Machining performance of titanium alloy Ti-6Al-4V in milling operation using CVD carbide insert

Adnan, Muhamad Nur Hadi (2015) Machining performance of titanium alloy Ti-6Al-4V in milling operation using CVD carbide insert. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Titanium alloy is widely used in many areas especially in aerospace, medical and food industry since it has properties of high strength-to-weight ratio, high fracture resistance and excellent corrosion resistance. CVD coated carbide insert is often used during machining titanium alloy, but the wear mechanism frequently occur because titanium is difficult to machine material. This research focuses on machining performance of Titanium Alloy Ti-6Al-4V in milling operation using CVD carbide insert. All the milling processes were conducted under dry condition. The objective of this study is to investigate the tool wear progression and surface roughness as well to study the effect of cutting parameter on wear rate and surface roughness in milling Titanium Alloy Ti-6Al-4V using CVD carbide insert under dry condition. Stereo microscope was used to measure the tool wear while portable surface roughness tester was used to measure the surface roughness. The cutting parameters used in this research were obtained from the research gap of previous related studies. It was found that, uniform flank wear was formed at the start of machining while notch wear occurs at the end of most experiments. Longer tool life of 625 minutes was recorded at cutting speed, Vc = 120 m/min, feed rate, Fz = 0.1 mm/tooth and depth of cut, DoC = 0.3 mm. A better surface finish was achieved at high cutting speed, Vc = 180 m/min, low feed rate, Fz = 0.1 mm/tooth and depth of cut, DoC = 0.3 mm. Wear rate increased due to the increasing of feed rate along with the depth of cut. However, the increasing of cutting speed did not reduce the wear rate significantly. Furthermore, the increasing of cutting speed at lower feed rate and depth of cut produced lower surface roughness.

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