Multi-process parameter optimization in face milling of Ti6Al4V alloy using response surface methodology

Titanium alloy, Ti6Al4V, is an exceptional material with several desirable properties, namely, high specific strength, high corrosion and heat resistance, which make it a promising contender in number of demanding applications. However, it has poor machinability, resulting from low thermal conductivity, high chemical reactivity with tool and spring effect during cutting. These properties lead to reduced tool life during machining, due to which its usage is limited despite excellent mechanical properties. Therefore, optimization of process parameters using response surface methodology in face milling of Ti6Al4V alloy with uncoated carbide tools has been investigated experimentally in this work. This article is focused on developing mathematical relation between input factors and response parameters, namely, surface roughness (Ra), tool wear (Tw) and tool vibration (Tv). The machining parameters are optimized for minimum Ra, Twand Tvvalues. The optimal parameters are validated experimentally which showed a good agreement with the predicted results. The feed rate was found to be the most influential parameter affecting Raand Tv, whereas cutting speed is the most effective in influencing Tw.