Feasibility Analysis of Machining Cobalt-Chromium Alloy (Stellite-6) Using TiN Coated Binary Inserts

The objective of the study was to check the feasibility of machining Stellite 6, a cobalt–chromium superalloy, using TiN-coated carbide inserts in an end milling operation. The inserts were coated using the magnetron sputtering process. The sputtering power and gas flow rate were considered as the variables during the coating process. The performance of the coated binary carbide insert was checked during the end milling of Stellite 6 (~45 HRC) through an experiment with a Taguchi design. Experimental runs based on an orthogonal array were executed for each insert type to check the feasibility of machining this cobalt-based alloy. Adequate precision and the optimum parametric conditions were determined and are reported in this study. Analysis of variance (ANOVA) with a two-factor interaction model was also undertaken to forecast the key elements influencing surface roughness. Based on the ANOVA model, the depth of the cut, combined with the insert type, was the factor that had the greatest influence on surface roughness, followed by the cutting feed, whereas the cutting velocity had the least significance based on the tests. Moreover, the regression analysis demonstrated that the created model can be used to accurately forecast surface roughness in end milling of Stellite 6 with confidence intervals of 95%.