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The objective of the current study is to investigate the performance of tungsten carbide tool inserts in face milling of EN-31 steel under various machining environments viz. dry machining, air cooling, minimum quantity lubrication(MQL) and flood cooling. Tool performance is generally determined by the progression of the tool flank wear during machining. Using Taguchi’s approach of design of experiments, machining environments is combined with machining parameters such as cutting speed, feed rate and depth of cut, and experiments is carried out as per mixed L18 orthogonal array. Taguchi based analysis of mean (ANOM) and analysis of variance (ANOVA) is utilized to check the effects of input parameters on tool flank wear. The optimum machining parametric setting for minimum tool flank wear is observed as MQL with lubricant flow rate (LFR) of 150 ml/hr, 110 m/min cutting speed, 60 mm/min feed rate and 0.4 mm depth of cut. From the results of the ANOM, tool flank wear in the case of MQL with LFR of 150 ml/hr is observed to be 5.29% lower as compared to flood cooling. The mathematical model revealed that the second-order regression model accurately determined the variability of tool flank wear with the input parameters with least error. |
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