Tribomechanical investigation and parametric optimisation of the cutting performance of Ni-based hardfaced turning tool insert

The prime objective of the current study is to illustrate not only the tribomechanical properties of hardfaced deposit but also the parametric study, modelling and optimisation of cutting performance of the Ni-based hardfaced turning tool insert. The modern manufacturing industry emphasises high productivity, precise dimensional accuracy and superior surface finish. Therefore, biological evolution-based multi-objective particle swarm optimisation (MOPSO) and the technique for order of preference by similarity to the ideal solution (TOPSIS) have been coupled to develop a hybrid optimisation technique for high machining efficiency and good surface finish. The input variables have been selected as speed, feed, and depth of cut for machining C30 steel using hardfaced cutting tool insert. Speed has been observed as the most significant factor followed by depth of cut for material removal rate. However, feed, depth of cut and speed contribute 39.34%, 20.05% and 19.34%, respectively in the overall inconsistency in surface roughness. The MOPSO-TOPSIS hybrid approach has provided the ideal machining condition at the combination of 415 rpm speed, 0.06 mm/rev feed and 0.5 mm depth of cut with marginal error of 2.496% and 3.352%, for material removal rate and surface roughness, respectively. The suggested hybrid optimisation yielded a maximum material removal rate of 2139.084 mm³/min and a minimum surface roughness of 2.713 µm. On the other hand, the overall hardness of hardfaced deposit was detected 1914.532 Hv. Moreover, adhesive strength and coefficient of friction of Ni-based deposit were observed as 3.981 N and 0.197, respectively.