Abstract

Energy consumption during any machining operation plays a big role in overall cost. In machining process, the power consumption is unpredictable and largely depends on process parameters and work / tool material used. In this paper, power consumption investigation while machining nickel-based alloy Inconel 600 using textured cutting tool is reported. The coated tungsten carbide cutting tool edges are modified with laser engraving process to produce three different texture patterns on flank face of the tool geometry. The energy consumption is calculated with reference to the input parameters namely, cutting speed (50, 100 and 150m/min), feed rate (0.08, 0.1 and 0.12mm/rev) and depth of cut (0.1, 0.2 and 0.3mm) along with tool texture (dimple, line and spline). To predict the optimal process condition, response surface method (RSM) and TOPSIS techniques are adopted. Optimization results conclude that an average cutting speed of 94 m/min with 0.102 mm/rev feed rate and 0.113 mm depth of cut can be used to machine Inconel 600 with a minimum power consumption of 0.385 kW.