Optimization of Cutting Forces and Surface Roughness in Turning Haynes 25 Superalloy

This research presents an evaluation of the effect of process parameters on surface roughness and cutting forces during the turning of Cobalt based superalloy Haynes 25. Although the demand for components made of this alloy are exponentially increasing due to its exceptional properties, machining of these alloys is posed to be a challenge. The target of achieving a superior surface with minimum cutting forces is still not addressed. In the current study, the input variables are depth of cut, cutting speed and feed rate along with the response parameters are cutting force and surface. A full factorial, L27 Taguchi based optimization is carried with the experimental results. The results of experimentation show that increasing cutting speed has distinct effect on cutting force and tends to slightly lower the surface roughness. The multifactor regression analysis shows a significant effect of feed rate and depth of cut on cutting forces. The optimum machining parameters obtained in this investigation are cutting speed as 1500 rpm, feed rate of 0.15 mm/rev and depth of cut as 1.8 mm. Moreover, it emphasizes additional investigation to find supplementary variables that could influence surface roughness so as to improve the overall machining performance of Haynes 25 superalloy.