Titanium turning data

Full description

The Titanium alloy (Ti-6Al-4V) has gained immense importance in the manufacturing
industry due to its superior characteristics, including a high strength-to-weight ratio, high
toughness, and excellent corrosion resistance. However, its inherent properties such as low
thermal conductivity, low elastic modulus, high hardness at elevated temperatures, and high
chemical reactivity make it exceptionally challenging to machine. This difficulty often leads
major businesses to invest heavily in developing cost-reduction methods. Ti-6Al-4V alloy is
the traditional and most widely used Ti-alloy, constituting over 45% of all Ti produced.
The primary aim of this research was to conduct real life experimental analysis on the
sustainable turning of Ti-6Al-4V using coated carbide cutting tools with variable nose radii to
determine the optimum cutting parameters for better surface roughness and to analyse the
resulting chip morphology. Furthermore, the theoretical tool life and the relationship between
parameters have been analysed. The methodology involved 45 physical experimental
analyses conducted on a Ti-6Al-4V bar using a Harrison M400 conventional lathe and coated
carbide inserts with nose radii of 0.40 mm, 0.80 mm, and 1.20 mm. The parameter ranges
investigated were cutting speeds between 50-160 m/min, feed rates between 0.05-0.18
mm/rev, and depths of cut between 0.1-1 mm. Surface roughness was the key
dependent/response parameter, measured using a Taylor Hobson Surtronic 3+ instrument.
The gathered data have been analysed using Design Expert software (Stat-Ease 360) to
create 3D graphs and validate the statistical significance of the models.
The results demonstrated that the nose radius and feed rate were the most statistically
significant parameters influencing surface roughness, as confirmed by ANOVA analysis. Both
the 3D surface plots and the theoretical relationship confirmed that is inversely proportional to
the nose radius and rises nonlinearly and quickly with increasing feed rate. The 1.20 mm nose
radius insert consistently produced a smoother surface finish compared to the smaller radii.
Cutting speed and depth of cut had less significant effects on surface roughness within the
optimum range tested.
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Theoretical tool life analysis confirmed an inverse relationship where tool life decreases as
cutting speed, feed rate, or depth of cut increase. The chips produced were characteristic of
difficult-to-machine materials like Ti-6Al-4V, identified as serrated chips.Serrated chips
produced characterised that Ti-6Al-4V is a difficult to machine material. Chip entanglement,
which impairs machining efficiency, was observed at higher cutting speeds and depths of cut.
This research aligns with the United Nations Sustainable Development Goal 12,
promoting sustainable industrial practices by focusing on efficient machining processes.The
significance of this research is to provide the manufacturing industry and Researchers with
optimal process data. Secondly, to showcase the importance of physical machining compared
to current mathematical models, simulation techniques and cooling methods.