Cutting Performance Analysis of Surface Textured Tools in Dry Turning: Optimisation of process parameters

¹ Department of Mechanical Engineering, National Institute of Technology, Rourkela, Odisha, India
² GITA Autonomous College, Bhubaneswar, Odisha, India
³ Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, Odisha, India
⁴ Mechanical Engineering Department, Indian Institute of Technology Kharagpur, Kharagpur – 721302, India

^* Corresponding author: trmahapatra_pe@vssut.ac.in

Abstract

Owing to minimum quantity or no use of toxic coolants, the dry machining technique has been evidenced to be a versatile sustainable method. However, during dry machining of ductile alloys, the severe tool wear and metal adhesion on the rake face of the cutting tool has been a matter of great concern. In the present work, an attempt has been made to assess the improvement in the tribological conditions in dry cutting by providing surface texturing on the rake face of High-Speed Steel (HSS) cutting tool. Dimples were produced on the rake surface of the HSS tool using pulsed Nd: YAG Laser and dry turning of pure aluminium is performed using the textured tool based on Taguchi’s L9 orthogonal array (OA) experimental design. The dry cutting of pure aluminium was also performed using the conventional/un-textured tool and the obtained results are used for comparison purpose. Improved turning performance in terms of material removal rate and surface roughness is found from the conformation tests using optimum process parameter determined by the Taguchi analysis. The ANOVA results suggests the effectiveness of using the textured tools during dry machining is significantly affected by feed and speed.