Parametric study and multi-criteria optimization during turning of X210Cr12 steel using the desirability function and hybrid Taguchi-WASPAS method

The present study examines the machining of a cold work tool steel (X210Cr12) using a triple chemical vapor deposition coated carbide tool (Al2O3/TiC/TiCN). The paper is focused on an experimental investigation as well as a modeling and optimization of the working cutting parameters in relationship with the studied material. For that, first, a set of experimental tests were built in order to evaluate the effect of cutting parameters (r, Vc, f, and ap) on the output parameters, namely surface roughness (Ra), cutting force (Fz), insert flank wear (Vb), and 3D roughness distribution. In a second step, a Taguchi L16 (4^3 2^1) design of experiment (DoE) was exploited with the aim to develop a modeling of output working parameters based on the response surface methodology. An optimization of the cutting conditions was performed using the desirability function (DF) approach and the hybrid Taguchi-weighted aggregate sum product assessment method. The desired objective is to obtain optimal cutting regime corresponding to the simultaneous minimization of parameters Ra and Fz, and maximization of material removal rate. The results found show that the factor f influences Ra with 42.55% and that parameter ap affects parameters Fz and Pc with 67.55 and 60.88%, respectively. For the DF and WASPAS methods, the optimal regimes selected is r = 1.6 mm, Vc = 366 m/min, ap = 0.17 mm, f = 0.16 mm/rev and r = 1.6 mm, Vc = 180 m/min, ap = 0.3 mm, and f = 0.08 mm/rev, respectively. The proposed work concerns all mechanical manufacturing companies, as it provides the necessary information on the optimal working conditions of the tool/material pair.