Application of response surface methodology (RSM) to the prediction of the service life of cutters used in milling super-alloy Waspaloy

Nickel-based materials are widely used in making engine parts, compressor rotors and energy production. Nickel-based materials are resistant to corrosive conditions, and have a high strength in extreme temperatures. They also feature satisfactory mechanical properties in extreme heat. The use of these nickel-based super-alloys is on the rise every day as they have been widely used in military and civilian aeronautical industries in recent years. For this reason, it was the intention of this study to do optimised cutting experiments on Waspaloy in order to identify the significant factors which have impact on the tool life of cutting tools using the response surface methodology (RSM) in regression analysis. Several factors were found in the results that had significant impact on the machining tools’ life, including machining speed, depth, and feed rate. Finally, a regression analysis was adopted to establish a formula for calculating the service life of cutting tools. It was found that the minimum wear was achieved with the cutting speed at V = 33.21 m/min, cutting depth at dp = 0.0367 mm and feed per tooth at Ft = 0.367 mm/tooth.