Optimization of Cutting Parameters in Face Milling of Waspaloy Superalloy

Waspaloy is a superalloy material with wide applications in the aerospace industry. In this study, Waspaloy superalloy was face milled using coated carbide inserts under dry cutting conditions. The effect of cutting parameters on cutting force was investigated experimentally and statistically. The Taguchi method was used as a statistical method. Cutting speed, feed rate, and cutting tool were selected as input parameters. Sixteen experiments were performed with a Taguchi orthogonal experimental design. A comparison of the experimental data with the data obtained from the prediction models showed results with acceptable accuracy. In measuring the prediction adequacy of the test results, the quadratic model was used and the coefficient of determination was R² = 87.58%. The effects of cutting parameters on cutting forces were analyzed using ANOVA. According to the results of the analysis, it was determined that the most effective parameter on the cutting forces was the cutting tool (GC2030) with a rate of 82.99%. The feed rate was 2.75% and the cutting speed was 1.80% effective. As a result of the optimization made with the Taguchi method, it was determined that the cutting speed was 20 m/min, the feed rate was 0.1 mm/tooth, and the cutting tool gave better results in GC2030. The data obtained as a result of the validation experiment is within the confidence interval. This result confirms the suitability of Taguchi optimization for cutting force.