Evaluation of the cutting performance of PVD, CVD and MTCVD carbide inserts in dry turning of AISI 4140 steel using RSM-based NAMDE optimization

An experimental study is carried out to investigate the performance of the cutting tool regarding the insert wear, surface roughness, cutting forces, cutting power and material removal rate of three coated carbides GC2015 (TiCN-Al₂O₃-TiN), GC4215 (Al₂O₃-Ti(C,N)) and GC1015 (TiN) during the dry turning of AISI4140 steel. For this purpose, a Taguchi design (L₉) was adopted for the planning of the experiments, the effects of cutting parameters on the cutting force components were studied using analysis of variance (ANOVA), and the response surface methodology was used for mathematical modeling, with which linear mathematical models were developed for forecasting of F_a, F_r, F_c, P_c and MRR as a function of cutting parameters. Then, a new adaptive mixed differential evolution algorithm (NAMDE) has been implemented for multi-objective optimization which allows manufacturers to enhance the production performances of the machined parts. Furthermore, in order to characterize and quantify the flank wear and surface roughness of the tested tools, another machining experiment was performed for 5 min of turning under a depth of 0.5 mm, a feed rate of 0.08 mm/rev and a cutting speed of 350 m/min. The wear results led to a ratio (V_B-GC4215/V_B-GC2015) of 2.03 and (V_B-GC1015/V_B-GC2015) of 4.43, thus demonstrating the efficiency of the cutting insert GC2015. Moreover, SEM analysis shows the main wear mechanisms represented by abrasion, adhesion and chipping. Also, it was found that the minimum values for the surface roughness were achieved by the CVD cutting insert.