Nickel based super alloys are excellent for several applications and mainly in structural components submitted to high temperatures owing to their high strength to weight ratio, good corrosion resistance and metallurgical stability such as in cases of jet engine and gas turbine components. The current work presents the experimental investigations of the cutting parameters effects (cutting speed, depth of cut and feed rate) on the surface roughness, cutting force components, productivity and power consumption during dry conditions in straight turning using coated carbide tool. The mathematical models for output parameters have been developed using Box-Behnken design with 15 runs and Box-Cox transformation was used for improving normality. The results of the analysis have shown that the surface finish was statistically sensitive to the feed rate and cutting speed with the contribution of 43.58% and 23.85% respectively, while depth of cut had the greatest effect on the evolution of cutting force components with the contribution of 79.87% for feed force, 66.92% for radial force and 66.26% for tangential force. Multi-objective optimization procedure allowed minimizing roughness Ra, cutting forces and power consumption and maximizing material removal rate using desirability approach.

Serviceable engineering components not only rely on their bulk material properties but also on the design and the characteristics of their surface. These characteristics influence directly the surface quality of the machined products. In terms of surface roughness, the influence of the tool material can be also caused by its tribological properties, i.e. a contact behavior between cutting tool and workpiece. This study presents a formulation of the nominal’s coefficient and friction forces generated in machining between workpiece and cutting tool using cutting force profiles. The obtained equations led to the evaluation of coefficient, frictional forces and cutting inserts characterization in terms of better surface finish and lowest frictional forces. Indeed, results show that the contact between cutting tool and workpiece depends on the materials cutting tool nature, and that the cutting tool type can influences the surface roughness of the machined surface.