Surface Roughness Optimization in Machining of Titanium Alloy (Ti-6Al-4V)

Abstract:

Titanium is one of the important kinds of material used in different engineering fields. They have very good properties like high strength to weight ratio, superior corrosion resistance and thermal properties. They are very attractive materials and has application aerospace, biomedical and automotive field. they are classified to be “difficult-to-Machine materials” as they posses poor thermal properties, poor machinability, etc.The prime important is with the study of machining characteristics and the optimization of the cutting parameters. In this paper Titanium alloy (Ti-6Al-4V) is taken, the dry turning experiments are carried out in semi-automatic lathe using poly crystalline diamond (PCD) cutting tool insert. The taguchi’s design of L₂₇ orthogonal array is done by four machining factors namely cutting speed, feed, nose radius and depth of cut at three levels. The optimal machining conditions are arrived by Signal-Noise ratio method with respect to surface roughness (Ra). The analysis of variance (ANOVA) and the percentage of contribution of feed, cutting speed, nose radius and depth of cut for better surface roughness is validated using S/N ratio. In this result indicated that the feed is a vital parameter followed by cutting speed, the nose radius and then by depth of cut. The worn out surface of the insert is examined by using scanning electron microscope (SEM).

• Periodical: Advanced Materials Research (Volumes 984-985)
• Pages: 42-47
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.984-985.42
• Online since: July 2014
• Authors: J. Nithyanandam*, Sushil Laldas, K. Palanikumar
• Keywords: ANOVA, PCD Insert, Surface Roughness (SR), Taguchi Design, Titanium Alloy, Tool Wear, Turning

References

[1] Mustafizurrahman, A Review on high –speed machining of titanium alloys-JSME international journal , series C, vol. 49. No. 1, (2006).

[2] Deng Jianxin, Diffusion wear in dry cutting of Ti -6AI -4V with WC/Co carbide tools wear 265(2008)1776-1783.

DOI: 10.1016/j.wear.2008.04.024

[3] G.A. Ibrahim, tool wear mechanism in continuous cutting of difficult –to-cut material under dry machining, advanced materials research vols. 126-128(2010) pp.195-201.

DOI: 10.4028/www.scientific.net/amr.126-128.195

[4] T.G. Ansalam raj, An improved genetic algorithm for the prediction of surface finish in dry turning of SS420 Materials, Int. J of Adv Manuf tech (2010)47: 313-324.

DOI: 10.1007/s00170-009-2197-2

[5] Peter J. Heath –Developments in applications of pcd tooling, journal of Materials processing technology 116 (2001) 31-38.

DOI: 10.1016/s0924-0136(01)00837-8

[6] N. Corduan Wear mechanisms of new tool materials for Ti-6AI -4v high performance machining.

DOI: 10.1016/s0007-8506(07)60534-4

[7] Albert J. Shih, Finite element modeling of 3D turning of titanium, International Journal Advanced Manufacturing technology (2006), 29 : 253-261.

DOI: 10.1007/s00170-005-2511-6

[8] Norihiko Narutaki and Akio murakoshi, Study on machining of titanium alloys –Annals of the CIRP Vol. 32/1/(1983).

DOI: 10.1016/s0007-8506(07)63362-9

[9] S. Ramesh , Fuzzy Modeling and Analysis of Machining Parameters in Machining Titanium Alloy –Materials and Manufacturing Processes, 23: 439 -447, (2008).

DOI: 10.1080/10426910801976676

[10] S. Ramesh , Surface Roughness Analysis in Machining of Titanium Alloy - Materials and Manufacturing Processes, 23: 175-182, (2008).

[11] Palanikumar,K. Application of taguchi and response surface methodologies for surface roughness in machining glass fiber reinforced plastics by PCD tooling. International Journal Advanced. Manufacturing . technology. in press. doi 10. 1007/s00170-006-0811-0.

DOI: 10.1007/s00170-006-0811-0

[12] D.A. Fadare, Effects of cutting parameters on surface roughness during high –speed turning of Ti-6AI-4V alloy, journal of applied sciences research, 5(7): 757-764, (2009).

[13] M.V. Ribeiro, Optimization of titanium alloy (6AI -4V) machining –journal of materials processing technology 143-144(2003)458 -463.

DOI: 10.1016/s0924-0136(03)00457-6

[14] AhmetHascalik; UlasCaydas. Optimization of turning parameters for surface roughness and tool life based on the Taguchi method. International Journal Advanced. Manufacturing . technology. 2007, doi 1o. 1007/s001 70. 007 -1147-0.

[15] Machado, A.R. Wallbank, j. Maching of titanium and its alloy- A review. Proceedings of Inst of mechEngg. J of Engg and Manuf part B 1990. 204, 53-60.

[16] Ezugwu, E. O, and Wang, Z,M., titanium Alloy and their Machinability-A review, journal of materials processing technology vol 68, no 3(1997). Pp. 262-274.

DOI: 10.1016/s0924-0136(96)00030-1

[17] NambiMuthukrishnan, etl, Influence of Coolant in Machinability of Titanium Alloy (Ti-6Al-4V) Journal of Surface Engineered Materials and Advanced Technology, 2011, 1, 9-14.

DOI: 10.4236/jsemat.2011.11002

[18] C.H. Che –Haron, The effect of machining on surface integrity of titanium alloy Ti-6%Al-4%V. Jour of materials Processing Technology 166 (2005) 188 – 192.

DOI: 10.1016/j.jmatprotec.2004.08.012