Title: Surface roughness evaluation using cutting vibrations in high speed turning of Ti-6Al-4V - an experimental approach

Authors: Grynal D'Mello; P. Srinivasa Pai; N.P. Puneet; Ning Fang

Addresses: Department of Mechanical Engineering, NMAM Institute of Technology, Nitte – 574110, Karkala Taluk, Udupi Dist., India; Visveswaraya Technological University, Belagavi – 590018, Karnataka, India, India ' Department of Mechanical Engineering, NMAM Institute of Technology, Nitte – 574110, Karkala Taluk, Udupi Dist., India; Visveswaraya Technological University, Belagavi – 590018, Karnataka, India, India ' Department of Mechanical Engineering, NMAM Institute of Technology, Nitte – 574110, Karkala Taluk, Udupi Dist., India; Visveswaraya Technological University, Belagavi – 590018, Karnataka, India, India ' College of Engineering, Utah State University, Logan, UT 84322-6000, USA

Abstract: This paper presents the experimental investigation of cutting parameters, tool flank wear, cutting tool vibrations and surface roughness parameters (R_a and R_t) while machining Ti-6Al-4V. High speed turning experiments have been carried out to study the variation in surface roughness due to changes in flank wear, cutting tool vibrations and cutting parameters. The effect of cutting tool vibrations in three directions (V_x, V_y and V_z) on surface roughness has been investigated. The results revealed that tool flank wear is highly influenced by cutting parameters and surface finish improved with the increase in flank wear. Cutting tool vibrations along cutting speed direction (V_y) showed direct correlation with surface roughness parameters, which has been established from ANOVA and surface roughness is highly influenced by cutting parameters.

Keywords: surface roughness; tool flank wear; cutting tool vibration; Ti-6Al-4V; high speed turning; high speed machining; titanium alloys; surface quality; surface finish; cutting speed; ANOVA.

DOI: 10.1504/IJMMM.2016.076281

International Journal of Machining and Machinability of Materials, 2016 Vol.18 No.3, pp.288 - 312

Received: 16 Jul 2015
Accepted: 15 Oct 2015
Published online: 30 Apr 2016 *

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