Effect of cutting parameter on surface roughness titanium alloy (Ti-6AI-4V) with drilling process

Mustafa, Siti Sara (2015) Effect of cutting parameter on surface roughness titanium alloy (Ti-6AI-4V) with drilling process. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Titanium alloys are extensively used in marine application, biomedical, and automotive industries. Drilling is one of the crucial machining process for aerospace industries especially in airframe production. Surface integrity is one of the relevant parameter in determining the quality of the machined surface. Hence, in this research surface roughness for drilling process on titanium alloy are investigated. The objectives of this study are to determine the effect of drilling parameter (cutting speed, feed rate) to the surface roughness of hole produced, to develop a mathematical model using ANOVA analysis and lastly to obtain an optimized drilling parameter for Ti-6Al-4V. Two factors are used this experiment which are cutting speed, and feed rate. The value for cutting speeds are 40 m/min and 60 m/min. In addition, the value for feed rate are 0.02 mm/rev and 0.04 mm/rev. The depth of cut remain constant at 10mm. Two level factorial design with three times replication are selected to arrange the cutting parameter. ANOVA was used to analyse the significant effect of the factors to response. Surface roughness tester are used to measure the surface roughness of the machine surface. The result show that lowest cutting speed, lowest feed rate produces lowest surface roughness while highest cutting speed, highest feed rate produces highest surface roughness. Based on the ANOVA analysis, feed rate is the most significant factor followed by cutting speed. Mathematical model is develop and the error between experimental and model is 15%. The optimum responses are obtained at cutting speed 40m/min, feed rate 0.02 mm/rev and this give out the lowest surface roughness of 0.41 μm. The error of optimization between experimental and model is 13%. From this research, eventhough titanium alloy, Ti-6Al-4V are difficult material to be machined, the suitable cutting parameter are able to give out the lowest surface roughness for better surface quality

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