Tool wear and surface roughness evaluation of mill insert tools in high-speed machining of Ti-6Al-4 V

Abstract

The experiment carried out using high-speed machining (HSM) in this study is primarily focused on producing high-quality products and lowering the cost of production. To increase tool life and surface quality, HSM is a metal cutting method that priorities quick speeds and feed rates. Determining the appropriate machining and cutting settings that can produce the best results in terms of tool performance and surface qualities becomes essential in this way. Experiments using the L9 orthogonal array were conducted to determine the ideal responses for the Ti grade −5 alloy using a variety of variables, including cutting speed, feed rate, depth of cut, and stepover. By machining at a fast speed, the ultimate goal is to provide a superior surface finish and lengthen the tool life. According to the results of the machining, the cutting speed and stepover have a significant impact on the machining outcome. The optimal value of surface roughness Ra = 0.51 m is achieved with the following parameters: speed = 450 m/min, feed rate = 2100 mm/min, depth of cut = 0.3 mm, and stepover = 60 %. Confirmatory tests with a value of less than 10 % have verified the results. The conclusion being drawn that it is in strong agreement with the experimental results. The findings of this research reveal that the Taguchi technique is capable of analysing the advanced features of boundaries in HSM. This demonstrates the validity of the Taguchi methodology as a specialized model for addressing the issue of high-speed machining settings for titanium grade 5 alloy.