Multi-objective optimization of turning parameters for Incoloy 825 using hybrid MEREC-RAM method

Abstract

Machining parameters play a crucial role in determining the surface finish, tool life and material removal rate in hard-to-cut advanced materials. Studies have been carried out to optimize machining parameters for numerous superalloys. However, optimum machining parameters for Incoloy 825 using modern methods such as the multi-criteria decision making-based hybrid Method Based on the Removal Effects of Criteria–Root Assessment Method (MEREC-RAM) approach are less explored. The present study suggests an optimal set of turning parameters with an objective of minimize the surface roughness, flank width, machining temperature and maximize the material removal rate after turning of Incoloy 825. The optimal combination is achieved by optimization of the above-mentioned output/characteristics using the hybrid MEREC-RAM method. The experiment has been conducted according to the Taguchi L₉ orthogonal array design. Carbide inserts used in the experiment are deep cryogenically treated for better performance. The optimal machining parameters were found at a cutting speed of 60 m/min, a feed rate of 0.2 mm/rev, and a depth of cut of 0.6 mm. Also, microscopic analysis of chips and worn-out tools was described for a better understanding of the effect of each combination of variables. The method used is robust and reliable and can be easily implemented in critical industrial areas where multiple attributes are involved.