Analysis, modelling and optimization on tool vibration in machining of nitronic 60 with SiAlON ceramic tool

ABSTRACT

The study investigates tool vibration during finish turning of austenitic steel (Nitronic 60) using a new-generation SiAlON ceramic cutting insert under dry conditions. Three parameters—cutting speed, depth of cut, and feed—are varied across three levels each. Experimental results are analyzed using ANOVA, response surface methodology (RSM), and desirability function approach. Depth of cut is found to be the main factor influencing tool vibration, with cutting speed exacerbating tool wear. A regression model yields a high correlation coefficient (R-square = 0.93) with low error percentage (6.05%). Optimization via RSM suggests machining conditions of cutting speed 100 m/min, depth of cut 0.1 mm, and feed 0.05 mm/rev for optimal results. The study proposes the use of SiAlON ceramic tools as an effective alternative to costly CBN tools for finish turning difficult-to-machine materials, offering practical industrial implications.

KEYWORDS:

• Finish turning
• Nitronic 60 steel
• SiAlON ceramic tool
• tool vibration
• ANOVA
• RSM

Disclosure statement

No potential conflict of interest was reported by the author(s).