Preliminary Investigation of Tool Wear When Machining Super Duplex Stainless Steel Using Coated Inserts Under Dry Environment

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Machining is a fundamental manufacturing process that entails the controlled removal of material from a workpiece to achieve desired shapes and dimensions. Super duplex stainless steel (SDSS) 2507 is a high-performance alloy which is notable for its superior mechanical strength and excellent corrosion resistance, making it particularly suitable for deployment in aggressive service environments, including offshore structures, subsea equipment, chemical industries, and marine engineering systems. Its low thermal conductivity, high hardness, and rapid work hardening pose significant challenges during dry machining, leading to accelerated tool wear. This study investigates the dry machining of SDSS 2507 by employing TiAlN-PVD (physical vapor deposition)-coated cutting inserts deposited to address these issues. The Taguchi method of experimental design was employed to evaluate the influence of key machining parameters on tool wear. The results demonstrated that PVD-coated inserts offered excellent wear resistance. Furthermore, the Taguchi signal-to-noise (S/N) ratio analysis and analysis of variance (ANOVA) identified feed rate as the primary factor influencing tool wear, with depth of cut and cutting speed ranking as secondary factors. This study highlights the effectiveness of tools with coatings for the dry machining of SDSS 2507-type difficult-to-machine material, offering a reliable solution for enhancing tool life and operational efficiency in industrial applications.