Title: Experimental investigations on tool wear in turning of Ti-6Al-4V alloy under different machining environmental conditions

Authors: M. Venkata Ramana; G. Krishna Mohan Rao; D. Hanumantha Rao

Addresses: Department of Automobile Engineering, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad, India ' Department of Mechanical Engineering, JNTUH College of Engineering, Hyderabad, India ' Department of Mechanical Engineering, Mathrusri Engineering College, Hyderabad, India

Abstract: This paper deals with the study of tool wear on different cutting tool materials under scanning electron microscope (SEM) and optimisation of process parameters to minimise tool wear in turning of Ti-6Al-4V under different machining environments such as dry, flooded and MQL machining. Optimisation of process parameters is carried out using Taguchi's Robust Design Methodology to minimise tool wear. The results reveal that MQL machining is shown less tool wear as compared to dry and flooded machining. Moderate cutting speed, high feed rate, moderate depth of cut are found to be the optimum conditions and uncoated tool is outperformed as compared to CVD and PVD coated tools. The SEM analysis has been carried out on the worn tools to evaluate the wear mechanisms. [Received 24 June 2016; Accepted 24 June 2016]

Keywords: tool wear; turning; machining environment; Ti-6Al-4V; titanium alloys; scanning electron microscopy; SEM; dry machining; flooded machining; MQL machining; minimum quantity lubrication; Taguchi methods; robust design; cutting speed; feed rate; depth of cut; wear mechanisms.

DOI: 10.1504/IJMR.2016.082820

International Journal of Manufacturing Research, 2016 Vol.11 No.4, pp.339 - 355

Received: 24 Jun 2016
Accepted: 25 Oct 2016
Published online: 12 Mar 2017 *

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