Title: Modelling and experimental study of chip serration frequency in dry turning of Ti-6Al-4V alloy

Authors: Vikas Upadhyay; P.K. Jain; N.K. Mehta

Addresses: Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247667, India. ' Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247667, India. ' Mechanical and Industrial Engineering Department, Indian Institute of Technology Roorkee, Roorkee 247667, India

Abstract: This paper presents the investigation on the effects of cutting speed, feed rate and depth of cut on chip serration frequency in dry turning of Ti-6Al-4V alloy. The chip serration frequency plays a vital role in determining the machinability of this alloy as the serrated chips are observed at low cutting speed. Serrated chip formation causes a cyclic variation of cutting forces and often leads to serious vibrations resulting in chatter. The chip serration frequency is calculated by the distance between two consecutive shearing planes. Using the results of experiments, a regression model has been developed for chip serration frequency. Based on analysis of variance at 95% confidence interval the model is found to be highly significant. Cutting speed is found to be the most significant factor affecting the chip serration frequency. The effect of feed rate is much less and that of the depth of cut is insignificant.

Keywords: chip serration frequency; titanium machining; response surface methodology; RSM; regression modelling; dry turning; titanium alloys; cutting speed; feed rate; depth of cut; machinability; cutting forces.

DOI: 10.1504/IJMMM.2012.050434

International Journal of Machining and Machinability of Materials, 2012 Vol.12 No.4, pp.358 - 371

Available online: 18 Nov 2012 *

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