In machining operation of mould cavities, the tool travels in various straight and corner profiles following predetermined toolpath. Such condition results in a fluctuation of cutting forces that may produce bad surface finish. The objective of this study is to investigate the most influential parameters on cutting operation for both straight and corner profiles of pocketing operation. Cutting speeds of 150, 200 and 250m/min, feedrates from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were selected for the cutting processes. Taguchi L9 orthogonal array with Pareto ANOVA analysis was employed to analyze the effects of the selected parameters. The result demonstrates there are different effects of cutting parameters on cutting forces for straight and corner profiles. Furthermore, it was found that cutting speed and feedrate are prevailing factors that affected cutting forces for both types of profile.

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Titanium alloys (Ti-6Al-4V) are greatly recommended for high performance applications because of their outstanding properties such as low weight, high corrosion resistance and high strength. However, drilling Ti-6Al-4V generates high cutting temperature, especially during high speed drilling (HSD), increased the chemical reactivity of Ti-6Al-4V, thus leading to poor hole quality. High cutting speed increases the temperature during the drilling process, therefore, it is important to consider this factor to achieve better hole quality. This study focuses on the correlation of machining parameter and the quality of the hole produced in terms of hole diameter, roundness and surface roughness. The experiment was conducted using a 6 mm diameter of coated (TiAlN) carbide tool under MQL and MQCL conditions with varying cutting speeds of 65, 75, 85 and 95 m/min and constant 0.02 mm/rev feed rate.