An experimental study on measurement of cutter vibration and optimization of process parameters in micro milling of Ti-6Al-4V

Abstract

In the present days, many equipments are used to measure vibrations produced in the machines, among them Laser Doppler Vibrometer (LDV) is a non-contact type equipment/sensor used to measure vibration of rotating body. In the present work, the LDV is used to measure vibration of a mill cutter in micro milling of Ti-6Al-4V alloy in terms of acoustic optic emission signals. A fast Fourier transformer is used to process the signals in to frequency domain. According Taguchi design of experiments L27, experiments were conducted on the Ti-6Al-4V alloy at three levels of spindle speeds, depth of cuts and feed rates. Experimental results of amplitude of tool vibration in X and Y directions and surface roughness were measured and analyzed using Response Surface Methodology. Analysis of variance was used to identify significant parameter which effects the tool vibration and surface roughness. A multi response optimization technique was used to optimize process parameters for minimum vibration amplitude and surface roughness. KeywordsMicro milling, response surface methodology, multi-response optimization, tool vibration.