Effects of different parameters of PVD coated turning on Aluminium Bronze Casting

This paper represents the experimental work where Aluminium Bronze, of high strength, excellent abrasion and corrosion resistance, is turned by other four edges of turning inserts which is not often used. The CNMG Turning inserts have eight edges, mostly four of them are used and then disposed off as scrap, but we can use other four edges of these scrap inserts as they have all the characteristics as that of four edges that are used generally. The process of turning work carried out at three different cutting speeds under dry cutting conditions. Three levels of spindle speed (Vc=260 rpm, 400 rpm, 600 rpm). Three levels of feed rate (0.1, 0.2, 0.4 mm/min) and three levels of cutting depth(1, 2, 3 mm). In this thin walled hollow cylindrical bush (48x40x60mm) casting of Aluminium Bronze is used, which is hard to machine due to its mechanical properties and wall thickness. Welded tools and brazing tools are used for turning in industries. But these tools lead to time consumption and high requirement of lubricant that further lead to energy loss, stress and load problems. These factors affect the re-melting process of Aluminium bronze scrap. Therefore, we use PVD coating technique with other four edges of insert that generally disposed off as scrap. PVD coating properties are favorable under dry conditions and scrap inserts lead to reduce the use of welded tools and tooling cost. In this, we analyses the effect of micro Hardness, Surface Roughness and Material Removal Rate (MRR) due to cutting parameters by using Taguchi method. The optimization is done using twenty seven experimental runs based on L'27 orthogonal array of the Taguchi method, and are performed to derive objective functions to be optimized within the experimental domain.