Experimental Study and Optimization of Residual Stresses in Machining of Ti6Al4V Using Titanium and Multi-layered Inserts

Abstract

Residual stresses are those types of stresses that are preserved in the material even after the applied force has been removed. These stresses have a direct influence in characteristics of superalloy along with the exterior finish of the same which plays a very pivot role in industrial applications especially aerospace. In this paper, the consequence of the residual stress has been given importance alongside the knowledge of machined part finish, tool wear, machining force, the heat generated and chip morphology. Superalloy commonly used aeronautical material Titanium (Ti6Al4V) workpiece has been taken and machined using CNC turning lathe with the help of titanium nitride (TiN) coated insert and multilayer-coated insert. The residual stress is obtained through the use of XRD technique. On the opposite side material removal rate, surface roughness and chip thickness have been also determined using defined machines and compared with various machining constraints like machining speed, depth of cut and feed rate. The tool wear was also interpreted and analysed. The machining parameters has been designated through the use of Taguchi Technique where L4 array have used to define the cutting constraints. Grey relational analysis has also been done to get optimal metal removal constraints and to get the optimal result. ANNOVA analysis is also used in this paper to acknowledge the best optimum result.