Cumulative effect of Shearing parameters and Ramp angle on Hole surface quality in Ti6Al4V by Helical milling strategy

Titanium alloys, such as Ti6Al4V, have become increasingly prevalent in aerospace and biomedical industries owing to their exceptional mechanical properties and corrosion resistance. However, the machining of these alloys presents significant challenges including high tool wear, poor surface finish, and low productivity. This study focused on enhancing the machinability of Ti6Al4V during CNC turning using the Taguchi optimization method. This approach aims to identify the optimal cutting parameters that minimize the surface roughness, flank wear, and crater wear, thereby improving the overall machining performance. This study systematically investigated the influence of various cutting parameters on machining outcomes. The experimental results demonstrate that the Taguchi method effectively determines the optimal process parameters, leading to a significant reduction in surface roughness and tool wear. These findings highlight the potential of the Taguchi optimization technique for achieving improved machinability and sustainability in the machining of Ti6Al4V.

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Machinability of Ti6Al4V Alloy: Tackling Challenges in Milling Operations

Patil,

Sunnapwar,

Bhole

et al. 2024

Qeios

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This study investigates strategies for improving the 3D milling of Titanium Alloy Grade 5 (Ti6Al4V) by optimizing machining parameters and cutting tool engagement techniques. Ti6Al4V presents significant machining challenges due to its low machinability index (20%), which directly impacts manufacturing efficiency. High temperatures during machining, often exceeding 8820C, lead to phase transformations, creating a harder Beta lamellar equiaxed microstructure. This, coupled with the alloy's poor thermal conductivity, results in heat concentration at the cutting tool interface, accelerating thermo-chemical wear and potentially catastrophic tool failure. This study explores how controlled cooling methods, coupled with appropriate lubrication, can effectively dissipate heat and flush away chips, mitigating the detrimental effects of high temperatures. Furthermore, the selection of cutting tool materials and coatings with high thermal conductivity and chemical inertness, along with aggressive rake angles and higher relief angles, are examined as methods to improve shearing, minimize smearing, and enhance surface quality. By optimizing these parameters, this study aims to provide manufacturers with practical strategies to overcome the challenges of Ti6Al4V machining, ultimately increasing tool life and overall milling efficiency.

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Cumulative effect of Shearing parameters and Ramp angle on Hole surface quality in Ti6Al4V by Helical milling strategy

Cited by 3 publications

References 16 publications

Performance Analysis of Solid and Hollow End Mills Under Hybrid Nano Flood Coolant in Milling of Titanium Alloy-5

Performance Analysis of Solid and Hollow End Mills Under Hybrid Nano Flood Coolant in Milling of Titanium Alloy-5

Modeling & optimization of Ti6Al4V turning for sustainable shearing considering rake angle

Machinability of Ti6Al4V Alloy: Tackling Challenges in Milling Operations

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