Performance Of CVD Coated Carbide Tool By Optimizing Machining Parameters During Turning Titanium Alloy Ti-6Al-4V ELI In Flooded Condition

Mohamad Saufi, Subari (2015) Performance Of CVD Coated Carbide Tool By Optimizing Machining Parameters During Turning Titanium Alloy Ti-6Al-4V ELI In Flooded Condition. Project Report. UTeM, Melaka, Malaysia. (Submitted)

Text (24 pages) Performance Of CVD Coated Carbide Tool By Optimizing Machining Parameters During Turning Titanium Alloy Ti-6Al-4V ELI In Flooded Condition 24 Pages.pdf - Submitted Version Download (507kB)

Abstract

Turning process involves the removal of material from a rotating workpiece with a single cutting tool to form a cylinder or intricate profile. In this research, coated carbide tools by Chemical Vapor Deposition,(CVD) were used in turning workpiece titanium alloy, (Ti-6AL-4V ELI). Titanium alloys have been used widely in many applications especially in aerospace, automotive, medical and chemical. This is because high strength to weight ratio, high fracture resistance, and excellent corrosion resistance of titanium alloy. However, titanium alloys have poor machinability even at elevated temperatures. It has low thermal conductivity, low elastic modulus and easy to react chemically with the cutting tools material. The objective of this study is to investigate the performance of cutting tools in turning Ti-6AL-4V ELI using CVD coated carbide tool in flooded condition. Experimental design of this study is based on Factorial method. Two Level Factorial design was selected to arrange the cutting parameters of cutting speed with range of 100 to 140 m/min, feed rate with 0.15 to 0.20 mm/rev, and depth of cut is constant at 0.35 mm. Flank wear was measured using a three axis microscope. The values were recorded for each length of the workpiece until flank wear (Vb) reached the tool life criterion followed by International Standard ISO 3685. From the result obtained, it is found that lowest cutting speed and feed rate resulted in longer tool life while highest cutting speed and feed rate resulted in a much shorter tool life. Based on the ANOVA analysis, cutting speed is the most significant factor followed by feed rate. Mathematical modeling was developed and the error between experimental results and generated model is 19%. The optimum responses are obtained at cutting speed 100m/min, feed rate 0.15 mm/rev and this give out the longest tool life of 15.43 minutes while shortest tool life, 4.07 minutes was obtained at cutting speed of 140m/min and feed rate 0.20 mm/rev. The error of optimization between experimental and model is 0.19%. From this research, even though titanium alloy, Ti-6Al-4V are considered as material with poor machinability, there are suitable cutting parameter available to give out the longest tool life and reducing machining cost.

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