Parametric Optimization during Dry Machining of Titanium Alloy (Ti6Al4V) with Innovative Textured Tools for Optimum Product Quality

  Pankaj Rathod,  S Aravindan,  Venkateswara Rao P

The quality of the surface generated through a machining process depends to a great extent on the conditions at the chip-tool interface.A reduction of friction and tendency of formation of built up edge (BUE) during the machining of a titanium alloy reduces the cutting forces, temperature generation and improves the surface finish and tool life. Friction at the tool-chip interface can be reduced by either proper application of the cutting fluid or modifying the geometry of the tool. In this research, textures have been developed at the rake face of the cutting tool insert. The textured inserts have been subsequently coated with Zr/WS2 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 reduced the friction by reducing the chip-tool contact area and acting as reservoirs for the solid lubricant. The best combination of the cutting parameters viz. cutting speed, width of grooves, depth of grooves and pitch of grooves have been achieved through Genetic Algorithm. The lowest surface roughness achieved with non-textured tools was 0.3722 µm at 60 m/min cutting speed and that for textured tools was 0.2626 µm at 60 m/min cutting speed and texture dimensions 3µm width, 3 µm depth and 5 µm pitch. It indicates an improvement of 29.44 %. The optimized tool further improved the surface finish by 18.66%.

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Unique Identification Number - IJEDR1603169
Page Number(s) - 1067-1074
Pubished in - Volume 4 | Issue 3 | September 2016
DOI (Digital Object Identifier) -   
Publisher - IJEDR (ISSN - 2321-9939)

  Pankaj Rathod,  S Aravindan,  Venkateswara Rao P,   "Parametric Optimization during Dry Machining of Titanium Alloy (Ti6Al4V) with Innovative Textured Tools for Optimum Product Quality", International Journal of Engineering Development and Research (IJEDR), ISSN:2321-9939, Volume.4, Issue 3, pp.1067-1074, September 2016, Available at :http://www.ijedr.org/papers/IJEDR1603169.pdf