Optimization of cutting parameters in hard machining of AISI 52100 with wiper and conventional ceramic insert using the DF, EDAS, and VIKOR methods

The present research aims at investigating the influence of the cutting conditions during hard turning of AISI 52100 bearing steel using two types of mixed ceramics with different geometries. The ceramic tools used were represented by the conventional mixed ceramics (Al2O3+TiC) of conventional shape (CC650) and Wiper (CC650WG). A Taguchi L 16 experimental design was applied to explore the impacts of the conditions of cutting, specifically the speed of cutting ( Vc ), rate of feed ( f ), and depth of cut ( ap ) on the output parameters through a statistical approach based on (ANOVA). The analysis of the results obtained enabled the development of mathematical models that predict output parameters represented by the surface roughness ( Ra ) and the tangential cutting force ( Fz ) for the two ceramics tested. Three multi-objective optimization methods represented by the Desirability Function ( DF ), the Evaluation based on Distance from Average Solution ( EDAS ) along with the VlseKriterijumska Optimizacija I kompromisno Resenje ( VIKOR ) were used to determine the optimal combination that ensures the minimization of both ( Ra ) and ( Fz ) along with the maximization of (MRR) simultaneously for both ceramics. The obtained results show that the Wiper CC650WG insert provides significantly superior surface quality compared to the CC650 insert. For f = 0.2mm/rev, the maximum Ra CC650WG does not exceed 0.37μm, whereas Ra CC650 slightly exceeds 1μm, with a ratio ( Ra CC650 /Ra CC650WG ) of 2.91. Additionally, the DF approach favored achieving a maximum (MRR of 14.40cm 3 /min) while obtaining the best roughness Ra = 0.24μm for CC650WG. The VIKOR method allowed for a minimum roughness of Ra = 0.32μm for CC650 while maintaining a low cutting force at Fz = 67.45N . Finally, the EDAS method achieved a minimal cutting force Fz = 30.70N for the CC650WG insert.