Micromilling of Ti-6Al-4V Titanium Alloy Using Ball-end Tool

Abstract

The present work experimentally investigates the characteristics of micromilling of Ti-6Al-4V workpiece using ball-end tool. Micromilling were performed using 400 ¼m ball-end milling tool with the consideration of effective tool diameter. The effective tool diameter in ball-end milling is different from flat-end milling due to variation in cutting zone with axial depth of cut which accounts actual cutting speed and feed the machining. Process input variables includes cutting speed, feed per tooth and axial depth of cut, each with three levels, whereas cutting forces and surface roughness as process responses. Response surface methodology (RSM) based quadratic regression analysis was utilized to develop the correlation between process inputs and responses. Experimental results of present study on micromilling of Ti-6Al-4V using ball-end tool showed that axial depth of cut and feed per tooth could significantly influence the cutting forces and surface roughness. However, present study shows cutting speed has least effect on process responses. Finally, suitable set of process variables were proposed based multi objective optimization approach to obtain minimum cutting forces and surface roughness which were also validated with conformation test results.