Effects of Machining Parameters on Feed Direction Cutting Forces in Meso-Scale End-Milling of Ti-6Al-4V Under Dry, Wet and MQL Environment

Abstract

High strength, resistance to corrosion, small density and remarkable strength to weight ratio of titanium distinguish it from other metals and is a reason for its use in in renowned industrial setups like bio-medical, automotive, aeronautics, and power generation industries. However, these are considered as difficult-to-machine elements because of less heat conductivity, minimum value of modulus of elasticity, substantial chemical reactivity and elevated temperature strength. Ti-6Al-4V is regarded as major industrial alloy and a focus of research studies. Measurement and analysis of machining forces provides a deep insight into the mechanics of machining and assist in understanding machinability, tool wear / fracture, machining precision, chatter stability, energy, surface quality and temperature. This further helps in finding optimum machinability parameters for different materials. Machining forces are affected by a number of factors including cutting conditions and lubrication / cooling environment. In this research, analysis of milling forces under three different lubrication / cooling environments i.e. Dry, Wet and MQL (Minimum Quantity Lubrication) along with effects of milling parameters during meso-scale milling of Ti-6Al-4V has been conducted. End milling experiments have been performed basing on Taguchi L9 orthogonal array for optimal combination of milling parameters, keeping spindle speed, depth of cut, feed per tooth and cooling conditions as the control factors. Contribution ratios of different milling parameters and lubrication / cooling environment on feed direction forces have been analyzed through ANOVA.