Experimental investigations of cutting parameters influence on cutting forces in turning of Fe-based amorphous overlay for remanufacture

Fe-based amorphous alloy is a new-type material dedicated to the remanufacture due to its unique property. Fe-based amorphous alloy is deposited on the abrased, fatigued, and fractured surface for resuming and upgrading its performance. In the present research, properties of amorphous alloy overlay, such as the microstructure, the phase content, thermal behavior, and mechanical property were evaluated and its machinability with respect to machining forces was experimentally investigated. Based on the response surface methodology and Box-Behnken design, four-factor (cutting speed, feed, depth of cut, and rake angle) three-level experiments were applied and analysis of variance (ANOVA) was performed. It is found that depth of cut is the dominant cutting parameter that affects the machining force components. Rake angle and interaction of feed rate and depth of cut can provide secondary significance to machining forces. Cutting speed, alone, has insignificant influence on machining force components. Predicting model for machining forces is established. ANOVA indicates that a linear model best fits the radial force and while a quadratic model best describes the axial force and cutting force. The optimal cutting parameters under these experimental conditions are searched.