Study of Insert Flank Wear and Surface Roughness Evolutions During Turning of Stellite 6 Based on RSM and Desirability Approaches

Abstract

In this research, turning experiments on Co-Cr-Mo, cobalt-based alloy Stellite 6 were carried out to examine the effect of four machining factors (tool tip radii, feed rate, cutting depth and cutting speed) on insert flank wear and surface roughness. On the basis of a design Taguchi plan (L¹⁸), the experiments were conducted. The response surface methodology (RSM) was employed to develop mathematical modelling of flank wear and surface roughness evolutions. The contribution of each individual parameter to process responses was assessed using ANOVA analysis. Predicted models in relationship with flank wear and surface roughness evolutions were obtained from the regression equation. These models show good correlations with experimental results. A maximum error of 13.82% and 10.90% of flank wear and surface roughness was observed between simulated and experimental results, respectively. The optimization of processing parameters was investigated in order to achieve both the minimum values of flank wear band and surface roughness.