High strength, resistance to corrosion, small density and remarkable strength to weight ratio of titanium distinguish it from other metals and is a reason for its use in in renowned industrial setups like bio-medical, automotive, aeronautics, and power generation industries. However, these are considered as difficult-to-machine elements because of less heat conductivity, minimum value of modulus of elasticity, substantial chemical reactivity and elevated temperature strength. Ti-6Al-4V is regarded as major industrial alloy and a focus of research studies. Measurement and analysis of machining forces provides a deep insight into the mechanics of machining and assist in understanding machinability, tool wear / fracture, machining precision, chatter stability, energy, surface quality and temperature. This further helps in finding optimum machinability parameters for different materials. Machining forces are affected by a number of factors including cutting conditions and lubrication / cooling environment. In this research, analysis of milling forces under three different lubrication / cooling environments i.e. Dry, Wet and MQL (Minimum Quantity Lubrication) along with effects of milling parameters during meso-scale milling of Ti-6Al-4V has been conducted. End milling experiments have been performed basing on Taguchi L9 orthogonal array for optimal combination of milling parameters, keeping spindle speed, depth of cut, feed per tooth and cooling conditions as the control factors. Contribution ratios of different milling parameters and lubrication / cooling environment on feed direction forces have been analyzed through ANOVA.
Nickel-based alloys are widely used in the aerospace industry, nuclear reactors and the automotive industry. These alloys exhibit excellent physical and chemical properties at high temperatures. However, nickel-based alloys are difficult to machine materials with high hardness and low thermal conductivity, which results in high cutting forces during machining. Additionally, increasing demand for meso-scale components in the industry has opened a door for research in this field. This paper focuses on meso-scale milling of Inconel 718 alloy. Aiming at the problem of high cutting forces, meso-scale milling experiments of Inconel 718 alloy were conducted. Due to its high strength and work-hardening characteristics, proper tool coating and process parameters should be selected. In this work, TiAlN, TiSiN, and nACo coatings were selected. Taguchi’s L9 orthogonal array was employed for conducting experiments in a dry environment. In this paper, feed per tooth, cutting velocity, depth of cut, and tool coatings are considered as input parameters, and their effects on cutting forces are analysed through the statistical technique of analysis of variance (ANOVA) to figure out the most important process parameters.
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