Optimization of Process Parameters for Dry Machining of Ti6Al4V with Textured Tools using Genetic Algorithm Approach

  Pankaj Rathod,  S Aravindan,  Venkateswara Rao P

Conditions at the chip-tool interface govern the cutting forces, heat generation, tool life and more importantly, quality of the finished product. Friction between the flowing chip and the rake and flank faces of the tool decides all these. One way of reducing friction at the chip-tool interface is proper application of lubrication andthe other way is modifying the geometry of the cutting tool. In this research, textures have been developed at the rake face of the cutting tool inserts using focused ion beam machining (FIB). The textured inserts have been subsequently coated with WS2/Zr solid lubricants through pulsed DC magnetron sputtering process. The various parameters of the textures have been varied to study their effect on the friction between the chip and rake face of the tool. Cutting speed is also varied keeping feed rate and depth of cut constant. The textures are reported to reduce the friction at the chip-tool interface by reducing the chip-tool contact area and behaving as reservoirs for the solid lubricant. The cutting parameters viz. cutting speed, width of grooves, depth of grooves and pitch of grooves have been optimized through Genetic Algorithm. The lowest main cutting force achieved with non-textured tools was 147 N at 80 m/min cutting speed and that for textured tools was 88.83N at 100 m/min cutting speed indicating an improvement of 39.57%. The optimized tool further improved the performance by 13.79%.

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Unique Identification Number - IJEDR1603166
Page Number(s) - 1046-1053
Pubished in - Volume 4 | Issue 3 | September 2016
DOI (Digital Object Identifier) -   
Publisher - IJEDR (ISSN - 2321-9939)

  Pankaj Rathod,  S Aravindan,  Venkateswara Rao P,   "Optimization of Process Parameters for Dry Machining of Ti6Al4V with Textured Tools using Genetic Algorithm Approach", International Journal of Engineering Development and Research (IJEDR), ISSN:2321-9939, Volume.4, Issue 3, pp.1046-1053, September 2016, Available at :http://www.ijedr.org/papers/IJEDR1603166.pdf