Cutting Force Analysis when Milling Ti-6Al-4V under Dry and Near Dry Conditions Using Coated Tungsten Carbides

Abstract

The effectiveness of the usage of coolant in high speed machining of highly reactive material like titanium and its alloys is still far away uncertain. For this reason, it is wiser to study the effectiveness of MQL under transient cutting speed before we go to the high speed machining. This paper discusses the effect of MQL on the machinability of Ti-6Al-4V by using PVD coated cemented carbide tools. The machinability of Ti-6Al-4V was investigated based on the effect on cutting force and the tool life. The performance of PVD coated cemented carbide tool was investigated at various cutting condition. Completely dry machining and near dry (MQL) were applied in this experiment. For near dry machining, two levels of coolant flow rate were investigated, 50 and 100 mL/H. The effectiveness of mist coolant was tested at three different levels of cutting speed, 120, 135 and 150 m/min. Application of mist coolant is more significant at cutting speed of 135 m/min. At this speed longer tool life was obtained when more coolant was applied. No significant effect of the cutting speed and coolant flow rate on the surface roughness. Surface roughness is more sensitive to the feed rate and the depth of cut. No significant effect of application of MQL on cutting force at early stage of machining. MQL seems to be more affective when tools start worn out where greater contact area between tool and work piece occur to give better lubrication effect.