Jestr Journal of Engineering Science and Technology Review 14 (2) (2021) 119 - 135

Review Article
JOURNAL OF
Engineering Science and
Technology Review

r
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Factors Affecting and Optimization Methods used in Machining Duplex Stainless Steel
- A Critical Review
Mahesh Gopal* and Endalkachew Mosisa Gutema

Department of Mechanical Engineering, College of Engineering and Technology, Wollega University, Post Box No: 395, Nekemte,
Ethiopia.

Received 19 February 2021; Accepted 24 April 2021

___________________________________________________________________________________________

Abstract

Due to exclusive universal value and usefulness, the combination of good mechanical properties and manufacturing
characteristics, Stainless steel is an indispensable tool for design engineers to design components. In oil and gas
companies, power plants such as nuclear and thermal, equipment’s used in chemical processing industries: such as heat
exchangers, seawater processing industries, Pipeline systems, face an incredible and exceptional challenge and the most
important one is the reduction of thickness due to corrosion. In order to overcome this complexity, researchers developed
a metal called duplex stainless steel (DSS). DSS is a mixture of Chromium – Nickel – Molybdenum - Ferric alloys that
consists of an equal quantity of Face Centred Cubic (FCC) - austenite and Body Centred Cubic (BCC) - ferrite grains.
DSS is designed to provide improved corrosion resistance, primarily stress corrosion and chloride pitting corrosion and
superior resistance to other standard austenitic stainless steels. The DSS material is very difficult to perform machining
operations due to high austenite, nitrogen content, alloy composition, high strength, work hardening rate and toughness.
High hardness requires high cutting force which tends to reduce machinability characteristics such as tool wear, surface
finish, low MRR, etc. This review article provides an overview of the research conducted during last one decade by the
researchers and the optimization methods used to examine the machinability characteristics of DSS to predict surface
unevenness wear in tool, machinability, MRR and chip volume ratio. Furthermore, this article indicates an efficient
means of machining behavior, future scope and the fruitful methodology for the successful machining of duplex stainless
steel.

Keywords: Duplex stainless steel, Austenite, Ferrite, Lean DSS, Standard DSS, Super DSS, Hyper DSS, Surface roughness, wear in
Tool, Machinability, Material removal rate (MRR), Chip volume ratio.
___________________________________________________________________________________________

1. Introduction tungsten, alloy metals: stainless steel, carbon steel, duplex

stainless steel, brass and bronze. Non-metals are plastics,
Machinability relates to how easily a metal may be machined wood, glass, polymers, ceramics, synthetic fibers,
to achieve a satisfactory surface finish., requires less energy composites. The metals are divided into ferrous and non-
to cut, can cut faster and less wear of the tools. Machinability ferrous metals. Although ferrous materials have great
is challenging to forecast during machining since there are applications in the engineering field. Besides, ferrous
too many factors that control it. They are the two sets of materials are categorize into cast iron, ductile iron, malleable
factors: work-related materials and physical properties of the iron, gray irons, austempered ductile iron, compacted
material. Microstructure, grain particle sizes, heat treatment, graphite iron, white iron, carbon steels: High-Carbon,
chemical properties, processing, stiffness, yield strength, and medium-Carbon, low carbon, and alloy steels: Low-alloy
tensile strength are the eight factors that make up the work steels, High strength low alloy steels, Micro Alloyed Steels,
content, and the physical properties are modulus of elasticity, Advanced High - strength steels, Maraging steels, Stainless
thermal conductivity, thermal expansion, and work steels. Nowadays the non-ferrous materials such as ceramics,
hardening. Operating environments, cutting instrument composite materials, and plastics place an outstanding and
content and geometry, and machining operation have sprung up in various applications in the field of
specifications are also critical considerations. Other important engineering due to their physical, mechanical and chemical
factors include operating conditions, cutting tool material and properties. At the time of steel production, the process
geometry, and machining process parameters. The process involved oxidation with a minimum combination of chrome
converts working materials from one shape to the next by of about 10.50%, manganese of about 01.65%, silicon of
adding value through machining. Machining is the collection about 0.60%, or copper of about 0.60% and other alloys
of the process where the cutter removes the material in the known as alloy steel. One of the alloy steels known as
form of a chip. Relative motion between both the workpiece stainless steels is a very tremendously useful material in
and tool is needed to achieve this. engineering applications; it offers high toughness, stiffness
The working materials are divided into metals and and durability. Low-alloy steel includes less than 8% of the
nonmetals. Metals are iron, aluminum, gold, silver, copper, total alloy added, whereas high-alloy steel contains more than
lead, pewter, magnesium, titanium, zinc and nickel, mercury, 8% of the total alloy added. Austenitic, ferritic, duplex,
martensitic, and precipitation hardened stainless steels are
______________ classified into five groups depending on their crystalline
*E-mail address: [email protected]
ISSN: 1791-2377 © 2021 School of Science, IHU. All rights reserved. form. In addition duplex stainless steel (DSS) is a new and
doi:10.25103/jestr.142.16
 Mahesh Gopal and Endalkachew Mosisa Gutema/Journal of Engineering Science and Technology Review 14 (2) (2021) 119 - 135

rapidly growing family. Duplex stainless steels contain

chromium, nickel and molybdenum and It's quenched with
water at a high operating temperature, resulting in a
microstructure that's around half austenite and half ferritic.
The ferritic content is 50%. The figure 1 and 2 shows the
longitudinal and transversal direction of microstructure of
Sandvik SAF 3207 HD tube material and figure 3 shows the
grain structure in a SAF 3207 HD umbilical tube [1]. Color
grains are austenitic phase and grey grains are ferritic phase.
DSS is specifically intended for stress corrosion cracking
induced by surface infectivity by iron and pitting corrosion
caused by chloride, and is engineered to provide improved
good durability, higher yield strength, and greater corrosion Fig. 3. Grain structure in a SAF 3207 HD umbilical tube Austenitic
resistance. phase - Color grains are ferritic phase - grey grains. (Source: Guocai Chai
et al, (2009), Sandvik Materials Technology)

Fig. 4. The microstructure of a stainless steel transitions from ferritic to

duplex to austenitic as the nickel content rises. (source: IMOA -
International Molybdenum Association, 2014)

Fig.1. Longitudinal direction Microstructure of Sandvik SAF 3207 HD

tube material. The white phase is called austenite, and grey phase is 2. Types of DSS and their properties.
called ferrite: (Source: Guocai Chai et al, (2009), Sandvik Materials
Technology) Duplex Stainless Steel primarily divided into four basic alloy
categories ranging from Lean DSS (LDSS), Standard DSS
(Std DSS), Super DSS (SDSS) and Hyper DSS (HDSS).

2.1. Lean Duplex Stainless Steel (LDSS)

Lean DSS (LDSS) contains a higher percentage alloy blend
of chromium, a lower level of molybdenum and
nickel. Nitrogen is applied to alloys with low nickel
concentrations to increase austenite content. To lower the
expense of the LDSS content, a small amount of
molybdenum and nickel is applied. It offers to pitting
resistance equivalent number (PREN) of approximately 26.
Fig. 2. Transversal direction Microstructure of Sandvik SAF 3207 HD [2] stated that nitrogen is added to provide a concentration of
tube material. The white phase is called austenite, and grey phase is austenites in alloys. Due to the reduction in carbon content
called ferrite: (Source: Guocai Chai et al, (2009), Sandvik Materials and the high chrome content, the machining and welding are
Technology)
much easier than other grades. The LDSS has a strong degree
of mechanical efficiency, corrosion tolerance, and tensile
The chemical composition of 18 to 30% chromium is
deterioration resistance to cracking, as well as decent
added to increase corrosion resistance, although the increase
weldability and durability. The LDSS categories are S32001,
in chromium ferrite content also increases by forming
S32101, S32202, S32304, S82011, S82012, S82122,
dispersed second-phase carbides. 4 to 8% nickel is added to
Molybdenum-containing lean duplex are S32003, S81921,
change the crystalline structure of ferrite to austenite and it
S82031, S82121, S82441, Er.no 1.4655. 1.4669,316L. Lean
has increased toughness and impact resistance. Figure 4
DSS materials are needed for applications that require high
shows how increasing nickel content affects the
strength, such as construction projects, storage tanks,
microstructure of a stainless steel from ferritic to duplex to
containers, etc., which requires long-term corrosion
austenitic. The addition of less than 5% molybdenum
resistance is needed.
improves pitting corrosion resistance and makes the material
avoid brittleness. A minimum of 0.14% nitrogen is added to
2.2. Standard Duplex stainless steel (DSS)
increase the corrosion resistance of pitting and crevices.
The standard duplex stainless steel microstructure has almost
Zirconium, cerium and calcium may also enhance toughness.
equal ratios of austenite and ferrite and is thermally treated
Forming manganese sulfides by incorporating lead, bismuth,
properly during production. Their characteristics are twice as
selenium, or tellurium may increase machinability. Other
high as those of other austenite stainless steels for excellent
compounds, on the other side, may be used to minimize
toughness, mechanical strength and high yield strength [3].
ferrite or austenite in grain.
Standard DSS includes more than chromium 22%,
molybdenum 3%, nickel 5–6% and nitrogen, whose

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microstructure guarantees greater stress-corrosion cracking chromium, 3.82 percent molybdenum, 6.880 percent nickel,
tolerance, greatly improves pitting and crevice-corrosion and 0.5 percent nitrogen and has the highest corrosion
resistance in the presence of chloride, and provides good resistance, strength, and mechanical properties, including
resistance to hydrogen sulphide stress corrosion. It provides a improved tensile and fatigue resistance, resistance to both
Pitting Resistance Equivalent Number (PREN) of about 35. chlorine and sulfur stress cracking, erosion-corrosion, and
The temperature at which normal DSS transitions from general acid corrosion resistance. The SDSS is made by
ductile to brittle is -50oC, and it embitter between 300oC and aging it at temperatures ranging from (800 - 1300)°C in an
550oC after its properties shift, forming sigma and chi phases isothermal setting. Hyper duplex stainless steel is described
between 550o C and 1000o C. as having a PREN value of around 50. S32707 and S33207
The application temperature of the standard DSS should are two Hyper DSS groups. The HDSS has been developed to
therefore range from -50ºC to 300ºC. S31803, S32205, address the growing demand for chemicals, deep umbilical
S32950, and S32808 are the regular DSS types. Normal DSS waters, oil and gas industries. The DSS family of chemical
uses include digesters for the pulp and paper industry, composition, pitting resistance equivalent number (PREN)
bleaching machines, thermal exchangers in the chemical and material used to conduct experimental work is given in
manufacturing industry, pressure reservoirs, reservoirs, Table 1 [4].
plumbing and pipes, tubing and gas and oil handling, and
stock handling devices, rotors, fans, blades, and pressing
rolls, freight tanks for ships and vehicles, food processing 3. Machining of DSS
machinery, and so on.
Owing to fragmentation, heat creation inducing plastic
2.3. Super Duplex stainless steel (SDSS) deformation during manufacturing, and severe wear craters,
Duplex is a mixed microstructure of austenite and ferrite duplex steels are more complicated to process in general. The
(50/50) that has increased the stability and durability of aim of this article is to review recent research on duplex
ferritic and austenitic steels. Super Duplex Stainless Steel stainless steel in the field of metal cutting in the turning
(SDSS) is a mixed microstructure of austenite and ferrite phase, as well as optimization methods for predicting various
(50/50) that has improved the resistant of ferritic and performance dependable factors such as surface roughness,
austenitic steels. The biggest distinction is that the super cutting power, machinability, chip volume ratio, and material
duplex produces a higher amount of molybdenum (3–4%), removal rate over the last decade. The international
chromium (24–26%), and nickel (5.5–8%). The need for conference was held in Grado, Italy, in 2007 to investigate
smaller thicknesses and low costs without compromising the recent developments in the field of duplex stainless
quality and lighter materials with higher mechanical and steel [5], unfortunately, no paper is examined in the field of
chemical properties resulted in the more frequent use of metal cutting and optimization methods used to predict
SDSS. The resistance to corrosion, tensile, yield strength, various output dependable factors. The researchers conducted
ductility, toughness and stress corrosion cracking resistance experimental work by using duplex stainless steel material to
is higher than other duplex stainless steel. The SDSS is predict surface unevenness, wear in tool, machinability, MRR
produced using an isothermal aging treatment at temperatures and chip volume ratio is shown in Table 2. Various factors
between 400°C and 600°C and a processing time between 3 used in experimental work and optimization of DSS are
to 120 hours. Super duplex stainless steels (SDSS) have a shown in Table 3.
PREN of more than 40. S32506, S32520, S32550, S32750,
S32760, S32906, S39274, and S39277 are the mega DSS 3.1.Factors affecting Surface Roughness
groups. Super Duplex is used in the oil and gas industry in Cutting criteria, as well as the condition and grain texture of
heat exchangers, chemical refining devices, pressure vessels, the working material, decide the surface quality of the
and boilers, and is ideal for usage in hostile conditions such machined component. Surface roughness is a vital metric for
as hot acidified ocean water and toxic environments with measuring cutting efficiency in turning operations. The
chloride. greatest emphasis has been placed on research in the area of
superficial roughness in the previous decade, to obtain the
2.4. Hyper Duplex stainless steel (HDSS) maximum level of surface finishing, various optimization
Hyper duplex is also known as HDSS and the latest type of techniques were used.
two-phase stainless steel. Hyper DSS has about 25.08 percent

Table 1. Family of DSS with Chemical Composition (Source: IMOA – International Molybdenum Association)
Types of Grade/Commercial UNS EN Nr.- C- Cr- Ni- Mo- N- Mn- Cu- W PREN
DSS Name-DSS Number- DSS Carbon Chromium Nickel Molybdenum Nitrogen Manganese Copper
DSS
329 S32900 1.4460 .08% 23% – 28% 2.5% – 5% 1% – 2% – 1% – – 30 to 31
First
generation 3RE60 S31500 1.4424 .03% 18% – 19% 4.3%– 2.5% – 3% .05% – .10% – – – 28 to 29
duplex 5.2%
stainless steel 324 S32404 .04% 20.5%– 22.5% 5.5% – 2% – 3% .20% 2% 1%– 2% – 29 to 30
8.5%
A789 S32001 1.4482 .03% 19.5% – 21.5% 1%– 3% .6% .05% – .17% 4%–6% 1% – 21 to 23
LDX 2101 S32101 1.4162 .04% 21% – 22% 1.35% – .1% – .8% .20% – .25% 4%– 6% .1% – .8% – 25 to 27
1.7 %
A815 S32202 1.4062 .03% 21.5% – 24% 1%– 2.8 % .45% .18% – .26% 2% – – 25 to 28
EDX 2304 S32304 1.4362 .03% 21.5% – 24.5% 3% – 5.5% .05% – .6% .05% – .2% 2.5% .05% – .6% – 25 to 28
ATI 2102 S82011 - .03% 20.5% – 23.5% 1% – 2% .1% – 1% .15% – .27% 2%– 3% .5% – 25 to 27
Lean duplex FDX 25 S82012 1.4635 .05% 19%– 20.5% 0.8% – .10% – .6 % .16% – .26% 2%– 4% 1% – 24 to 26
stainless steel 1.5%
NSSC 2120 S82122 - .03% 20.5% – 21.5% 1.5% – .6 % .15% – .2% 2%– 4% .50% – 1.5% – 24 to 26
2.5%
A815 S31803 1.4655 .03% 22% – 24% 3.5% – .1% – .6% .05% – .2% 2% 1%– 3% – 25 to 27
5.5%
- 1.4669 .045% 21.5% – 24% 1% – 3% .5% .12% – .2% 1% – 3% 1.6% – 3% – 25 to 27
316L - 1.4404 .03% 16.5%-18.5% 10% – 2 %-2.5% ≤ 0.11% 2% - -

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13%
A790 S32003 - .03% 19.5% – 22.5% 3%– 4 % 1.50% – 2% .14% – .2% 2% – – 27 to 31
Molybdenum - A240 S81921 - .03% 19%– 22% 2% – 4% 1% – 2% .14% – .2% 2%– 4% – – 27 to 28
containing FDX 27 S82031 1.4637 .05% 19% – 22% 2% – 4% .60% – 1.4% .14% – .24% 2.5% 1% – 27 to 28
Lean duplex A790 S82121 - .035% 21% – 23% 2% – 4% .30%– 1.3% .15% – .25% 1%– 2.5% .2 – 1.2% – 27 to 28
stainless steel
LDX 2404 S82441 1.4662 .03% 23% – 25% 3% – 1%– 2% .20% – .30% 2.5 % – 4% .1 % – .8% – 33 to 34
4.5%
2205 S31803 1.4462 .03% 21% – 23% 4.5% – 2.5% – 3.5% .08% – .20% 2% – – 33to 35
6.5%
2205 S32205 1.4462 .03% 22% – 23% 4.5% – 3% – 3.5% .14% – .20% 2% – – 35 to 36
Standard
6.5%
duplex
A473 S32950 - .03% 26% – 29% 3.5% – 1% – 2.5% .15% – .35% 2% – – 36 to 38
stainless steel
5.2%
DP28W S32808 - .03% 27% – 27.9% 7% – .8% – 1.2% .30% – .4% 1.1% – 2.1% – 36 to 38
8.2% 2.5%
NAS 64 S32506 - .03% 24% – 26% 5.5% – 3% – 3.5% .08% – .2% 1% – .05% – 40to 42
7.2% .30%
F255 S32520 1.4507 .03% 24% – 26% 5.5% – 3% – 4% .20% – .35% 1.5% .50% – 2% – 40 to 43
8%
255 S32550 1.4507 .04% 24% – 27% 4.4% – 2.9% – 3.9% .10% – .25% 1.5% 1.5% – 2.5% – 38 to 41
6.5%
2507 S32750 1.4410 .03% 24%– 26% 6% – 8% 3% – 5% .24% – .32% 1.2% .5 % – 40 to 43
Super duplex
stainless steel F55 S32760 1.4501 .03% 24% – 26% 6% – 8% 3% – 4% .20% – .3% 1% .5 % – 1% 0.5% – 40 to 43
1%
SAF 2906 S32906 1.4477 .03% 28%– 30% 5.8% – 1.5% – 2.6% .30% – .4 % .8 %– 1.5% .8 % – 41 to 43
7.5%
S39274 - .03% 24% – 26% 6.8% – 8% 2.5% – 3.5% .24% – .32% 1% .20% – .8% 1.5% – 40 to 42
2.5%
A790 S39277 2- .025% 24%– 26% 6. %5 – 3% – 4% .23% – .33% .80% 1.2% – 2% .8% – 40 to 42
8% 1.2%
SAF 3707 HD S32707 - .03% 26%– 29% 5.5% – 4% – 5% .3 % – .5% 1.5% 1% – 49 to 50
Hyper duplex 9.5%
stainless steel SAF 3207 HD S33207 - .03% 29% – 33% 6% – 9% 3% – 5% .40% – .6 % 1.5% 1% – 52 to 53

The experimental work is carried out by considering the and finally concluded that EN 1.4404 stainless steel was best
different cutting speed, the rate of feed with a constant considered for machining the part. The experiment is
cutting depth of S32205 and S32750 duplex cast stainless performed by considering the cutting speed and low and high
steels using Titanium Carbo Nitride coated cemented carbide fluid pressure cooling conditions of the super duplex
and Titanium carbide tools. The author suggests that during UNS32750 stainless steel to determine the parameters that
the experiment of texture analysis, the increasing cutting have the greatest impact on corrosion resistance. The results
speed decreases the roughness of the surface, the roughness indicate that extended life of tool, good surface unevenness
of the surface decreases with decreasing feed speed [6]. The and high resistance due to corrosion is achieved while turning
experiment was conducted to analyze the hardness of duplex with high-pressure-cooled PVD - physical vapor deposition
coated carbide tools during the machining of 1.4462 steel coated inserts [12]. The study was conducted using dry
using statistical techniques. Hardness measurements were machining of duplex stainless steel to determine surface
carried out at varying cutting speeds and under both wet and roughness using the load curve with different cutting speeds,
dry environments. [7]. The author [8] built a mathematical feed and cutting depth according to cutting conditions using
model using the Response surface method to quantify surface TNMG 160408 cutting tool inserts and detected that rate of
roughness while turning the DSS using the turning feed is the major parameter influencing surface unevenness
mechanism, taking into account cutting speed, feed, and [13]. An experiment was conducted by [14] to reduce surface
cutting depth. The main factor influencing surface roughness, roughness and cutting force using 2205 DSS material and
according to the source, is feed velocity. The cutting pace, multilayer milling cutter PVD CNMG 120408 SM grade
rate of feed, and cutting depth of SAF 2507 super duplex 1115 by taking into an account of cutting speed, rate of feed,
stainless steel bars were measured using uncoated carbide cutting depth and tool nose radius. The optimization
cutting equipment, with the feed rate being the parameter that was performed using ANOVA, BBD and RSM. The author
has the largest effect on surface roughness. The work is suggests that an increase in the speed, rate of feed influences
designed and the analysis is conducted using variance the roughness of the surface. The author optimized the
analysis (ANOVA) and the surface roughness and S/N ratio machining parameter: cutting speed, rate of feed and cutting
were measured using the L18-Taguchi method during depth to predict surface unevenness and force due to cutting
optimization. [9]. The ANOVA statistical technique is used of cast material DSS ASTM grade 995 4A and 5A utilizing
to identify significant variables and optimization was the Taguchi and ANOVA method. The outcomes revels that
performed using the full factorial design of Taguchi rate of feed is the most considerable parameter that affects
experiments to measure surface roughness. The super duplex the surface unevenness and cutting force [15]. Wet and dry
SAF 2507 stainless steel bars with uncoated carbide cutters longitudinal turning tests are carried out using duplex grades
are used in turning operation. Cutting speed, feed speed and of stainless steel EN(1.4462) and EN(1.4410) using carbide
cutting depth are the parameters used in wet, dry and gas- inserts to analyze the unevenness of the surface, the wear in
cooled cutting conditions to optimize surface roughness and the tool, the forces, the power using the input
tool wear. When liquid CO2 is used as a coolant, the surface variables: feed, cutting speed and cutting conditions. The
unevenness and flank wear on the tool are minimized, optimization technique called bat algorithm is used to achieve
according to the results [10]. The evaluation made by the multi-objective optimization of adversarial performance. The
author [11] to compare the EN (1.4404) austenitic steels, author ensures the most appropriate cutting configuration for
duplex standard EN (1.4462) and super duplex EN (1.4410) making efficient turning operation [16]. The EN (1.4404),
in turning operation by facilitating ANOVA and optimized EN (1.4462) and EN (1.4410) duplex material are considered
using the Taguchi coupled with fuzzy-multiple attribute for turning operation, the ANOVA analysis is carried out to
decision-making methods (FMADM). The ANOVA model the performance characteristics. The MADM methods
predicted that the feed speed is an impact on surface quality such as GTMA and AHP - Technique for order preference by

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similarity to ideal Solution (AHP-TOPSIS) are RSM to examine the interaction effect of each parameter:
simultaneously adapted to associate well-known surface cutting speed, feed, cutting depth of EN 1.4410 super duplex
excellence features into a single index called MSQCI .The stainless steel. The ANFIS is convened using fuzzy logic
author suggested that the performance of multiple machining systems. Lastly, the accuracy of the predictive models is
and surface qualities could be optimized efficiently based on comparative examination and concludes that feed
using MADM methods are coupled to the fuzzy set theory speed has the greatest effect on surface unevenness. In dry
[17]. The author [18] tested different rate of feed and cutting and cryogenic conditions, turning operations were performed
speeds using SAF 2507 DSS materials and concluded that the on the DSS 2205 using PVD coated nano-multilayer TiAlN.
maximum surface finish is achieved with a high cutting speed As opposed to dry spinning, cryogenic cooling improves
and lower rate of feed. The turning operation is formed roughness by around 18-23 percent [29]. The machining is
using 1.4462 duplex stainless steel, to analyze the optimal performed by means of vegetable oil (Neem and Coconut
machining conditions, which cut back pollution generated oils) as cutting fluid to measure surface roughness, tool wear
by the coolant and lubricant. The surface unevenness, cutting and tool temperature, while turning AISI 2205 DSS,
force and tool wear are analyzed. The results indicate that considering the spindle speed, feed rate, cutting depth and
higher parameters necessary to energy consumption type of cutting fluid. The Taguchi L27 methodology is used
minimization will also result in an increase in surface to improve the parameters. Coconut oil-based cutting fluid
unevenness [19]. The cutting operation is accomplished on was found to be more effective at increasing surface
the SAF2507 duplex stainless steel by considering the cutting roughness [31] analyzed the M.R.R, surface unevenness, feed
speed, feed and cutting depth to analyze the wear of the tool rate, thrust force and cutting force using Duplex 2205. The
and the roughness of the surface. The comparison is done by author concluded that surface roughness are high in high
the author [20] of three PVD coating tool: TiAlSiN, AlTiN spindle speed and cutting depth by considering the spindle
and AlTiN using HiPIMS method, results shows that the rate, feed rate, and depth of cut, of turning operation. The
presence of the buildup edge for the surface roughness are analysis is carried out using DOE, ANOVA and RSM. The
aggravated at a slower speed. Dry and wet turning work are experiment was carried out using SAF 2507 - DSS to
carried out [21] to examine the effect of the cutting fluid and measure the surface texture, using RSM and ANN technique.
lubricant using the MQCL turning process to ensure the clean The validation is done by the author using a genetic
production of DSS (1.4462) by using the surface morphology algorithm. The findings show that perhaps the feed rate has
examination using an IFM and found that MQCL cooling been the most important element in reducing surface quality
improves surface effects over dry machining. Researcher [22] [32]. The researcher [33] performed the study to determine
performed the experiment using the super duplex EN the impact of surface unevenness and residual stresses on
(1.4410) to analyze the machinability and surface roughness coated and uncoated carbide tools. The experiment conducted
using a cooling and lubrication fluid. ANOVA was used to under dry working condition and material considered for
create the mathematical model, RSM was used to create the turning is 2205 Duplex Stainless Steel and cutting tool
predictive model, and GA was used to optimize the model. as Cemented carbide tools. The effect of reduced surface
When machining DSS 2205 in a conventional turning unit, unevenness was three times greater in uncoated tools than in
the author [23] looked at the impact of surface unevenness coated tools. The experimental work is performed by [34] to
and tool wear. Comparison of machining output between focuses on the practical analysis to turn SDSS UNS
normal coolant and cold air coolant using TiAlN coated S32760 with nano-coated MEGACOAT carbide
carbide with constant cutting pace, feed, and cutting depth. In insert. The surface unevenness, force due to cutting and MRR
comparison to the traditional flood coolant, the findings are analyzed using ANOVA and the results are
indicate that the cooled air coolant generated a better surface optimized using Taguchi Analysis to predict the experimental
finish. The TiAlSiN PVD coated tool (3.3 micrometer), values. The result emphasized that the feed rate is a
AlTiN (3.0 micrometer), and AlTiN (7.0 micrometer). To test predominant constraint for Ra. Machining carried out under
tool life and surface roughness, the super DSS (2507) dry turning to examine surface unevenness, MRR by
material is used under dry cutting conditions with parameters considering velocity due to cutting, rate of feed and approach
such as cutting pace, rate of feed, and cutting depth. The angle. ANOVA was used for mathematical research, and the
authors [25] have developed a strategy for the best Taguchi process of the DSS material was used to refine the
combination of tool geometries, feed, coolant used to WC-Co coated carbide inserts.
increase life of tool life, productivity, to reduce surface The findings showed that the rate of feed is the most
roughness. The longitudinal, tapered section is made using influential parameter [35]. The author [36] discussed an
UNS S32750 DSS. This results in the shortest life of the tool impact on cutting speed, rate of feed and cutting depth to
life and lowest roughness values for longitudinal cuts with analyze the characteristics of cutting force, surface
reduced feed rates. Using ANOVA and the Taguchi L9 unevenness and MRR when turning UNS S32760 SDSS
orthogonal matrix, a predictive model is created to determine using nano-plated MEGACOAT carbide inserts. The
the surface texture of 2205 DSS content. Cutting speed, rate ANOVA and Taguchi experimental design helps
of feed, and approach angle are all seen as input process predict factors. The relationship analysis in Taguchi gray is
parameters. For longitudinal cuts with decreased feed speeds, carried out for simultaneous optimization. The findings
this result is the shorter tool life and the lowest roughness indicate that the feeding rate is a dominant constraint for Ra.
values [26]. S32205 is a nitrogen alloyed DSS that was used Experiments were carried out using SDSS- 2507 and a
in this study. Input parameters include cutting tempo, feed handled cryogenic instrument, with cryogenic coolant
rate, and cutting depth. The mathematical model is developed explicitly passing through the insert of the changed cutting
using ANOVA and optimization is performed using the tool. The findings are compared to those of dry cutting. The
Taguchi technique to forecast surface unevenness. The effect of cryogenic coolants LN2 injected into holes drilled in
researcher proposes that rate of feed is the most significant the tungsten carbide cutting tool's flank and rake surfaces.
variable that affect surface unevenness [27]. The author [28] Chip breaking is strong in cryogenic machining, which
developed a predictive model by means of ANOVA and decreases friction between the device and tool interface while

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maintaining a good dimensional accuracy [37]. The impact of tool. The flange, crater and notch wear are studied. The
TiAlN and TiN coated drills, as well as cutting criteria, on mathematical model is developed by using multi-regression
drilling performance was examined. In the tests used to analysis and analyzed by ANOVA. The aim of the study was
quantify cutting force and surface roughness, various cutting to find the turning variables affected the reduction of
speeds and rate of feed were used. An experiment was flank wear rate and chip formation. The working material and
performed under FFD conditions and optimal situations were tools are made of 2507 – SDSS, an uncoated carbide tool.
determined from the values measured by the GRA method. In Cutting speed, rate of feed and cutting depth serve as
addition, ANOVA method was conducted. The feeding rate variables to measure flank wear. The optimization was
is calculated to be the most significant element on Ra performed using the RSM [46]. The study was conducted by
dependent on the ANOVA data. [38]. In this current work, [47] to fix the coated carbide tool surface structure. The
[39] 2507 super duplex stainless steel was used to examine cutting material is 1.4462 - DSS and cutting tool inserts are
the carbide inserts have a multilayer coating of MT-TiCN/ TNMG 160408 taken to do turning operation. The tool wear
Al203.The experiment was conducted at a constant cutting study examines the wear of the wedge on the rake face as
rate and cutting depth. Five different feeding rates were used well as the outline of the cutting point. SEM analysis is used
- Poor surface finishing resulting from dry cutting resulted in to examine the rake and flank wear of the cutting tool, and
higher stress concentration and chloride accumulation in the the results show that cutting edge wear raises as cutting speed
surface defect area. The use of MQL has improved the increases [48]. The author [49] observes the impact of the
surface finish which has helped reduce pit formation. All cutting parameters: cutting speed, the advance and the cutting
tests were conducted on a SDSS 2507 hot-forged material. depth on the life of the tool in the DSS turning process. This
Cutting with CCMT120408MR style inserts is advised, experiment is carried out using DSS (1.4462) using TNMG
implying that there is an optimum pace beyond which surface 160408 as cutter. The factor design of an experiment is used
roughness does not deteriorate [40]. Wear in the instrument, to forecast the lifetime of the tool. The established equations
cutting power, and surface unevenness were all measured and concluded that cutting speed is the major influencing
when dry turning DSS 2205 with tungsten carbide inserts factor that affect the life of the tool. The author [50] carried
coated with AlTiCrN and AlTiN. Magnetron with a High out an experimental study in two phases considering 1.4410
Power Impulse Under dry spinning, the sputtering method EN SDSS, 1.4462 EN DSS and 1.4404 EN austenitic steel. A
was used with various cutting speeds, feeds, and a set depth new methodology based on Mamdani's fuzzy interference is
of cut of 0.8 mm as cutting parameters. The lower surface used to classify chip shapes to predict the chip volume ratio.
finish was caused by a mixture of high speed (180 m/min) TOPSIS, GRA, VIKOR and UA method was used for
and low feed (0.12 mm/rev) [41]. optimization. The results showed that the conversion of the
results of the different MADM methods is used to determine
3.2. Factors affecting Tool wear an optimal combination of cutting parameters. In the next
The process of wear and tear of the tool depends mainly on stage, the force exerted due to cutting and current
the cutting parameters. The wear of the tool point causes consumption signals of the machine are adopted as indirect
worsening in the superiority of the machined surface and techniques used to observe the wear of the cutting tool. The
therefore reduces effectiveness and production. Irregular SAF 2507 SDSS is used to allow a detailed distinction
wear and accumulated edge (BUE) often occur during between dry, wet, and gas-cooled turning. Cutting speed, rate
processing of duplex stainless steel because of its properties, of feed, and depth of cut are considered as input parameters.
namely high robustness, low thermal conductivity and a high It has been revealed that gas-cooled machining performed
degree of work strengthening. There are various kinds of better than wet and dry machining [51]. The author [12]
wear of the tools during machining. Fatigue-induced failure, emphasized experimentation to prevent wear and tear of
diffusion wear, wear in flank, crater wear, notch wear, cutting tools, suggests that the observed that notch wear
abrasive wear, wedge wear, notch wear etc. The affected by the chilling effect created by the burr, the use of
investigational study is conducted to observe the wear on tool the high-pressure cooling system has brought advantages,
by means of abrasive wear mechanisms, fatigue-induced such as the prolonged lifetime of the tool. In the time of
failure mechanisms and wear mechanisms of the adhesive machining, it's important to use high-pressure cooling to
and diffusion made of duplex 2205 stainless steel. Tin-coated ensure a long service life. The cutting speed was recognized
HSS and Tin - coated cemented tools are used for machining as the greatest important factor that affects the wear in the
purposes. To minimize tool wear, the study concluded that tool. The wear on the tools was examined using a SEMI. The
tin-coated HSS is used at low cutting speeds [42]. The author suggests that the wear in the tool is owing to
experiment was carried out with a X2CrNiMo22-5 (2205) attrition at lower cutting speeds [15]. The study
stainless steel duplex cutting tool using DNMG 15 06 08 MF purposeful the cutting conditions of the turning 1.4462 -
and the cutting factors are the advance, the cutting depth and DSS with coated carbides to predict tool life. The wear
cutting speed. Cutting force, surface unevenness and wear in results are compared between the two tool points. The author
the tool are tested. The experiment is conducted by means of concluded that raising the cutting speed causes the
a high-pressure water jet assisted turning [43]. The results increase cutting edge to wear, particularly at higher feed
indicate that chip fragmentation is fine, and tool lifetime is speeds, and that using mineral oil-based lubricants reduces
increased. The researcher [44] investigated tool wear the cutting tool's durability [52]. In terms of tool wear rate,
behavior during machining of 2507 - SDSS, 2205 - total wear depth, and tool temperature, the simulation results
Std DSS and 2101 - LDSS. The wear of the cutting tool, in were obtained. While machining, the TOPSIS, VIKOR,
many serious belongings, has been observed to a certain level GRA, and UA are used at the same time to maximize the
on all the dissimilar cutting data is studied. The researcher average wear flow of DSS tool. In contrast to EN 1.4410, the
[45] conducts the research using stainless steel Austenitic tool wear intensity is lower than EN 1.4462 [53]. The
ferritic (Duplex) tempered PH. The comparison is performed document describes the optimization method used to predict
using four different ceramic cutting tools based on alumina to tool wear using DSS 1.4462 (DIN EN 10088-1).
determine the size of the surface unevenness and life of the Experimental design (DOE) is used to create a mathematical

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model to create the experimental data. An ANOVA edge forming were found, which ruined the tool edges,
examination was established to determine the significance of according to the source. Dry machining showed the most tool
the processing parameters. The Taguchi method with the flank wear, and values improved as cutting pace increased
orthogonal matrix L9 and the signal-to-noise relationship is [32]. The experimental work is carried out using a feed,
used to optimize. The cutting speed and rate of feed are affect cutting depth and cutting speed as input parameter using
the permanence of the tool [54]. The experimental work is molded DSS. The shape of the insert and quality of the
performed [55] to optimize using dynamic programming of cutting tool and technical viables of the machining, flank
the cutting variables of 1.4462 - DSS. Dijkstra's modified wear and crater wear determined [63]. In cryogenic
optimization algorithm results the optimum value of cutting machining, chip breakage is high, which results in less
variables using coated carbide tool. The ANOVA method resistance between the chip-tool interfaces [37]. The effect of
specifies that the cutting speed and feed speed affected the LN2 cryogenic coolants delivered through holes on the flank
tool lifespan. and rake surface of tungsten carbide cutter tool
The aim of this research is to find out cause of tool wear material in SDSS - 2507 turning using a cryogenic
and tear. images of worn areas obtained bu using SEM were configuration built in-house is the focus of this study. Under
included in this study. To understand the causes of tool wear dry and cryogenically cutting prepared inserts, the
using a EDS system Wear has arisen while machining super temperature of the cutting instrument does not alter
duplex stainless steels owing to a rough burr [56].The tool substantially. When the LN2 is provided by a specifically
comparison is carried out by [57] using 2507 -SDSS by using adjusted insert, though, there is a noticeable change in the
PVD and CVD coated tools. The author accessed the wear in temperature of the cutting instrument, which has resulted in
wear, force exerted, surface integrity and rise in temperature the tool having a long service life. In dry cutting, abrasion
and according to the findings, the MT-TiCN-Al2O3 coating and obedience governed the wear process, resulting in
outperforms other coatings. As compared to chilled cooled increased tool wear [64]. In contrast to dry cutting, flood
air coolant, tool life was improved utilizing traditional flood machining and the MQL setting decreased edge accumulation
coolant. Despite their low hardness, AlTiN coated tools and increased tool wear efficiency by 11.95 percent and
outperform AlTiSiN coated inserts [23].An experimental 33.08 percent, respectively [39]. The existence of AlTiCrN
study [24] on the 2507 SDSS with non coated and coated and AlTiN coated instruments is 6 and 4 times that of
with PVD carbide inserts considering rate of feed, cutting uncoated tools, respectively [41].
speed, and dry cutting depth. The study includes the
recognition of the wear mechanism of the tools on the rake 3.3. Factors affecting Machinability
and tool flank face. Cutting at a higher speed improves the DSS are considered difficult to automate. During machining
cutting edge's wear strength dramatically. The usage of processes, built-up edges and rough wear show off often. As
cemented carbide turning cutting tool inserts with CVD- high-strength DSS are machined, the processing problems
TiCN + Al2O3 and TiCN PVD and AlTiN coatings to the increase. Machinability is commonly related to the stainless
32750 - SDSS content was explored by the author [58]. This steel counterpart of pitting corrosion resistance, which is a
activity suggests that AlTiN PVD coated inserts had double value that reflects the alloy material of the steel. Modern
the tool life of TiCN + Al2O3 CVD coated inserts. The duplex stainless steel grades are difficult to machine due to
researcher [59] studied the tribological execution and higher austenite and nitrogen content, as well as growing
wear mechanisms of uncoated, coated carbide tools when alloy content [65]. Tests were conducted using a DSS -
turning of 2507 SDSS. T chip characteristics are used to X2CrNiMo22-5 (2205). The authors suggest that by
evaluate chip width, compression ratio, shear angle, and improving machinability characteristics, productivity
bottom surface morphology. The show that the wear improves proportionately [43]. To improve the strength of an
mechanisms of the AlTiN coating tool perform better than LDSS, lowering its FN appears to be a good solution. It could
the TiCN + Al2O3 CVD insert. The author [60] discovered be obtained by increasing the most austenitic elements (C, N,
that the strain hardening of 2205 DSS content is highly Ni, and Cu) and/or reducing the most ferritizing elements
vulnerable to cutting pace during the operation. This paper (Mo, Si, Cr) [66]. The authors discussed the effect of cutting
explores the process of built-up edge forming in the parameters and conditions to calculate machinability index
stagnancy area of duplex alloys in order to solve this issue. and effect of different tool materials is emphasized and
Experimental studies were carried out in the machining of concluded that tool wear mechanisms is the most responsible
S32750 DSS using uncoated and coated carbide inserts. The for tool failure [49], [67]. EN 1.4462 and super EN 1.4410
wear and failure mechanisms were studied during turning DSS are machined at a steady cutting pace to meet industrial
operations using a comprehensive tool wear analysis. The requirements. The author emphasizes that reducing the
results indicate that turning with a TiAlN coating applied in cutting speed during dry cutting EN 1.4410 improves
PVD on a carbide insert extended the life of the tool, reduced machinability. Wet cutting EN 1.4462 got a higher choice
chip thickness and improved the presence of chips below the than equivalent dry cutting EN 1.4462 and wet cutting EN
surface [61]. The author [30] carried out experiments to 1.4410 [11]. The chip forming process and machinability of
observe abrasive wear and tear. According to the results, the two-phase materials is investigated using the wrought DSS-
cutting speed is high, and then there is an increase in flank SAF 2205 and SAF 2507. Drilling tests were carried out on a
wear. The cumulative edge was not shaped when the CNC machining center with solid carbide twist drills coated
traditional insert was used in the longitudinal cut, according with (TiAlN+TiN). The highest machinability for tool wear
to Investigator [25], and flank wear stayed thin until the tool's and cutting strength is SAF 2205 [68]. To boost
useful life finished, before abruptly rising. Under cryogenic machinability and reliability, the author [30] proposed that
cooling, tool wear and saw tooth development were all vegetable oil-based cutting fluids could be a safer alternative
minimized [29]. [62] Using G X2CrNiMoCuN 26-6-3-3 cast to mineral oil. The machinability indices for DSS-2205 under
SDSS, PVD coated cutting inserts, TiAlN, and TiAlSiN with liquid nitrogen cryogenic cooling worked higher than dry
constant cutting speed and feed rate, an experimental test was cutting conditions, according to experimental findings [29].
conducted. In the machining tests, extreme burrs and build-up Different cooling media, such as dry cutting, flood coolant,

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and MQL , were used to examine the SDSS's machinability Ac - Chip with cross sectional area
and surface integrity conduct [39]. The machining reliability Vc - Cutting Speed
projections indicate that increasing the nose distance F - Rate of Feed
increases the total secure cutting depth below which ap - Cutting Depth
unpredictable vibrations exist, according to the researcher R - Chip Volume ratio
[40]. This observation can be used to direct the selection of Qsp - Volume of chips
cutting parameters for SDSS machining to ensure high- R -Volume needed for randomly arranged metal chips,
performance and vibration-free results. However, according material volume of the same amount of metal
to the literature, DSS is not as machinable as ASS. For dry removal
spinning, a cemented M35 grade unglazed carbide method
was used. HiPIMS has been used to cover cemented carbide A SEM was used to examine the chips produced during
substrates with AlTiN and AlTiCrN. Cutting tempo, feed, the process, which were optimized using three methods: dry,
and depth are all maintained at the same level. Benchmarking wet, and gaseous cooling machining. Dry machining
requirements included nose wear, tool life, and surface produces constant and rippling chips, which curl inside the
roughness. Because of its high heat reliability, the AlTiCrN tool work attachment and must be withdrawn abruptly during
coated tool had a tool life 5 times longer than non-coated machining. Since the chips produced in gas-cooled
tools and performed higher. Due to the higher wear rate of machining split at regular intervals and shape discontinuous
uncoated equipment, the surface unevenness of coated tools chips, the tool's working interface is less affected [9]. The
was observed to be 1.006 m compared to 3.14 m for uncoated author [10] investigated the morphology of chips under
tools [69]. different working conditions and came to the conclusion that
gas-cooled machining is ideal for higher output ratio
3.4. Factors affecting Material Removal Rate (MRR) machining. The aim of this research was to develop a method
The material removal rate (MRR) is the volume of material for determining the minimum chip thickness. According to
extracted every minute or second. It can also be calculated by the author [72], a considerable amount of component content
dividing the amount of material separated by the machining can only be bent on the machined surface or shape lateral
period [70]. flow and will not be withdrawn as a chip. An overview of
soft computing techniques and optimization methods
MRR = π. Davg. d. f. N in mm3/min (1) Selecting optimal process parameters plays a significant
role in ensuring quality of product, lowering manufacturing
where, costs and increasing productivity, better surface unevenness,
Davg - Average diameter of workpiece in mm higher MRR and low wear in cutting tool. In the case of a
D - Cutting Depth in mm turning process, the important variables to optimise are the
f - Rate of Feed in mm/rev cutting speed, rate of feed, cutting depth, spindle speed,
N - Rotational speed of workpiece in rpm nomenclature of tool etc. To optimize the machining process,
modelling and optimization of process variable of any
The authors [71] identify the most important criteria for industrialized process is usually a difficult work. The author
increasing efficiency thus maintaining target product output [73] in-process input-output and parameter optimization
at a low cost and shorter lead time. The tests were carried out techniques are divided into traditional optimization
under dry and wet conditions using ANOVA and Taguchi's algorithms, nontraditional optimization algorithms. The
mixed orthogonal network L18 to process duplex alloy steel traditional and nontraditional technique used for optimization
work pieces using a cemented carbide method. Taguchi's is show in figure 5.
person method was used to find the best criteria for minimal
surface roughness and optimal MRR. By integrating
optimization problem into an equal target, the outcomes are 4. The traditional optimization techniques are Modeling
comparable to those produced by GRA. The key aim of this and Optimization Techniques
experiment is to find the best process parameters for
achieving high MRR and low surface unevenness. The author Statistical Regression method and ANOVA, Fuzzy Set
came to the conclusion that when the spindle speed is strong, Theory - Artificial Neural Networks, Gray Relational
the MRR is high, and vice versa [31]. Ra and Fc are reduced, Analysis (GRA), Taguchi Robust Design Method, Taguchi
and MRR is maximized, to obtain the output attributes. Fuzzy-Based Approach, Factorial Design Method, Response
Relational research Taguchi-grey [34] using S/N ratio review, Surface Methodology, Knowledge-Based Expert Systems,
the author [36] estimated MRR. As a consequence, the Principal Component Analysis (PCA).
cutting forces and material removal intensity are largely
defined by the depth of break. The chip volume ratio is Mathematical Iterative Search Methods:
determined by the chip shape. [50] The equation for Chip Dynamic Programming, Goal Programming, Generalized
volume ratio was derived. To estimate chip volume ratio, the reduced gradient Method (GRG), Geometric Programming,
author developed a new technique focused on Mamdani Quadratic Programming, Integer Linear Programming [74],
fuzzy intervention of chip shapes classified in chip split [75].
diagrams. The nontraditional optimization algorithms are Meta-
Heuristics optimization techniques:
Qw = Vc. Ac = Vc. f. ap (2) Genetic Algorithms, Simulated Annealing, Tabu Search,
Particle Swarm Optimization, Ant Colony Optimization,
Qsp = R. Qw (3) Artificial Bee Colony Algorithm, Artificial Immune
Algorithm, Shuffled Frog Leaping Algorithm, Harmony
Where, Search Algorithm.
Qw - Volume of the removed material

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Hybrid Algorithms: Genetic Simulated annealing global best harmony search (hgHS) algorithm and hybrid
algorithm (GSA), Hybrid immune algorithm (artificial modified global best harmony search (hmgHS) algorithm,
immune algorithm and hill climbing local search algorithm), Hybrid meta-heuristics with evolutionary algorithms, Hybrid
Memetic algorithm (GA is combined with the heavy local harmony search (hHS) algorithm Apart from the
search), Hybrid approach (GA, SA, and tabu search), optimization the author added some the optimization
Heuristic algorithms such as SA, GA and hybrid techniques that are used while conducting literature survey
algorithm(hybrid-GASA), Novel hybrid ant colony in Duplex stainless steel.
optimization approach, Adaptive network based fuzzy Modeling and Optimization Techniques:
inference system (ANFIS) with the genetic learning Dijkstra's optimization algorithm, MADM METHODS
algorithm, Hybrid Taguchi-genetic learning algorithm (Multiple Attribute Decision Making and Multiple Objective
(HTGLA), Multi-objective optimization method based on Decision Making).
adaptive simulated annealing genetic algorithm, Hybrid

Table 2. DSS Material used in Experimental Work

Generations Grade/ UNS EN Surface Roughness Tool Wear Machinability MRR Chip
of DSS Commercial Number - Nr.- volume
Name- DSS DSS DSS ratio
First generation 329 S32900 1.4460 - - - - -
duplex stainless 3RE60 S31500 1.4424 - - - - -
steel 324 S32404 - - - - - -
Lean duplex A789 S32001 1.4482 - - - - -
stainless steel LDX 2101 S32101 1.4162 - 44 72 72
A815 S32202 1.4062 - - - - -
EDX 2304 S32304 1.4362 - - - - -
ATI 2102 S82011 - - - - - -
FDX 25 S82012 1.4635 - - - - -
NSSC 2120 S82122 - - - - - -
A815 S31803 1.4655 -- - - - -
- - 1.4669 - - - - -
316L - 1.4404 11, 17 50 11 - -
Molybdenum - A790 S32003 - - - - - -
containing Lean
A240 S81921 - - - - - -
duplex stainless
FDX 27 S82031 1.4637 - - - - -
steel
A790 S82121 - - - - - -
LDX 2404 S82441 1.4662 - - - - -
Standard duplex 2205 S31803 1.4462 - - - - -
stainless steel 2205 S32205 1.4462 6, 7, 8, 11, 13, 14, 15, 16, 17, 15, 23, 29, 30, 41, 42, 43, 44, 47, 48, 11, 41, 43, 49, 68, 69 71, 72 72
19, 21, 23, 26, 27, 29, 30, 31, 49, 50, 52, 53, 54, 55, 60
33, 35, 38,41,71
A473 S32950 - - - - - -
DP28W S32808 - - - - - -
Super duplex NAS 64 S32506 - - - - - -
stainless steel F255 S32520 1.4507 - - - - -
255 S32550 1.4507 - - - -
2507 S32750 1.4410 6, 9, 10, 11, 12, 15,16, 17, 18, 12, 15, 24, 25, 32, 37, 39, 44, 46, 50, 11, 68 9, 10, 72 9, 10, 72
20, 22, 24, 25, 28, 32, 37 39, 40 51, 53, 57, 58, 59, 61, 64
F55 S32760 1.4501 34, 36 34, 36 - -
SAF 2906 S32906 1.4477 - - - - -
A790 S39277 - - - - - -

Hyper duplex SAF 3707 HD S32707 - - - - - -

stainless steel SAF 3207 HD S33207 - - - - - -

Table 3. Various factors and Optimization used in Experimental work

Author Material used & Tools used Quantative insight (Input & Optimization Outcomes & Critical evaluation
Output Responses) Methods used
Philip and Material: ASTMGradeA-995, Input- Vc (80,100,120,140 Statistical regression ASTM A 995 Grade5A leads to better surface
Chandramohan ASTMGrade-4A and ASTM Grade and160m/min), ap (0.04,0.08 and technique, Texture finish. Texture analysis only carried out, recent
(2013) [6] A-995 ASTMGrade-5A 0.12mm/rev), Constant fz (0.5mm/rev) analysis(Bulk) optimization methods are not used for prediction.
Tools: TiCN Coated and TiC Output - Surface Roughness
Coated Cemented Carbide
Krolczyk et al. Material: 1.4462 (DIN EN 10088- Input- Vc(50,100,150m/min), ap(2 mm), Statistical regression Increase of Vc (from 50 m/min to 150m/min) tends
(2013) [7] 1) DSS & fz(0.3mm/rev) technique to increase of surface hardness. Work is done to
Tools: Duplex coated carbide tools Output - Surface Roughness perform the hardness using different grade of tools
(T1 MM 2025 ) (T2 CTC 1135 )
Krolczyk et al. Material: 1.4462 (DIN EN 10088-1) Input- Vc (50and150m/min), ap (2mm), fz Statistical regression fz was main factor influences surface roughness.
[8] DSS & (0.2and0.4 mm) technique The ranges is not specified by author to get
Tools: TNMG 160408(Coatings: Output - Surface Roughness optimum cutting conditions
Ti(C,N)-(2μm)(top layer),
Al2O3-(1.5 μm) (middle layer),
TiN-(2 μm) (bottom layer) Coating
technique:CVD.
Senthil Kumar Material: SAF 2507 DSS Input- Vc (100and120 m/min), fz (0.6,0.8 ANOVA and Taguchi Vc -100 m/min, fz - 0.06 mm/rev, and Depth of cut
et al. (2013) [9] Tools: Uncoated cemented carbide and1.00mm/rev) , ap (0.5,0.75 and method - 0.75 mm. Feed rate was main factor influences on
cutting tool inserts - CNMG 120408-1.00 mm ) surface roughness
QM, grade H13A Output - Surface Roughness and S/N ratio
Senthil Kumar Material: SAF 2507 DSS Input- Vc (80,100and120m/min), fz ANOVA and Taguchi Using liquid CO2 as coolant the surface roughness
and Tools: Uncoated cemented carbide (0.6,0.8and1.00mm) , ap (0.5,0.75and method and the flank wear was reduced.
SenthilKumaar cutting tool inserts - CNMG 120408- 1.00mm )
(2014) [10] QM, grade H13A Output - Surface Roughness and Flank
wear
Rastee et al. Material: EN 1.4404 austenitic, EN Input- Vc (50,100,150,200), ap Taguchi method, The ANOVA result emphasizes that feed flow is

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(2014) [11] 1.4462 Std DSS and EN 1.4410 SDSS (0.5,1.5,2.5, 3.5), fz (0.1,0.25,0.4,0.55) MADM, AHP-TOPSIS the most important factor affecting surface
Tools: Coated carbide inserts - Output - Surface Roughness FMADM quality. The machining of austenitic stainless
CNMG 120408-MM 2025 steel EN 1.4404 was considered easier to
machine.
De Oliveira Material: Super duplex stainless steel Input- Vc (110and130m/min), fz SEM analysis with Cooling pressure and cutting speed and their
Junior et al. UNS S32750 Tools: Cemented (0.15mm/rev), ap (1mm), low and high EDS. effect on tool life, roughness of part surface .
(2014) [12] carbide grade - ISO M25 grade PVD fluid pressure cooling conditions PVD-coated inserts results long tool life
multi-coated with TiAlN and TiN Output - Surface Roughness, Tool wear,
layers Corrosion resistance
Krolczyk and Material: 1.4462 (DIN EN 10088-1) Input- Vc (50-150m/min), ap (1-3mm), fz SRT, Surface texture The fz is the main parameter which affects the
Legutko (2014) Tools: Cutting tool inserts - TNMG (0.2-0.4mm/rev) analysis- IFM method surface roughness.
[13] 160408 Output - Surface Roughness, Tool wear
Thiyagu and Material: UNS 31803 (2205) DSS & Input-Vc (21,49,77m/min), fz ANOVA, RSM The fz and Vc were the main parameter which
Arunkumar Tools: CNMG 120408 SM grade (0.4,0.8,1.2mm/rev), ap (0.051,0.128,0.205 affects the surface roughness.
(2014) [14] 1115 Sandvik Coromant make with mm), Nose radius (0.4,0.8,1.2)
PVD multi-layer coating (TiAlN + Output - Surface Roughness and Cutting
Chromium Oxide) force
Philip et al. Material: Cast DSS ASTM A 995 Input- Vc (80,100,120m/min), ap TRDM, ANOVA signalThe fz is the main parameter which affects the
(2014) [15] grade 5A and grade 4A (0.5mm), fz (0.04,0.08and 0.12mm/rev) to noise ratio surface roughness. The Vc was the influencing
Tools: TiC and TiCN coated carbide Output - Surface Roughness and Cutting the tool wear.
cutting tool force
Koyee et al Material: Standard duplex EN 1.4462 Input- Vc-200 m/min, ap-1.5mm, fz-0.25 ANOVA, RSM, AHP- Vc and fz is the most influencing parameters
(2014) [16] and super duplex EN 1.4410 stainless mm/rev,Length of cut - 12mm process TOPSIS, CSNNS
steel rods Tools: Coated condition
carbide inserts with ISO code of Output - Surface Roughness, radial
CNMG120408-QM 2025 cutting force , effective cutting power,
maximum tool flank wear and chip volume
ratio
Ali. 2015 [17] Material: Austenitic EN 1.4404, Input- Vc – (100,180 m/min), ap (1mm), fz SRT, Fuzzy Set The fz is the main parameter which affects the
standard duplex EN 1.4462 and super (0.15, 0.2, 0.25, 0.3, 0.35, 0.4 mm/rev), Theory, GRA, RSM, surface roughness.
duplex EN 1.4410 Tools: Cooling medium - Dry, Wet AHP-TOPSIS, FANNS
Coated carbide inserts - CNMG Output - Cutting Power, Surface
120408-MM 2025 and CNMG Roughness, Chip volume ratio, Tool wear,
120408-QM 2025. Temperature
Ramadhan et al. Material: Super duplex stainless steel Input- Vc (12.5, 22.5m/min, ap (0.25 mm), Comparison between The higher Vc and lower fz is the main parameter
(2015) [18] SAF 2507 Tools: TiC insert fz (0.06,0.08,0.1,0.12 and 0.14 mm/rev) heat, non-heat treated which affects the surface roughness.
Output - Surface roughness DSS material
Krolczyk et al. Material: Duplex stainless steel Input- Vc (100m/min), ap (2mm), fz Comparison between Low fz and high of cutting speed results minimum
(2016 ) [19] 1.4462 (DIN EN 10088-1) (0.3mm/rev), Dry and wet cooling dry and wet cooling surface roughness.
Tools: TNMG 160408 conditions conditions
Output - Surface roughness, Tool wear
Rohit et al. Material: SAF2507 DSS & Input- Vc (60-360m/min), ap (0.5-2mm), Comparison between At higher Vc, surface quality get damage due to
(2016) [20] Tools: PVD coated carbide inserts - fz (0.05-0.35mm/rev) tools chip gets adhere to the machined surface.
TiAlSiN, AlTiN (3 μm) and AlTiN (7 Output - Surface Roughness,
μm) machinability cutting force, tool wear
Krolczyk et al Material: 1.4462 (DIN EN 10088-1) Input- Vc (50m/min), fz (0.05mm/rev) Dry and MQCL cutting If an increase of Vc has a positive effect on surface
.(2016 b) [21] DSS Tools: Coated carbide Output - Surface Roughness technology quality.
inserts with ISO code of TNMG
160408 – GC 2025
Mario and Jozić Material: EN 1.4410 Input- Vc, fz, ap ANOVA, RSM, GA. The fz is the main parameter which affects the
(2017) [22] Tools: TiC insert Output - Machinability, Surface surface roughness.
roughness
Liew et al. (2017) Material: 2205 DSS & Input- Vc (210m/min), fz (0.10mm/rev), Comparison between The surface roughness is low when the temperature
[23] Tools: TiAlN coated carbide ap (1.00mm) dry and wet cooling of chilled air coolant decreases.
Output - Surface Roughness, Tool wear conditions The tool wear is lower when using conventional
coolant method.
Kadam et al. Material: Super DSS -2507 Input- Vc (60-360m/min), fz (0.05- Comparison between Higher Vc the temperature of the Continuous
(2017) [24] Tools: TiAlSiN PVD coated 0.35mm/rev)and ap (0.5-2mm) tools chips effects the machined surface and the
tool (3.3μm), AlTiN (3 μm) and Output - Surface Roughness, Tool wear increase of the Vc effect the tool wear.
AlTiN (7μm).
Gamarra et al. Material: Super duplex stainless Input- Vc (150m/min), Ap (0.5mm), Tool Comparison between For long tool life and low surface roughness the
(2018) [25] steel-SAF 2507 Tools: Carbide geometries, coolant tools fz value should be maintain very less
inserts - CNMG120408MM-GC 1115 Output - Surface Roughness, Tool wear
and index able wiper inserts
CNMG120408WF-GC 1115
Pawan and Material: DSS (2205) Input- Vc (550,930,1210m/min), fz ANOVA, TRDM fz is the most influential parameter reduces surface
Misra (2018) Tools: WC-Co cutting inserts, TNMG (0.05,0.20,0.36mm/rev) and approach roughness
[26] 160404 FM TN8135 angle (60,75,90mm )
Output - Surface Roughness
Philip. (2018) Material: ASTM A 995 Grade 5A Input- Vc (80,100,120m/min), fz ANOVA, TRDM fz is the most influential parameter reduces surface
[27] Tools: Carbide inserts coated with (0.04,0.08,0.12mm/rev), Ap (0.4, roughness
TiC and TiCN with a specification of 0.8, 1.2mm)
SNMG 120408 MT TT5100 Output -Surface Roughness
Auteur Mario Material: EN 1.4410 super DSS Input- Vc (0.063, 0.063m/min), fz ANOVA, RSM, ANFISfz is the most influential parameter reduces surface
Veić et al. (2018) Tools: C5-CSRNR/L-27060-12-4 (28,45and ap(1,2mm) roughness
[28] Output - Surface Roughness
Dhananchezian et Material: AISI 2205 DSS Input- Vc (72,119,197m/min), fz Dry and Wet Cooling liquid nitrogen decreased the Surface Roughness,
al. (2018) [29] Tools: PVD coated Nano-multilayer (0.111mm/rev), ap (1mm),cryogenic conditions Tool wear, machinability
TiAlN cutting tool insert cooling
Output -Surface Roughness, Tool wear,
machinability
Ghatge et al. Material: AISI 2205 DSS Input- Vc (100,150,200m/min), fz (0.1, TRDM Lower tool wear is observed at low Vc and high fz
(2018) [30] Tools: Multi-layer coated carbide 0.2, 0.3mm/rev), ap (0.4,0.8,1.2mm), and by using mineral oil to improving
insert (TiN/Al2O3/TICN/TiN) cutting fluid. machinability
Output - Surface roughness, Tool wear
and Tool temperature
Vijayan et al. Material: Duplex 2205 Input- Spindle speed, fz and ap ANOVA, RSM High Surface roughness is attained when spindle
(2019) [31] Tools: Tungsten carbide Output - M.R.R, surface roughness, feed speed and DOC is high and high spindle speed the
force, thrust force and Cutting force MRR is high
Subhash et al. Material: SDSS SAF 2507 Input- Vc (40, 60, 80, 100, and ANOVA, RSM, fz is the most significant parameter which effects

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(2019) [32] Tools: Carbide tool insert of ISO 120m/min), fz (0.05, 0.1, and ANN,GA on surface finish, Tool flank wear is observed
CNMG 120408TF IC6015 0.15mm/rev ) and ap (0.5mm), dry and wet more in dry cutting condition, and increased with
machining increasing Vc.
Output - Temperature, Surface Roughness
Sonawane and Material: DSS 2205 Input- Vc (100, 40,180m/min), constant fz RSM, PVD High Pulse Increase in Vc, results better surface roughness
Sargade (2019) Tools: AlTiCrN and AlTiN with 4 μm (0.18mm/rev) and ap (0.8mm) Impulse Magnetron
[33] thickness Output - Surface Roughness, Cutting Sputtering (HiPIMS)
Temperatures, Compressive Residual technique.
Stresses
Dinde and Material: Super-DSS UNS S32760 Input- Vc (110,120,130m/min), fz (0.20, ANOVA,TRDM, GRA Optimal cutting conditions are to minimum surface
Dhende Tools: Nano-coated MEGACOAT 0.22, 0.25mm/rev) and ap(1.8, 2.0, 2.3mm) roughness are Vc = 120 m/min, fz = 0.20 mm/rev,
(2020) [34] carbide inserts Output - Cutting force, Surface roughness, ap = 2.0 mm and For MRR is optimum value is
MRR attained at 48 cc/min
Kumar and Material: DSS 2205 & Input- Vc (43.18, 73.0, 94.99 m/min), fz ANOVA, TRDM Feed rate is most influencing factor affecting each
(2020) [35] Tools: WC-Co coated carbide inserts (0.05,0.20,0.36mm/rev), approach machining characteristics
angle(60, 75. 90degree)
Output - Surface roughness, MRR
Dinde and Material: Super-DSS UNS S32760 Input- Vc (110, 120, 130m/min), fz (0.20, ANOVA, TRDM, S/N For Least surface roughness the Vc : 120 m/min,
Dhende (2020) Tools: Nano-coated MEGACOAT 0.22, 0.25mm/rev) and ap (1.8, 2.0, ratio analysis fz :0.20 mm/rev, depth of cut 2.0 mm should be
[36] carbide insert 2.3mm) maintained., highest MRR is attained at Vc = 130
Output - Surface roughness, Cutting m/min, fz = 0.25 mm/rev, and ap = 2.3 mm
force, and MRR
Narayanan et al. Material: Super DSS – 2507 Input- Constant Vc (113m/min) , fz Dry machining, fz has more influencing parameter that affect
(2020) [37] Tools: PVD-coated tungsten carbide (0.35,0.26, 0.21mm/rev) , ap (1.2, Cryogenic machining surface roughness and tool life
inserts (CNMG 120408MT12) 1.6, 2.0mm)
Output - Surface roughness, MRR
Mavi. (2020) Material: DSS – 2205 Input- Vc (15,20,25m/min), , fz (0.05, Gray relational fz most significant factor that affect surface
[38]. Tools: TiN and TiAlN coated carbide 0.75, 0.1mm/rev ), , Cutting tool types analysis,, ANOVA roughness
drills Output - Cutting force (Fc) and surface
roughness (Ra)
Rajaguru and Material: Super DSS – 2507 & Input- Dry, Flood, MQL, Vc (140 m/min) SEM Analysis Poor surface finish is obtained at dry cutting
Arunachalam Tools: Tungsten carbide inserts , ap (1 mm), Five different fz (0.05, 0.10, conditions, Machining under flood
(2020) [39] (KCM15) 0.15, 0.20 and 0.25 mm/rev) and MQL reduces tool wear and Machinability.
Output - Tool wear, cutting force, surface
Roughness, morphology of chips and
residual stress
Subhash et al. Material: Hot forged SDSS 2507 Input- Vc (160,175,190,205m/min), fz Frequency response The optimal speed reduces the surface roughness
(2020) [40] (ASTM A240 – UNS S32750) (0.15; 0.175; 0.2; 0.225mm/rev)and ap functions (FRFs) and increases Machinability
Tools: CCMT120408MR type with a (1.5mm)
grade of GC2220 Output - Cutting forces, Surface
roughness
Sonawane and Material: DSS2205 Input- Vc (100, 140 and 180m/min), fz Regression Analysis, Combination of high Vc (180 m/min) and low fz
Sargade (2020) Tools: M35 grade Indexable Carbide (0.12, 0.15, 0.18mm/rev ) and constant ap High Power Impulse (0.12 mm/rev) resulted in least surface finish.
[41] tool - CNMG120408 (0.8mm) Output - Tool Magnetron Sputtering AlTiCrN and AlTiN coated tools show
wear, Surface Roughness, Machinability technique, respectively 6-times more tool life than uncoated
tools
Jiang et al. Material: HIP austenitic steel (PM Input- Vc (15,35,45,55m/min), fz (0.15 SEM and EDS analysis Vc should be below 35m/min to achieve less tool
(1996) [42] 316L), HIP DSS (PM 2205) mm/rev) and constant ap (1.0 mm) wear
Tools: TiN - coated cemented Output - Cutting force, surface
Carbide Roughness, Tool wear
Bouchnak et Material: Duplex stainless steel, Input- Vc (350, 450 m.min-1), fz (0.15 High pressure water jet The improvement of tool life by using high
al.(2010) [43] X2CrNiMo22-5 mm.tr-1.) , ap (0.5mm ) assisted turning pressure water jet assistance
Tools: HPWJAT tool Output - Surface Roughness, Tool wear (HPWJAT)
Schultheiss et Material: SAF 2507, SAF 2205 and Input- Vc, fz , ap ANOVA fz is the most influencing parameter - tool wear
al.(2011) [44] LDX 2101 Output - Tool wear
Tools: Coated carbide tools
Ahmadi et al. Material: Austenitic ferritic Input- Vc (120, 170, Multi-regression Alumina-based ceramic cutting tools the flank
(2012) [45] (Duplex) stainless steel (330HRC) 220 and 270m/min), fz (0.12mm/rev) , ap analysis (MRA), wear has a considerable effect
Tools: Ceramic cutting tool with (0.5mm) (ANOVA).
Alumina base (aluminium oxide) Output - Tool wear
Kumar and Material: Super DSS - SAF 2507 Input- Vc (100,120m/min), fz Regression analysis, Tool wear is low in gas cooled machining
Senthilkumaar Tools: Uncoated Cemented carbide (0.06,0.08,1.0mm/rev), ap (0.5,0.75,1mm) TRDM, SEM analysis
(2013) [46] cutting tool inserts(CNMG 120408- Output - Tool wear
QM, grade H13A)
Królczyk et al. Material: 1.4462 (DIN EN 10088-1) Input- Vc (50,150m/min), fz (0.3mm/rev) SEM analysis Wear of tool is due to Increase of the Vc
(2013) [47] steel , ap(2mm )
Tools: Cutting tool inserts of TNMG Output - Tool wear
160408
Królczyk et Material: 1.4462 (DIN EN 10088-1) Input- Vc (50, 150m/min), fz Factorial Design Wear of tool is due to Increase of the Vc. The
al.(2013b) [48] steel (0,2,0,4mm/rev) , ap (1, 3mm) Method, CVD - Ti(C, N)/Al2O3/TiN coated carbide tools
Tools: Cutting tool inserts of TNMG Output - Tool wear, surface Roughness Metallographic has greater resistance to abrasive wear
160408 microscopy analysis
Krolczyk et Material: 1.4462 (DIN EN 10088-1) Input- Vc (50, 150 m/min), fz (0,2,0,4 Factorial Design Wear of tool is due to Increase of the Vc
al.(2013 c) [49] steel mm/rev) , ap (1, 3 mm) Method
Tools: Cutting tool inserts of TNMG Output - Tool wear
160408
Rastee et al. Material: Super DSS EN 1.4410, Input- fz (0.1, 0.175, 0.25, 0.325, TOPSIS, GRA, VIKORDominant at lower fz the tool wear is high
(2013) [50] standard DSS EN 1.4462 and 0.4mm/rev) , ap (0.5, 1, 1.5, 2, 2.5, 3, method, Utility
austenitic EN, 1.4404 stainless steels 3.5mm) Analysis (UA),
Tools: Coated carbide inserts (CNMG Output - Tool wear MADM, MOO
120408-MM 2025)
Kumar et al. Material: Super DSS SAF 2507 Input- Vc (100,120m/min), fz (0.06,0.08, Dry, wet, gas cooled Gas cooled machining increases tool life
(2014) [51] Tools: Uncoated cemented carbide 0.10mm/rev), ap (0.50, 0.75 1.0mm) Machining, SEM
cutting tool inserts(CNMG 120408- Output - Tool wear analysis
QM, grade H13A)
Krolczyk et al. Material: Duplex stainless steel Input- Vc (50,100,150m/min, fz Factorial Design Vc Increases tool wear also increases
(2015) [52] 1.4462 (DIN EN 10088-1) (0.2,0.3,0.4mm/rev, ap (1,2, 3mm) Method, Dry and Wet
Tools: Cutting tool inserts of TNMG Output - Tool wear cutting condition, Tool
160408 comparison

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Rastee et al. Material: Standard DSS EN1.4462 Input- Vc (100, 180m/min), fz (0.15, 0.2, MOBA, ANOVA At low Vc is the most dominant parameter for tool
(2014) [53] and Super DSS EN 1.4410 0.25, 0.3, 0.35, 0.4mm/rev) , ap (1mm) wear
Tools: carbide inserts (CNMG Dry and Wet cutting condition,
120408-MM 2025) Output - Tool wear
Krolczyk Material: DSS- 1.4462 (DIN EN Input- Vc(50 100 150m/min), fz (0.2 0.3 ANOVA, TRDM, Vc and fz were affecting the life of the tool
Grzegorz et al. 10088-1) 0.4mm/rev) , Signal-to-noise Ratio
(2015) [54] Tools: TiCN / Al2O3 / TiN about 5.5 Output - Tool wear
μm thickness (T1) and TiN / Ti(C,N) /
Ti(N,B) / TiN / Ti(C,N) / Ti(C,N)
about 12 μm thickness (T2).
Metelski Andrzej Material: DSS 1.4462 (DIN EN Input- Vc (50,100,150m/min), fz { 0.2 ANOVA, Dijkstra's Vc and fz were affecting the tool life
et al. (2016) [55] 10088-1), 0.3 0.4mm/rev) algorithm
Tools: Coated carbide inserts with Output - Tool wear
ISO code of TNMG 160408: GC 2025
and CTC 1135
Diniz et al. Material: S41000 martensitic and Input- Tool material, the cutting SEM analysis with Depth of cut is the most important parameter that
(2016) [56] S41426, super martensitic stainless conditions, and the cooling/lubrication EDS device affect the life of the tool
steels system
Tools: Coated cemented carbide tools Output - Tool wear
Rajaguru and Material: SDSS - S32750 Input- Variable speed from 150- 5600 rpm SEM, EDS, X-ray The tool wear [MT-TiCN]- Al2O3 coated tool
Arunachalam Tools: Tungsten carbide cutting insert with the power rating of 10 kW, Vc (120 diffraction (XRD) provided good wear resistance
(2017) [57] with geometry of TNMG 160408 m/min), feed(0.3mm/rev) depth of cut technique
(1mm)
Output - Tool wear, cutting force and
surface integrity
De Paiva et al. Material: Super DSS (UNS32750) Input- Back rake angle, clearance angle, XPS analysis AlTiN-coated tool have the longest tool life
(2017) [58] Tools: chemical vapor deposited cutting edge angle, rake angle, side cutting
(CVD) TiCN + Al2O3as well as edge angle, and nose radius.
physical vapor deposited (PVD) TiCN Output - Tool wear
and AlTiN coatings
Ahmed et al. Material: Super DSS—Grade UNS Input- Back rake angle, clearance angle, (SEM) equipped with Tool life is the twice that of the CVD TiCN +
(2017) [59] S32750 wedge edge radius angle, and nose radius. energy EDS, X-ray Al2O3 coated insert
Tools: Cemented carbide inserts Output - Tool wear, Chip characteristics Photoelectron
coated with PVD AlTiN and CVD Spectroscopy (XPS).
TiCN + Al2O3
Nomani et al. Material: Duplex SAF 2205 Input- Vc (94m/min), fz (0.15mm/rev) , SEM and electron Tool wear is dominated by built-up edge
(2017) [60] Tools: WNMG-TF solid carbide Output - Tool wear backscatter diffraction
inserts (EBSD)
Ahmed and Material: Super DSS - S32750 Input- Point angle of 80°, negative (SEM) with energy AlTiN insert Longest tool life
Veldhuis (2017) Tools: PVD deposited TiAlN coating geometry, nose radius of 0.8 mm dispersive spectroscopy
[61] on a carbide insert Output - Tool wear, Tribological (EDS)
performance, Chip microstructure
Nagy et al.(2019) Material: G X2CrNiMoCuN 26-6-3-3 Input- Vc (70m/min) and feed (f = Stereo microscope Vc is the dominant parameter that effects the tool.
[62] casted super duplex steel 0.15mm), image analysis
Tools: Coated with TiAlN and other Output - Tool wear-burr and built-up edge
with TiAlSiN formation
Dyl (2019) [63] Material: Duplex cast stainless steel Input- Vc (70m/min), fz (0.2mm/rev), ap Arithmetical mean At lowest tool wear occurred at fz - 0.1 mm/rev, Vc
type GX2CrNiMoCuN25-6-3-3 (0.5mm), Nose Radius, Flank Angle, Rake deviation and the - 70 m/min, depth of cut -0.5 mm
Tools: 2025 grade - CCMT 09T308- Angle maximum height of
MM , Output - Surface roughness, flank wear profile
CCMT 09T308-UM , CCMT 09T304- (VB, mm) and crater wear (KB, mm)
UM
Narayanan and Material: Super DSS – 2507 Input- Vc (113 m/min), fz (0.35,0.26,0.21 SEM analysis The coolant reduces the amount of flank wear up
Jagadeesha Tools: PVD-coated tungsten carbide mm/rev), ap (1.2,1.6,2.0 mm) to 77.19 percentage as compared to dry machining
(2020) [64] inserts (CNMG 120408MT12) Output - Cutting Temperature, Tool Wear
Nomani et al. Material: Wrought duplex stainless Input- Vc (60 m/min) , fz (0.15 mm/rev), SEM and optical SAF 2205 holds the better machinability in terms
(2015) [68] steel alloys SAF 2205 and SAF 2507. ap (30 mm) microscopic analysis of tool wear
Tools: TiAIN+ TiN coated solid Output - Tool wear, Machinability
carbide twist drill
Sonawane et al. Material: DSS 2205 Input- Vc (100 to 180m/min), , fz (0.12 to BUE formation method For maximum tool life an machinability - the
(2020) [69]. Tools: AlTiN and AlTiCrN on 0.18mm/rev), , ap -0.8 mm constant parameter should be maintained at low cutting
cemented carbide Output - Nose wear, tool life and surface speed and feed rate
roughness
Dinesh et Material: Duplex alloy steel Input- Vc, fz , ap and tool nose radii ANOVA, TRDM, GRAVc, fz is the most influential parameter for surface
al.(2016) [71] Tools: Cemented carbide tool Output - MRR and Surface roughness roughness and MRR
Schultheiss et al. Material: DSS- LDX 2101, SAF Input- Vc (125 m/min), fz (0.06, 0.10, Finite element Decreasing size of the tool nose radius leads to
(2019) [72] 2205, SAF 2507 0.15, 0.20mm/rev), ap (3mm) and tool simulation increased minimum chip thickness
Tools: Ti(C,N) and Al2O3-coated nose radii (0.4, 0.8, 1.2, 1.6mm),
cemented carbide CNMG120412 Output - Minimum chip thickness
cutting tools.

Meta-Heuristics optimization techniques: Multi objective Comparsion methods: Tool Comparison, dry and wet
bat algorithm (MOBA). (cooling / lubricating conditions).
Hybrid Algorithms: Hybrid global best harmony search The literature review on surface roughness, tool wear,
(hgHS) algorithm, Taguchi coupled Fuzzy Multi Attribute machinability, chip volume report, material removal rate is
Decision Making (FMADM), Analytical Hierarchy process - presented in Table 2, shows that there is a limited research is
Technique for Order Preference by Similarity to Ideal available in the field of conducting the experiment
Solution (AHP-TOPSIS), Taguchi-VIKOR coupled with using duplex stainless steel. The traditional and non-
Firefly Algorithm Neural Network System (FANNS). traditional technique used for DSS optimization is shown in
Table 4. It also shows that there are numerous algorithms
that can be used to optimize DSS materials.

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Modelin 1. Statistical Regression Technique and ANOVA 7. Response Surface

g and Methodology,
Tradit
Optimiz 2. Fuzzy Set Theory Artificial Neural Networks, 8. Knowledge-Based Expert
ional
ation Systems,
optimi
Techniq 3. Gray Relational Analysis (GRA), 9. Principal Component Analysis
zation
techni Mathe
1. Dynamic Programming, 4. Geometric Programming,
ques matical
2. Goal Programming, 5. Quadratic Programming,
Iterativ
3. Generalized reduced gradient Method (GRG), 6. Integer Linear

Meta- 1. Genetic Algorithms, 6. Artificial Bee Colony Algorithm,

Heuristi 2. Simulated Annealing, 7. Artificial Immune Algorithm,
cs 3. Tabu Search, 8. Shuffled Frog Leaping Algorithm,
Optimi Optimiz 4. Particle Swarm Optimization, 9. Harmony Search Algorithm.
zation
Metho
ds 1. Genetic Simulated annealing algorithm (GSA),
Nontra 2. Hybrid immune algorithm (artificial immune algorithm and hill climbing
ditiona local search algorithm),
l Hybrid 3. Memetic algorithm (GA is combined with the heavy local search),
optimiz Algorith 4. Hybrid approach (GA, SA, and Tabu search),
ation ms 5. Heuristic algorithms such as SA, GA and hybrid algorithm (hybrid-GASA),
6. Novel hybrid ant colony optimization approach,
7. Adaptive network based fuzzy inference system (ANFIS) with the genetic
learning algorithm,
8. Hybrid Taguchi-genetic learning algorithm (HTGLA),
9. Multi-objective optimization method based on adaptive simulated annealing
genetic algorithm,

Fig. 5. The traditional and non - traditional technique used for optimization

Table 4. Optimization methods used in Turning of DSS

Optimization methods used in turning of DSS - Reference in Numbers
2010& 2012 2013 2014 2015 2016 2017 2018 2019 2020
Modelling& Before
Optimization Ra VB KM Ra VB KM MRR Ra VB KM MRR Ra VB KM Ra VB KM MRR Ra VB KM Ra VB KM Ra VB KM MRR Ra VB KM MRR
Methods
Modelling Technique
Statistical 45 6,7,8,9 46 9 10, 13, 15,16, 10 17,18 54 55 71 22 26,27, 31, 32 32 34, 41 41 34,35,
Regression 14, 15, 53 28 35, 36
Technique & 16 36,
ANOVA 38,
41
Fuzzy Set Theory 17

Artificial Neural 16 32 32
Networks
Gray Relational 50 17 71 34, 34
Analysis (GRA) 38
Taguchi Robust 9 46 9 10,11, 16 10 54 71 26,27, 30 30 34, 34,35,
Design Method 15 30 35, 36

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36
Taguchi Fuzzy- 26,27
Based Approach
Factorial Design 48,49 49 13,52 13, 52
Method
Response Surface 8 46 14,16 16 17 22 28 31, 32 32, 33 31
Methodology
Dijkstra's 55
optimization
algorithm
MADM Methods 50 11

Meta-Heuristics
Genetic Algorithms 22 32 32

Multi objective bat 53

algorithm (MOBA)
Hybrid Algorithms
Adaptive network 28
based fuzzy
inference system
(ANFIS)
Taguchi coupled 11
Fuzzy Multi
Attribute Decision
Making (FMADM)
Analytical 50 11, 16 16 17
Hierarchy process -
Technique for
Order Preference
by Similarity to
Ideal Solution
(AHP-TOPSIS)
Taguchi-VIKOR 50 17
coupled with
Firefly Algorithm
Neural Network
System (FANNS)
Cuckoo search 16
neural network
systems (CSNNS)
Tool Comparison 42 45 47 52 68 68 20 20 24 24, 24,57, 69 25 25 33 63 37 37, 64
69 58,59,
61,69
Dry and Wet 43 45 11 11,51, 19, 19,56 23 23 29 29 29 37, 39, 64 39
(Cooling / 52 21 39
Lubricating )
SEM , IFM, XPS , 47,48 12,14 12,14 56 57,58, 62 64, 68
Stereo microscope 59,60,
image analysis 61

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5. Future Studies optimization that means computational techniques by using

New duplex grades have been added to the market in recent hybrid algorithms places a virtual role in the field of
years, with the primary aim of improving tolerance to research. The computational techniques are very easy to
reducing acids, pitting, and crevice corrosion. optimize, precision accuracy, time saving, reliable and
However, the duplex is also far from achieving its maximum efficient way to solve any type of completed problems. The
capacity. DSS have high strength, superior pitting corrosion
The study, which started in 2010 and based on metal cutting resistance, work hardening, two times the tensile strength of
utilizing the turning operation, indicates that there is a lack other austenitic alloys, outstanding pitting and crevice
of analysis and literature in the DSS families. corrosion. This review concludes that there is a reach
Past studies have focused on 2205, 2507, and Zeron 100 possibilities in the field of turning of DSS and heuristic
products, with the primary goal of reducing surface methods used for optimization. The elaborated research is
roughness, tool wear, machinability, chip volume ratio, and required in the field of DSS families considering different
material removal rate. As a result, there are many study parameters and cooling conditions. The Duplex grade is the
opportunities in other duplex households. alternative to austenitic grade for their excellent corrosion
With the aid of meta-heuristics and hybrid optimization resistance. Today, the growth of new duplex stainless steel
methods, there are various study opportunities to maximize grades is tremendously energetic with a high possibility of
and forecast performance responses. success in several new markets.

6. Conclusion
This is an Open Access article distributed under the terms of the
Because of their higher hardness, duplex steels are more Creative Commons Attribution License.
complex to machine than traditional austenitic stainless
steels. The application of DSS is high due to its physical and
chemical properties. Nowadays the growth of machining
process is glowing improved. The highly developed

______________________________
References

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Nomenclature

vc Cutting speed in mm/min GTMA Graph theory and matrix approach

fz Feed per tooth in mm/tooth FDM Factorial Design Method
ap Depth of cut in mm RSM Response Surface Methodology
n Spindle speed in r/min DOA Dijkstra's Optimization Algorithm
rn Nose radius in mm MADM Multiple Attribute Decision Making (MADM) and
P Cutting power in W Multiple Objective Decision Making (MODM)
Ra Machined surface roughness in μm GA Genetic Algorithm
VB Tool Wear in mm MOBA Multi objective bat algorithm
KM Machinability of a material ANFIS Adaptive network based fuzzy inference system
F Cutting force in N FMADM Taguchi coupled Fuzzy Multi Attribute Decision
MRR Material Removal Rate in mm3/min Making
RS Residual stress AHP-TOPSIS Analytical Hierarchy process - Technique
Mi Machinability index for Order Preference by Similarity to Ideal Solution
z Number of cutting teeth IFM Infinite Focus Measurement Machine
SRT Statistical Regression Technique MSQCI Multi-Surface Quality Characteristics Index
ANOVA Analysis of Variance FANNS Taguchi - VIKOR coupled with Firefly Algorithm
BBD Box–Behnken Design Neural Network System
ANN Artificial Neural Network CSNNS Cuckoo search Neural Network Systems
GRA Gray Relational Analysis HiPiMS High Power Impulse Magnetron Sputtering
TRDM Taguchi Robust Design Method UA Utility Analysis
TFBA Taguchi Fuzzy-Based Approach SEMI Scanning Electron Microscope Image

135