Box–Behnken based investigation of surface quality and tool wear rate and FEM analysis of tool wear in TiAlN/CrN coated carbide tool

The quantitative effects of cutting speed, feed and depth of cut on surface quality of the turned 316 LVM stainless steel work piece and tool wear of the TiAlN/CrN coated insert was investigated using Response surface methodology. Subsequently, FEM analysis of the tool wear using DEFORM-3D software was carried out. ANOVA analysis was formulated and regression was performed to understand the interactive effect of the process variables on the quality indicators. Further, a FEM-based method is defined to predict the advancement of tool wear during cutting operations. The cutting process was simulated using Deform 3D FEM software, and a suitable subroutine was added to the software to assess tool wear. An estimation of the tool wear value is made using well-known analytical models. The FEM model was calibrated and validated through experimental tests by turning 316 LVM stainless steel with ISO P40 TiAlN/CrN coated tools. The results from the FEM analysis and the experimental data were in good agreement.