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In the present study an attempt has been made to investigate the effect of process parameters on surface roughness and cutting forces generation in machining of Duplex Stainless Steel (DSS 2205) grade material with TiN coated carbide tool. Taguchi technique is used for optimizing the process parameters. L27 orthogonal array was used to conduct the experimental trials. Cutting forces recorded using piezo-electric based mill tool dynamometer and surface roughness measured using surface roughness measuring instrument. The obtained results indicated that the cutting force increases with increase in feed rate and depth of cut whereas cutting forces decreases with increase in cutting speed. Surface roughness decreases with increase in cutting speed and low feed rate. Scanning Electroscope Microscopic (SEM) images indicates the feed marks, undeformed material and patches on the machined surface. The formation of material side flow and burrs on the feed marks ridges observed at higher cutting speed, low feed rate and depth of cut. It is mainly due to the material behavior like elastic-plastic deformation of the surface layer. The material side flow causes the considerable deterioration of surface quality of the DSS 2205 steel.

Nano Composites (nano MMCs) exhibit outstanding engineering properties like wear resistance, better stiffness, low density, and excellent ratio of strength to weight and so on. Unhybrid and hybrid nano MMC composites were fabricated using liquid metallurgical stir casting technique. Turning of Al2219 through TiN coated carbide tool was carried out to investigate surface roughness and cutting forces, by considering the cutting parameters like feed rate and speed. Response surface methodology (RSM) was used to design the experiments and to analyze the obtained results. The obtained results indicated that the cutting forces and surface roughness increases with increase in feed rate and decreases with increase in cutting speed. RSM displayed model and measured values are truly close to each other, which shows that created model can be effectively used to predict the cutting force and surface roughness on turning of MMCs. The predicted model values and obtained experimental values were close to each other with minimal error of 5 %, so the model is adequate. HIGHLIGHTS Nano Metal Matric Composites reinforced Al2219 with n-B4C & MoS2 particles successfully using stir casting Feed rate is the key influencing factor and the cutting speed had slight influence on cutting force, surface roughness and tool wear The experimental values obtained and predicted modeled values are within 5 % of each other, then the model is adequate GRAPHICAL ABSTRACT