Analysis of surface roughness and hardness in titanium alloy machining with polycrystalline diamond tool under different lubricating modes

Goutam Devaraya Revankar,Raviraj Shetty,Vinayak Neelakanth Gaitonde,Shrikantha Srinivas Rao

doi:10.1590/1516-1439.265114

Abstract

The present work deals with the investigation on machining of difficult-to-machine material titanium alloy (Ti-6Al-4V) using poly crystalline diamond (PCD) tool under different coolant strategies, namely dry, flooded and MQL. Taguchi technique has been employed and the optimization results indicated that MQL lubricating mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.25 mm depth of cut is necessary to minimize surface roughness and dry mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.75 mm depth of cut is necessary to maximize surface hardness. The results indicate the substantial benefit of the minimum quantity of lubrication (MQL) and justify PCD inserts to be the most functionally satisfactory commercially available cutting tool material for machining titanium alloys for better surface finish and hardness.

Highlights

Titanium alloy (Ti-6Al-4V) has been generally used in modern manufacturing processes due to high strengthto-weight ratio at higher temperatures and superior corrosion resistance and finds extensive applications in aerospace, automotive, nuclear, chemical, marine and biomedical industries
The corresponding signal to noise (S/N) ratios for each trial of L27 orthogonal array were determined using Equations 1 and 2 for surface roughness and surface hardness respectively and are presented in Table 3 which gives the combinations of experimental machining parameters and parameter levels in the L27 orthogonal array (OA).A total of 27 experiments were conducted in accordance with the parameter level of each factors and observed values of surface roughness and surface hardness were noted, which were further converted to S/N ratio
Taguchi optimization method for titanium alloy (Ti-6Al4V) machining with poly crystalline diamond (PCD) tool for minimizing the surface roughness and maximizing surface hardness is presented in the paper

Summary

Introduction

Titanium alloy (Ti-6Al-4V) has been generally used in modern manufacturing processes due to high strengthto-weight ratio at higher temperatures and superior corrosion resistance and finds extensive applications in aerospace, automotive, nuclear, chemical, marine and biomedical industries. Titanium alloy with low density, high specific strength, corrosion resistance and good process performance is the ideal structural material, especially for the aerospace engineering[1,2,3]. The surface roughness is an estimate of technological quality of component and indicator for evaluating the productivity of machine tools and machined parts. Desired value of surface roughness of a product is generally defined to achieve the required fatigue strength, corrosion resistance, precision fits, tribological and aesthetic requirements.

Methods

Results

Conclusion