Effect of cutting parameters on machining surface and cutting tool in milling of Ti-6Al-4V alloy

Abstract

Nowadays, materials with lower weight and higher strength are preferred in many fields, such as aerospace, chemical industry and medicine industry. However, these materials are quite difficult to machine. Therefore, in this study, the effects of cutting parameters on cutting force, tool wear and surface roughness are investigated during milling of the Ti-6Al-4V alloy having low weight and high strength. For this purpose, this alloy milled under dry cutting conditions by using 8 mm diameter TiN coated high speed steel (HSS) and tungsten carbide (WC) end mills at different cutting parameters (0.05, 0.075 and 0.1 mm/rev feed rates, 5, 10 and 15 m/min cutting speeds and 2 mm depth of cut) on the computer numerical control (CNC) vertical machining centre. Cutting force, tool wear and surface roughness increase when feed rate is increased for both cutting tool. With increasing cutting speed, contrary to increase in tool wear, cutting force and surface roughness reduced. Maximum cutting force values for TiN coated HSS and WC end mills are obtained as 599 N and 197 N, respectively, in same the cutting parameters. Maximum tool wear values for TiN coated HSS and WC end mills are measured as 0.249 mm and 0.109 mm, respectively, in maximum cutting parameters. Surface roughness obtained from WC end mills was found to be better than those of TiN coated HSS end mills.