The chatter during machining process has a profound effect on the surface quality, power consumption, tool and machine failure and it is applied to a various machining processes such as turning, milling and grinding. The objective of this paper is to validate the influence of tool geometry and machining parameters such as cutting feed, cutting speed and Radial Rake Angle (RRA) of end mill cutter (- 7°, 0° and 7°) on the induced vibration or acceleration amplitude during end milling using statistical tool. Because, the formation ofthis vibrations have resulted to cause critical effects such as reduction in tool life, lowest surface finish. For conducting experiments, L27 orthogonal array has been employed. The experiment has been conducted on Nimonic 263 using TiAlN coated Tungsten carbide tool and Tri-axial accelerometer (Model:7543A). Statistical tool such as Regression and Analysis of variance are employed to develop a mathematical model and predict optimum parameters and the data analysis confirmed that the cutting speed has a dominant effect on vibrationamplitude followed by tool nomenclature and cutting feed.

In this study, the critical effects of variants in machining behavior on the microcrystalline characteristics and its dependence on the corrosion as well as Impedance behavior of the machined Nimonic 263 alloy have been investigated. Because the resulting effect, which arises from the machining process (slotmilling) with varying cutter nomenclature or terminology (Radial Rake Angle (RRA)) and machining conditions (cutting feed) under constant Minimum Quantity Lubrication (MQL) flow rate plays a vital role in severe deformation process (SDP) on the machined work surface. Additionally, the Electrochemical Impedance Spectroscopy (EIS) analysis has been conducted over the SDP processed surface to analyze the influence of variants in machining behavior over the corrosion performance through the impedance of machined samples and from the above experimentation, it is stated that the SDP through slot milling has a superior influence on the corrosion and EIS behavior leads to reduction in the resistance against the corrosion tendency of the machined samples related to the nascent Nimonic 263 sample.

The occurrence of Severe Plastic Deformation (SPD) on any material has a critical effect over the surface and material features such as elastics constants and residual stress, etc. Among various deformation processes, such as Equal Channel Angular Pressing (ECAP), machining, etc. machining (slot or end milling) has a vital role in various sectors, due to its versatility and ease of material removal and surface finish. In this study, the slot milling operation has been carried out on Nimonic 263 alloy and this operation is governed by variousMachining Environments (ME) (wet, dry and Minimum Quantity Lubrication (MQL)) and machining parameters (cutting feed and cutting speed) to analyze its influence on the material characteristics of machined samples associated to the as-received (Nascent) samples using X-Ray Diffraction (XRD) spectral analysis and ultrasonic pulse echo method. Through the above experimentation, it is found that the machined samples have undergone SPD over the machined surface which lead to cause superior enrichment in surface features such as bulkmodulus, young’s modulus, wear resistance, etc.