Study and Analysis of Machining Characteristics and Optimization of cutting parameters in Milling of Ti_6Al_4V and AISI 316

Abstract

Ti-6Al-4V is a super alloy consisting of excellent physical and mechanical newlineproperties which make the alloy difficult to machine materials resulting in lower newlineproduction rates and excess tool wear. Ti-6Al-4V is used in many industries like newlinemedical, marine and chemical processing industries. AISI 316 is an austenitic steel used in battery storage units because of its good mechanical characteristics. The newlinetitanium alloy (Ti-6Al-4V) and stainless steel (AISI 316) were taken as samples in newlinethis work to study their machining characteristics. The aim of the present study is to newlineinvestigate effect of cutting parameters like cutting speed, feed and depth of cut on newlinemachining characteristics such as surface roughness, amplitude of tool vibration in x newlineand y directions, elastic recovery and tool wear. As per full factorial design of newlineexperiments, 27 experiments are conducted on two proposed metals with two fluted newlinetungsten carbide end mill cutters at three levels of cutting speed, feed and depth of cut and experimental results are collected. newlineThe experimental results are analyzed with statistical techniques to get newlineoptimum parameters for output responses. The interacting effect of cutting speed, feed newlineand depth of cut on the machining characteristics are also studied using Response newlineSurface Methodology for both the metals. Finite element analysis based simulation newlinewas carried out for all the experiments to study machining characteristics. Cutting newlineforces and cutter vibrations are predicted to study the effect of forces on the cutter newlinevibrations. The process parameters are optimized using multi response optimization newlinetechnique to reduce surface roughness, cutter vibration, elastic recovery and tool newlinewear. For Ti-6Al-4V, The composite desirability value is 0.8855 and the optimal newlinedesirability value is 0.8855.All the values are close to 1 or equal to 1.So all the newlineresponses have been accepted for Ti-6Al-4V or Ti alloy. For AISI 316, the newlinecomposite desirability value is 0.9216 and the optimal desirability value is newline0.9216.