Experimental Research and Mathematical Modeling of Parameters Affecting Cutting Tool Wear in Turning Process of Inconel 625

This study aims to present the effects of cutting parameters on cutting tool wear during turning process of material Inconel 625 using Taguchi experimental design. Taguchi L9 orthogonal array was used to investigate the effects of machining parameters. Optimal cutting conditions are determined using the signal/noise (S/N) ratio which is calculated by average cutting tool wear. Using results of analysis, effects of parameters on both average of cutting tool wear calculated on Minitab 18 using ANOVA method. It was clear from the ANOVA that the regression model is capable to predict the tool wear with high accuracy. Numerical simulation of orthogonal cutting operation is presented using FEM modeling with Deform 3D v.11.0. The results of tool wear during the turning of Inconel 625 material are obtained by changing the cutting regimes (v, f, d), without cooling means. After using the three cutting regimes levels, we found that the optimal parameters go to the numerical level so that the cutting speed remains the same used in the experiment (v=65m/min), while the other optimal parameters come out the depth of cut (d=0.733mm) and feed (f=0.06mm/rev) so it can be seen in the two forms of research, the theoretical one with FEM and the experimental one. During the research, numerical methods and FEM simulations analysis were used for turning process. Confirmation test of results showed that the Taguchi method was very successful in the optimization of machining parameters for minimum cutting tool wear during CNC turning process. (c) 2022 Jordan Journal of Mechanical and Industrial Engineering. All rights reserved