate surface roughness and tool wear. Purpose of this research is to compare the performance of two tools. Experiments were conducted on full factorial design of experiments in which three levels of depth of cut, feed rate and cutting speed were taken as input variables and surface roughness and tool wear were the response for both tools. Machining time was taken as 30 minutes. Tool wear is measured by CMM and surface roughness by Surftonic. For the analysis of data response surface regression technique are used. Pareto coefficient and marginal mean plot shows the effectiveness of this approach. It is observed that depth of cut has great dominance on tool wear and surface roughness followed by cutting speed. Optimum levels are investigated to gain minimum tool wear and surface roughness for both coated and uncoated tools.