Effects of dry turning parameters of Incoloy 800H superalloy using Taguchi-based Grey relational analysis and modeling by response surface methodology

Incoloy 800H is an austenitic Fe-Ni-Cr based superalloy and used in many applications due to their high corrosion resistance and creep-strength. However, this alloy is difficult to machine or cut material because of their eminent characteristics such as rapid-work hardening, lesser thermal conductivity and easy to tool-material attraction. Hence, the necessary experimental investigation is required to study and optimize the turning parameters of this alloy. This work presents the investigation of turning parameter effects on the Incoloy 800H superalloy with cryogenically treated cutting tool. The dry turning experiments were conducted based on Taguchi L9 Orthogonal array (OA) with the input parameters of cutting speed, feed rate and depth of cut. The outputs such as material removal rate, surface roughness, cutting force and tool-tip temperature were considered as the responses. The measured output responses were optimized and modeled using Taguchi-based Grey relational analysis (GRA) and response surface methodology (RSM), respectively. The tool flank wear and tool life were examined on coated insert with cryogenically treated, coated insert (without cryogenic treatment) and uncoated insert for comparison. The results revealed that greater amount of tool-wear reduction was observed in the case of coated tool with-cryogenically treated about 47.88%, coated tool without-cryogenically treated about 27.51% when compared with an uncoated tool. Besides, analysis of variance (ANOVA) was performed to find the most significant parameter over the obtained responses. The obtained mathematical model through RSM was agreed with the experimental result. Further, the machined surface topography was examined using White Light Interferometer (WLI).