Machinability Analysis of PH Stainless Steel with Uncoated and Textured Tool Inserts with Minimum Quantity Lubricants 2022-28-0543

The alloy investigated in this research is Precipitation Hardened Stainless Steel (PHSS) 15-5, which provides good corrosion, high strength and hardness. 15-5 Stainless Steel is extensively employed in a variety of applications, including aero plane components, high-pressure corrosive environments that include valves, fasteners, shafts, fittings and gears. In this current exploration, an analysis of the machinability of PHSS is analyzed with textured inserts and the outcomes as compared to conventional inserts. To increase the machinability conditions, two distinct types of textures were produced on the rake face of the tool inserts and employed for this machining procedure utilizing a Wire Electric Discharge Machine (WEDM).The dimensions of the textures were cut on the trial-and-error method. Three different machining parameters with three different levels were chosen. Cutting Speed, feed rate and depth of cut were chosen as the input parameters. Cutting force, surface roughness, and tool wear, all of which influence machinability, were measured and studied. Scanning Electron Microscope (SEM) was used to measure the tool wear. During machining, molybdenum disulfide was employed for Minimum Quantity Lubrication (MQL). Taguchi’s design of experiments approach was applied to optimize the experiment, and analysis of variance was employed to discover the most important factor among the input parameters on output variables. It is noticed that for the lower levels of cutting speed 80 m/min and at feed rate 0.05 mm/rev and depth of cut 0.2 mm the cutting force measured was less while machining with textured inserts while the surface finish was better at higher cutting speed 240 m/min and at feed rate 0.05 mm/rev and 0.2 mm depth of cut. The results reveal that the textured inserts with MQL system can assist in remarkable improvement in decreasing the cutting force, enhancing the surface finish and reducing tool wear.