Machining performance analysis of micro-abrasive peened tungsten carbide inserts using multi-objective optimisation

This study developed a micro-abrasive peening setup to enhance the hardness and wear resistance of tungsten carbide inserts using alumina (Al 2 O 3 ) powder. Micro-abrasive peening experiments were conducted at three pressures (4, 6, and 8 bar) and three durations (60, 120, and 180 s). Results showed a hardness increase of ∼21% at 8 bar for 120 s. Surface roughness of the inserts increased by 150–350% with higher pressure and duration. Flank wear decreased by up to 16% under the 4 bar, 60 s condition, while severe cutting-edge damage under the 6 bar, 120 s condition is observed. Workpiece surface roughness improved by up to 17% using the insert treated at 8 bar for 120 s. Crater wear decreased by ∼11% and ∼17% under the 8 bar, 120 s and 180 s conditions, respectively. Finally, TOPSIS-based multi-objective optimisation identified the 8 bar, 120 s condition as the optimal combination of treatment parameters for improved machining performance.