A New Approach of Wear Mechanism Map in Turning Inconel718 with PVD-Coated Inserts Using Advanced Techniques

In this paper, the relationship between the cutting conditions and the wear mechanisms in turning Inconel718 from both modeling and experiment points of view has been studied. The tool chosen consists of a hard fine-grained WC with 6% Co with TiAlN layer. As a result, the recommended machining conditions with minimal wear would be the selection of a tool with a radius of 1.6 mm and the cutting velocity in the range of 45 to 55 m/min. The optimal variables obtained from artificial neural networks and genetic algorithm are found to be in good agreement with the results of laboratory findings on the wear mechanism map. Also, the results showed that at lower cutting velocities and feed rates, the TiAlN layer acts to prevent the transfer of elements between the tool and workpiece (mild and transient wear zones), causing the turning forces to stabilize over time. However, with an increase in the cutting velocity and feed rate (severe zone), the TiAlN layer breaks off the tool surface resulting in a considerable increase in the friction coefficient, cutting forces, and the adhesive wear. The main reason for this phenomenon is the transfer of elements such as nickel, chrome, and iron to the flank face.