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The austenitic nickel-chromium based super alloy Inconel 718 is considered a difficult material to machine due to a combination of nickel, iron and cobalt. The material exhibits mechanical strength and resistance to surface degradation under extreme pressure and heat. It employed widely in aerospace, jet engines, gas turbine etc. This research work focuses on the optimization of cutting variables for each performance measure obtained by employing grey-Taguchi techniques. The orthogonal array, grey relation analysis and analysis of variance are employed to study the performance characteristics in turning Inconel 718 using a carbide cutting tool insert. Further, a simulation model based on an finite element approach is proposed using DEFORM-3D software for the prediction of tool wear through Usui's tool wear model. The study highlights the optimum cutting conditions and a favorable range of the machining variable values. Finite element method results show that predicted tool wear values according to DEFORM-3D produce a useful and adequate level of accuracy.

Application of the grey based Taguchi method and Deform-3D for optimizing multiple responses in turning of Inconel 718