Measurement 88 (2016) 223–237

Contents lists available at ScienceDirect

Measurement
journal homepage: www.elsevier.com/locate/measurement

Influence cutting parameters on the surface quality and

corrosion behavior of Ti–6Al–4V alloy in synthetic body
environment (SBF) using Response Surface Method
Sergio Luiz Moni Ribeiro Filho a, Carlos Henrique Lauro b, Alysson Helton Santos Bueno a,
Lincoln Cardoso Brandão a,⇑
a
Federal University of São João del Rei, Department of Mechanical Engineering, Center for Innovation in Sustainable Manufacturing, Praça Frei Orlando,
170, São João Del Rei, Brazil
b
Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal

a r t i c l e i n f o a b s t r a c t

Article history: Most of the global manufacturing of titanium alloys is related to produce biphasic struc-
Received 16 January 2016 tures with grains alpha and beta. The development of modern applications of titanium
Received in revised form 7 March 2016 alloy is a great challenge due to the chemical composition of Ti–6Al–4V alloy and the com-
Accepted 23 March 2016
plexity of the manufacturing technology. This study proposed an optimal investigation of
Available online 31 March 2016
the variation of cutting speed, feed rate, and depth of cut in the turning of Ti–6Al–4V alloy
on surface roughness, cutting efforts, and corrosion resistance. Response Surface Method
Keywords:
has been established to optimize and model the responses mathematically. The adequacy
Ti–6Al–4V
Surface quality
of the models and a significant contribution of parameters were determined by analysis of
Corrosion behavior variance (ANOVA). The biocompatibility of the machined surface for different cutting
Turning forces parameters was evaluated by the electrochemical polarization in simulated body fluids
(SBF). Furthermore, desirability function analysis was used to determine the optimal values
for surface quality, the turning force, and the passivation rate. It was clearly noticed that
the multi-responses of the desirability function improved the machine process. The feed
rate and depth of cut were the most relevant factors to minimize surface roughness and
the turning forces. Moreover, the experimental results showed that the corrosion behavior
was strongly related to minimal surface roughness. Finally, the optimization reduced the
surface roughness Ra and Rz in 5.5% and 11.9%, respectively and increased the corrosion
resistance in 18.8%.
Ó 2016 Elsevier Ltd. All rights reserved.

1. Introduction tance, high strength at high-temperature values, and

The use of titanium and its alloys has grown over last
decade due to their excellent properties for application as
biomaterials or aeronautic materials. The main properties
of titanium that should be considered are corrosion resis-
⇑ Corresponding author.
E-mail addresses: sergiolmrf@gmail.com (S.L.M. Ribeiro Filho), carlos.
lauro@ua.pt (C.H. Lauro), alyssonbueno@ufsj.edu.br (A.H.S. Bueno), lincoln@
ufsj.edu.br (L.C. Brandão).
strength-to-weight ratio. However, the use of titanium as
a biomaterial depends on the high quality of products,
mainly when the surface quality is considered. The quality
of machined products is related to good surface roughness
that can represent a decrease of the friction or avoid
surface corrosion. However, according to Sun et al. [28]
titanium is classified as hard-to machine material because
of its low thermal conductivity, high chemical reactivity,
and low modulus of elasticity.

http://dx.doi.org/10.1016/j.measurement.2016.03.047
0263-2241/Ó 2016 Elsevier Ltd. All rights reserved.
224 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237
The mechanical components have been exposed in sev-
eral instances to moderate or severely harsh environments,
mainly to corrosive environments, such as sea water,
industrial wastes, and the human body [19]. The environ-
ment of the human body fluids, especially, is chemically
and physically different from any other natural exposure
conditions [6]. This behavior affects the metal performance
and can generate a toxic reaction inside the human body.
Besides, the component manufacturing process can influ-
ence this behavior; it should have high quality so as to
restore the function into the human body. Gravier et al.
[10] state that corrosion behavior is largely dependent on
the machined surface characteristics in salt atmosphere.
Prakash et al. [19] postulated that the rake angle and turn-
ing speed affected the corrosion behavior of mild steel. The
authors concluded that the corrosion rates in salt atmo-
sphere increase with the decrease in rake angle, and on
the other hand the decrease occurred with the increase
in turning speed.
Several investigations has been proposed to enable high
levels of the machinability of titanium alloys. Generally,
these studies cover the usage of new cutting fluids [25],
new cutting parameters [6] and new tool materials [26].
Turning is a process that is widely used in the metalwork
sector, mainly because it provides the machining of com-
plex surfaces on hardened materials. This technology has
been used throughout the industry since the 1940 s, and
it was adapted to the biomechanical and dental technology
with the goal of accelerating precision manufacturing in
macro and micro scale. Moreover, the need for devices
and components of high complexity contributed to the
evolution of manufacturing in a variety of materials [16].
The economic importance of micro and macro systems
grows, constantly, and is mainly applied to industries such
as automotive, medical, and telecommunications. An ideal-
ization of this importance would be best when integrating
micro and macro components to traditional products,
which involves an optimization of the production cells in
the molds and dies industries.
In the turning process, the temperatures and shearing
stresses on the workpiece surface can reach high levels
and thus generate a layer on the metal surface in a micro-
scopic scale, which may be called area affected by the cut-
ting forces and high temperature [31]. This feature
introduces defects to the surface of metals that are not
reduced or eliminated contributing to a premature failure
of materials. Consequently, surface roughness or surface
texture is generated by pits or marks left on the surface
of the machined material. It occurs due to contact between
the tool edge and workpiece interface, which is superim-
posed, and a ripple profile is caused by deficiency in
machine movements, deformation, heat treatment, resid-
ual stresses, among others.
Surface roughness has a significant relation to the
application of the product and may influence the optical,
mechanical, electrical, and magnetic properties. However,
there is still no general theory that explains the influ-
ence of the roughness on the physical and electrochem-
ical phenomena. The surface roughness in micro and
macro machining is one of the first conditions for the
success of any operation and has been cited as a major
influence of the microstructure of machined material.
The performance of micro components is influenced
by the quality of the surfaces generated by machining
processes [20].
Mathematical modeling is one of the attractive ways to
study the integrity of surface and the cutting forces in
machining processes. The techniques and methods
involved in predicting the responses of the turning process
are extremely complex, show a nonlinear behavior, and
involve multiple variables. The current algebraic models
are usually based on the adjustment of curves extracted
from experiments [27]. Due to the variety of the machining
process, the proposed model has, therefore, an important
role in determining the features and relationship of the
input factors and their interactions with the experimental
responses. Among the optimization methods, the highlight
is the Response Surface Method (RSM), mainly because this
methodology is able to analyze and solve problems in
which the responses of interest are influenced by the many
input variables and defines conditions that optimize these
responses [4].
The RSM has been widely used for optimization of the
cutting parameters in a variety of the machining processes.
Aouici et al. [3] evaluated the influence of the feed rate,
depth of cut, cutting speed, and hardness of workpiece
on the surface roughness and cutting forces using RSM
technique in hard turning of AISI H11 steel with tools of
cBN 7020. Yan and Li [32] reported a multi-objective opti-
mization approach in which an optimal combination
between sustainability, production rate, and cutting qual-
ity during milling the medium-carbon steel was identified.
Davoodi and Eskandari [7] modeled the tool life of PVD
TiAlN-coated carbide tools and material removed of work-
piece, as a function of cutting speed and feed rate, using the
response surface methodology in turning of the N-155
iron–nickel-base super alloy. Kumar and Chauhan [14]
optimized the surface roughness in turning of the alloys
Al 7075 hard ceramic composite and Al 7075 hybrid com-
posite using the RSM, artificial neural networking (ANN),
and the multi response optimization providing a good
technical database for aerospace, automobile, and military
applications.
The present research aims to understand and evaluate
the effects of machining parameters (cutting speed, feed
rate, and depth of cut) on the corrosion behavior, surface
quality, and cutting forces of a Ti–6Al–4V alloy. Further-
more, this study investigated the effect on biocompatibility
of the titanium alloy by the variation of the cutting param-
eters on the surface quality with the help of electrochem-
ical polarizations using synthetic body fluids (SBF) as
electrolyte. The mathematical prediction models of the
responses have been developed employing a Response
Surface Method (RSM). The results have been optimized
using Central Composite Design (CCD) and desirability
function analysis. ANOVA was carried out to determine
the adequacy of the models and a significant contribution
of the cutting parameters. Finally, the electrochemical
measurements of the machined surfaces were compared
to polished samples to better understand the effect of
machining on surface roughness and the subsequent
relation with corrosion behavior.
 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237
Table 1
Chemical composition of titanium alloy Ti–6Al–4V and standardization by ASTM F136 (% mass).
Element Mass (%)
Al V Fe
Ti–6Al–4V 5.5 3.5 0.25
ASTM F136 5.5–6.5 3.5–4.5 0.25 Max
2. Methodology
2.1. Experimental setup
The experimental tests were carried out in the CNC
lathe manufactured by ROMI company model GL 240-M,
with maximum feed speed of 30 m/min (in the X and Z
axes using the G0 function), 22.5 kW in main motor, and
maximum spindle speed of 6000 rpm. A cylindrical bar of
Ti–6Al–4V titanium alloy of 200 mm in length and
13 mm in diameter with hardness of 325 ± 11 Hv was used
as workpiece. The cutting length was equal to 10 mm.
Table 1 shows the chemical composition and the reference
according to ASTM F136. The chemical analysis demon-
strates that the titanium alloy complies with the concen-
trations determined by the ASTM F136 standard.
The experiments were performed in dry condition so as
not to interfere in the samples for electrochemical tests.
The cutting tool used was a carbide insert supplied by
Sandvik Company and specifically developed for machin-
ing of titanium and its alloys. The carbide insert code
was TPGN 160304 T01020 650 with tool nose radius of
0.4 mm. A Kistler 9272 piezoelectric dynamometer, charge
amplifiers 5070, and the Dynoware program was used to
measure the forces in turning operation. The sampling rate
was of 500 Hz, with a low-pass filter, and long-time con-
stant in the data acquisition.
The surface finish was determined by measuring the
surface roughness in the patterns Ra and Rz. The surface
roughness was measured in three angularly equidistant
positions across the tool feed direction using an SJ-400
Mitutoyo profilometer. The cut-off value was 0.8 mm and
sample length was 5 mm providing a sample length in
accordance with ASME B46.1, which avoids noisy data.
2.2. Electrochemical analysis
The polarization measurements were carried out apply-
ing an electrochemical workstation Model PGSTAT 128N
manufactured by Autolab instruments, controlled by the
NOVA 1.10 software. Electrochemical tests were record in
electropositive direction at scan rate of 10 mHz to
100 kHz and a disturbance of 10 mV, with an acquisition
rate of 0.05 mV/s. Ti–6Al–4V alloy cylinders with cross sec-
tion
1 cm2 were embedded in polyester resin holders and
used as working electrode. The reference electrode was a
saturated calomel electrode and the counter-electrode
was a platinum wire. Initially, the samples were kept in
solution for 3600 s and then the ECORR was determined.
Previously, the working electrodes of titanium alloy were
machined with different parameters, rinsed with distilled
water and air dried. The electrochemical tests were
225
O C H N Y Ti
0.14 0.08 0.01 0.03 50 ppm Balance
0.23 Max 0.08 Max 0.012 Max 0.05 Max – –
performed at 37 °C controlled by thermostatic bath using
a conventional tree-electrode.
A simulated body fluid (SBF) was used as the electrolyte
solution (pH = 7.24), which was prepared from analytical
grade (p.a. Merck) reagents and distilled water. Corrosion
behavior of titanium alloys was investigated in naturally
aerated solutions. The potentiostatic polarization curves
for each condition of the turning tests were replicated
three times for concordant values. The electrochemical
measurement of the polished samples were recorded to
be compared to machined surfaces, and subsequently,
better understand the relation of the surface quality and
cutting parameters in corrosion behavior of Ti–6Al–4V
alloy.
2.3. Experimental planning
The response surface method corresponds to a set of
mathematical and statistical models that provide an
approach for the modeling and analysis of the problems
of the multi variable process or system. The RSM approach
is important to determine the best condition of input
parameters to obtain a desired response [17]. This method
is very useful to punctuate values with significant varia-
tions and optimize the process by minimizing the variability
of results. A Central Composite Design (CCD) was per-
formed to evaluate the effect of the cutting speed (Vc),
depth of cut (ap), and feed rate (f) on the turning forces,
surface quality, and the corrosion behavior.
In general, the CCD is a 2 k factorial design with nf fac-
torial points, 2 k axial points, and nC center points, but CCD
does not include all combinations of the experimental fac-
tors (k) and their respective levels (n). Thus, the CCD is very
effective design for modeling and control of first and sec-
ond order models. Thus, the experimental planning was
composed of a 23 factorial design, and therefore 8 factorial
runs. Table 2 shows the experimental levels of the cutting
parameters. The schematic diagram of experimental setup,
the electrochemical measurements, and the RSM analysis
are illustrated in Fig. 1.
3. Analysis of the results
The experimental tests were carried out in order to
obtain greater knowledge regarding surface roughness,
turning forces, and corrosion behavior for machined sur-
faces. In general, the phenomenon discovered by these
experiments is assigned to mathematical models that
describe the behavior during the process. Thus, through
the experimental tests, an analytical method using the
CCD arrangement was proposed and it was tested to adjust
a second order response surface model for optimizing the
process.
226 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237

Table 2
Factors and levels of CCD design.

Factors Symbol Levels

1.68 1 0 1 1.68
Cutting speed (m/min) Vc 53.1821 60 70 80 86.8179
Feed rate (mm/rev) f 0.06591 0.10 0.15 0.20 0.23409
Depth of cut (mm) ap 0.131821 0.20 0.30 0.40 0.468179

Amplifier

Dynamometer

Data acquisition

∅ 13
0.
0.2
Surface roughness
0.15
ƒ [mm/rev]
mearurements
60
70 0. 1 10 mm
80
Vc [m/min]

RSM analysis

Corrosion cell
Fig. 1. Schematic diagram of experimental setup and electrochemical polarization measurements for the Ti–6Al–4V alloy.

A response surface analysis was developed based on the
adjusted surface. If the surface has an adequate approxi-
mation set, then the analysis will be exactly equivalent to
the analysis of the actual process. The answer being mod-
eled by a linear function of the independent variables and
the relationship between ‘‘y” and the predictor variables
can be expressed according to a Taylor’s expansion series.
Based on this, the approximation function will be the
first-order model according to the Eq. (1).
y ¼ b0 þ b1 X 1 þ b2 X 2 þ . . . þ bk X k þ e
If there is curvature in the system, then the approxima-
tion function is a polynomial of higher order, as the
second-order model, as can be seen in Eq. (2):
X
K X
k XX
y ¼ b0 þ bi xi þ bii x2i þ bij xi xj þ e
i¼1 i¼1 i<j
The coefficients (b) are estimated in the polynomial
adjusters. These coefficients, therefore, are responsible for
minimizing the sum of squared errors in the model, based
on this, the least square minimum can be written accord-
ing to Eq. (3).
1
b ¼ ðX T XÞ X T y ð3Þ
The analytical models can be useful to predict the sur-
face finish and the cutting forces considering the continu-
ous input parameters coupled with the RSM. The adequacy
of the quadratic model of response surface was justified
through the analysis of variance (ANOVA) and the results
are showed in Tables 3 and 4. The ANOVA also determined
the significant contribution of the factors in the process.
The ‘‘F” parameter represents the ‘‘F ratio”, which is calcu-
ð1Þ lated by the quadratic average adjusted in each factor by
the quadratic average adjusted in the error.
The ‘‘P-value” indicates the probability that these two
parameters, adjusted MS factor and adjusted MS error,
have the same value and the model is appropriate. When
the ‘‘P-value” is lower or identical to ‘‘a”, it is possible to
ð2Þ
affirm that the effects are significant. The effect is consid-
ered significant when the ‘‘P-value” is lower or equal to
0.05. This analysis was out of a confidence interval of
95%, i.e, for a 5% significance level (a-level of 0.05).
The ‘‘P-value” for models was 0.000, indicating that the
terms in the RSM-model influence the turning forces and
surface roughness. This means that at least one of the
 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237 227

Table 3
Analysis of variance considering the turning forces for RSM.

Factors and interactions Turning forces

Passive force – Fp Feed force – Ff Cutting force – Fc
F P-value Contribution F P-value Contribution F P-value Contribution
Model 140.53 0.000 99.22% 181.52 0.000 99.39% 688 0.000 99.84%
Linear 418.46 0.000 98.48% 538.89 0.000 98.36% 1982.13 0.000 95.88%
Vc (m/min) 0.05 0.823 0.00% 0.6 0.458 0.04% 25.51 0.000 0.41%
ap (mm) 50.15 0.000 3.93% 1350.89 0.000 82.19% 3401.54 0.000 54.85%
f (mm/rev) 1205.17 0.000 94.54% 265.19 0.000 16.13% 2519.34 0.000 40.62%
Square 0.19 0.900 0.05% 4.31 0.034 0.79% 2.57 0.112 0.12%
Vc vs. Vc 0.23 0.642 0.01% 5.17 0.046 0.21% 3.09 0.110 0.03%
ap vs. ap 0.23 0.642 0.01% 5.17 0.046 0.26% 3.09 0.110 0.04%
f vs. f 0.23 0.642 0.02% 5.17 0.046 0.31% 3.09 0.110 0.05%
2-Way Interaction 2.94 0.085 0.69% 1.35 0.313 0.25% 79.31 0.000 3.84%
Vc vs. ap 1.71 0.220 0.13% 1.29 0.283 0.08% 4.8 0.053 0.08%
Vc vs. f 4.42 0.062 0.35% 0.25 0.629 0.02% 18.02 0.002 0.29%
ap vs. f 2.69 0.132 0.21% 2.51 0.144 0.15% 215.1 0.000 3.47%
Lack-of-Fit 0.49 0.776 0.1 0.986 0.84 0.572
S 1.64963 1.19082 1.99745
R2 99.22% 99.39% 99.84%
R2 (adj) 98.51% 98.84% 99.69%
R2 (pred) 96.89% 98.68% 99.20%

Table 4
Analysis of variance considering the surface roughness for RSM.

Factors and interactions Surface finish

Surface roughness – Ra Surface roughness – Rz
F P-value Contribution F P-value Contribution
Model 558.25 0.000 99.80% 44885.32 0.000 100.00%
Linear 1670.99 0.000 99.58% 133,917 0.000 99.45%
Vc (m/min) 42.80 0.000 0.85% 11269.02 0.000 2.79%
ap (mm) 2.47 0.147 0.05% 431.1 0.000 0.11%
f (mm/rev) 4967.71 0.000 98.68% 390,051 0.000 96.55%
Square 0.00 1.000 0.00% 0.81 0.519 0.00%
Vc vs. Vc 0.00 0.994 0.00% 0.97 0.349 0.00%
ap vs. ap 0.00 0.994 0.00% 0.97 0.349 0.00%
f vs. f 0.00 0.994 0.00% 0.97 0.349 0.00%
2-Way Interaction 3.75 0.049 0.22% 738.14 0.000 0.55%
Vc vs. ap 0.66 0.436 0.01% 3.38 0.096 0.00%
Vc vs. f 10.21 0.010 0.20% 2204.22 0.000 0.55%
ap vs. f 0.38 0.549 0.01% 6.81 0.026 0.00%
Lack-of-Fit 0.05 0.997 1.76 0.274
S 0.0741204 0.0340156
R2 99.80% 99.84%
R2 (adj) 99.62% 99.75%
R2 (pred) 99.64% 99.7%

terms in full quadratic equation has a significant effect on
response. The Lack-of-Fit indicates the variation due to the
inadequacy of the model. The Lack of Fit P-value of 0.776,
0.986, 0.575, 0.997, and 0.274 implies that the Lack of Fit
was non-significant for the models on the passive force,
feed force, cutting force, surface roughness in Ra and Rz
pattern, respectively, which suggests that this models fit
the input factors properly.
The R2 shows the proportion of the variability in the
observations of the responses turning forces and surface
roughness in Ra and Rz patterns. This coefficient indicates
that the variability of the observed response values can be
explained by the predictor factors (cutting speed, feed rate,
and depth of cut) and their interactions. Thus, when the R2
value is close to 1 (100%), the estimation quality of the
response values is better. The R2 was 99.22%, 99.39%,
99.84%, 99.80% and 99.84% for the turning forces and sur-
face roughness, respectively.
This means that 99.22%, 99.39%, 99.84%, 99.80%, and
99.84% of the variance of the independent variable (y) is
explained by the change of the input parameters. The
CCD was used to develop a correlation between surface
roughness and the turning forces. The quadratic response
surface model that describe the turning parameters can
228 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237

be explained based on factors of the process cutting speed
(Vc), feed rate (f), and depth of cut (ap), according to the
equations below.
Fp½N ¼ 129:2  0:420  Vc þ 43:9  ap þ 56  f
þ 0:00208  Vc  Vc þ 20:8  ap  ap þ 83  f  f
 0:764  Vc  ap þ 2:45  Vc  f þ 191  ap  f
Ff½N ¼ 107:9  1:179  Vc þ 22:2  ap  50:1  f
þ 0:00713  Vc  Vc þ 71:3  ap  ap þ 285  f  f
þ 0:477  Vc  ap þ 0:420  Vc  f þ 133:5  ap  f
Fc½N ¼ 130:0  1:132  Vc  159:3  ap þ 230  f
þ 0:00924  Vc  Vc þ 92:4  ap  ap þ 370  f  f
þ 1:547  Vc  ap  6:00  Vc  f þ 2071  ap  f ð6Þ
Ra ¼ 3:53 þ 0:0182  Vc þ 2:28  ap þ 40:96  f
þ 0:000001  Vc  Vc þ 0:01  ap  ap þ 0:06  f  f
 0:0212  Vc  ap  0:1675  Vc  f  3:25  ap  f
Rz ¼ 12:428 þ 0:0660  Vc þ 3:87  ap þ 194:85  f
þ 0:000088  Vc  Vc þ 0:881  ap  ap þ 3:52  f  f
 0:0221  Vc  ap  1:1292  Vc  f  6:27  ap  f
The coded coefficients of the cutting parameters corre-
sponding to the model for the passive force, feed force, cut-
ting force, and surface roughness in Ra and Rz patterns are
presented in Table 5. The effects confirm the influence and
the contribution of these coefficients evaluated by the
ANOVA. The largest value in ‘Effect’ represents the influ-
ence value of the factor’s coefficient in the respective
response. The models and coefficients of the responses in
the electrochemical tests were used to accomplish the
desirability function analysis. In this way, a multi-
response optimization was established in the surface
roughness Ra and Rz, turning forces (passive force, feed
force, and cutting force), and corrosion response.
3.1. Turning forces
Table 3 shows that the first-order model based on feed
rate (f) and depth of cut (ap) affected the turning forces,
significantly. However, the pairwise interactions of cutting
speed (Vc), feed rate (f), and depth of cut (ap) showed a rel-
ð4Þ evant effect only on the quadratic model for feed force (Ff).
Considering the cutting force (Fc) in the turning process
the individual effects and the 2-way interactions were
significant in the predict model.
The contribution for each value in Table 3 indicates the
most effective factor on the turning forces. As can be seen,
ð5Þ the depth of cut was the factor that affected the cutting
and feed force with a contribution of 54.85% and 82.19%,
respectively. Whereas, the feed rate was also the most sig-
nificant factor that affected the passive force (94.54%). This
behavior can be attributed to the vibration and thermal
effects generated by the variation in the cutting section
that was influenced by the feed rate and depth of cut in
machining. The variation of cutting section based on the
simultaneous increase of feed rate or depth of cut or both
provided a proportional increase of cutting efforts and
temperature in machining processes.
ð7Þ The cutting force is function of the cutting section and
the shear coefficient of the material. The increase of feed
force has relation with the increase of feed rate, but in
some situations it can be influenced by nose radius, mainly
when tools with great nose radius are applied in turning,
the increase of feed rate has influence on passive force
ð8Þ due to the decomposition of the resultant vector between
the passive and feed forces. Furthermore, the secondary
shear flow that occurs on the rake face of the tool increases
the thickness of the chip. This situation provides high shear
stress on tool face and it is accompanied by an increase in
cutting forces.
Figs. 2–4 illustrate the 3D response surface and contour
plots for the passive force (a–a0 ), feed force (b–b0 ), and cut-
ting force (c–c0 ). The variation of the input cutting param-
eters provided different results for the turning forces. A
trend/relationship can be observed between the cutting
parameters and the forces; passive force, feed force, and
cutting force. As shown in the illustrations, the cutting
force showed the highest value, followed by the passive
and feed forces, which can be explained owing to the fact

Table 5
Coded coefficients of the regression model.

Terms Forces in turning Surface roughness

Passive force Feed force Cutting force Ra Rz
Effect Coeff. Effect Coeff. Effect Coeff. Effect Coeff. Effect Coeff.
Constant 153.631 92.693 162.203 2.2262 10.565
Vc 0.206 0.103 0.498 0.249 5.46 2.73 0.262 0.1312 1.954 0.977
ap 6.322 3.161 23.687 11.844 63.048 31.524 0.063 0.0315 0.3822 0.191
f 30.993 15.497 10.495 5.247 54.259 27.13 2.827 1.4136 11.497 5.748
Vc vs. Vc 0.417 0.208 1.426 0.713 1.849 0.924 0.0003 0.0001 0.0176 0.009
ap vs. ap 0.417 0.208 1.426 0.713 1.849 0.924 0.0003 0.0001 0.0176 0.009
f vs. f 0.417 0.208 1.426 0.713 1.849 0.924 0.0003 0.0001 0.0176 0.009
Vc vs. ap 1.527 0.764 0.955 0.477 3.095 1.547 0.042 0.0213 0.044 0.022
Vc vs. f 2.452 1.226 0.42 0.21 5.995 2.998 0.167 0.0837 1.129 0.564
ap vs. f 1.913 0.956 1.335 0.667 20.715 10.357 0.032 0.0163 0.062 0.031
 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237 229

0.45 Passive
(a) (a’) Force [N]
0.4 < 150
150 – 153
153 – 156
160 0.35 156 – 159

[mm]
m]
159 – 162
Fp [N] 155 0.3

p [m
> 162

aAp
150 0.25
0.4
145 0.3 0.2
50 00.22 app [[m
A mmm]]
60 70 80 0.1 0.15
Vc [m/min] 55 60 65 70 75 80 85
Vc [m/min]
(b) 0.45 Feed (b’)
Force [N]
< 80
0.4 80 – 90
90 – 100
0.35 100 – 110
[mm]

120
m]

> 110
0.3
p [m
aAp

0.25
Ff[N] 100

0.2 80 0.4
0 .3
0.15 00.2 app[[m
A mmm]]
50
50 60
55 60 65 70 75 80 85
70 80 0.1
Vc [m/min] Vc [m/min]

0.45 Cutting
(c) (c’) Force [N]
0.4 < 120
120 – 140
140 – 160
0.35 160 – 180
200
[mm]
m]

180 – 200
Fc [N] 0.3
p [m

200 – 220
aAp

150 > 220

0.25
0 .4
100 0 .3 0.2
0.2 app [[m
A mmm]]
50 60 70 800 0 .1 0.15
Vc [m/min] 55 60 65 70 75 80 85
Vc [m/min]
Fig. 2. Surface and contour for interaction depth of cut (ap) vs. cutting speed (Vc) on the passive force (a–a0 ), feed force (b–b0 ) and cutting force (c–c0 ).

that the cutting section is perpendicular to action of
cutting force mainly in turning process.
Fig. 2 indicates the influence of the depth of cut (ap) and
the cutting speed (Vc) on the passive force (Fp), feed force
(Ff), and cutting force (Fc). The surface and contour curves
show that the value of the turning forces was minimized
when the lowest values of the depth of cut were used.
These effects suggest that the reduction of the depth of
cut provided a decrease in the material removal rate and
in the plastic deformation. Therefore, it can be affirmed
that a decrease in the shearing stresses generated a reduc-
tion in the cutting forces during the machining.
Fig. 3 shows the effect of the feed rate (f) and cutting
speed (Vc) on the cutting forces. From Figs. 2 and 3, it
can be seen that the machining force and its three compo-
nents varied, significantly, influenced by the variation of
cutting speed. Considering that the cutting speed
increased, the temperature increased proportionally at
the cutting zone, generating the softening of material and
therefore reducing the forces of the cutting process.
According to Shaw [29] the influences of temperature on
strain rate may be considered in atomic level in terms of
dislocation or in macrolevel in terms of homogeneous
material. The thermal energy of a material is available to
assist the applied shear stress during the chip dislocation.
This behavior was intensified by intermediate level of
depth of cut (0.30 mm) and feed rate (0.15 mm/rev), which
can be related to the increase of the friction coefficient at
the interface between the tool edge and the workpiece.
The increase of friction coefficient generates vibrations
and heat in machining processes due to the increase of
the amount of material removed per second.
As stated in the 3D surface and contour plots in Figs. 2
and 3, the cutting speed was not significant in reducing the
230 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237

Passive
(a) (a’) 0.22 Force [N]
0.2 < 130
130 – 140
0.18 140 – 150
180

ƒ [mm/rev]
150 – 160
0.16 160 – 170
Fp [N] 160 170 – 180
0.14 > 180
140 0.25
0..2 0.12
120 0.15 ƒ [mm/re v] 0.1
50
50 60 0 .1
70 80 0.08
Vc [m/min]
55 60 65 70 75 80 85
Vc [m/min]
(b) Feed (b’)
0.22 Force [N]
0.2 < 90
90 – 95
0.18 95 – 100
ƒ [mm/rev]

100 – 105
0.16 > 105 108
0.14 102
Ff [N]
0.12 96
0.25
0.1 90 0..2
0.08 0.15 ƒ [mm/re v]
50 60 0.1
70 80
55 60 65 70 75 80 85
Vc [m/min]
Vc [m/min]

Cutting
(c) (c’) 0.22
Force [N]
0.2 < 120
120 – 140
240 0.18 140 – 160
ƒ [mm/rev]

160 – 180
200 0.16 180 – 200
Fc [N] 200 – 220
0.14 > 220
16 0 0.25 0.12
0 .2
120 0.15 ƒ [mm/rev] 0.1
50
50 60 0.1
70 80 0.08
Vc [m/min] 55 60 65 70 75 80 85
Vc [m/min]

Fig. 3. Surface and contour for the interaction feed rate (f) vs. cutting speed (Vc) on the passive force (a–a0 ), feed force (b–b0 ) and cutting force (c–c0 ).

passive and feed forces. On the other hand, the cutting
speed contributed to the cutting force reduction. This influ-
ence can be attributed to the reduction of cutting area and
the softening in material. The cutting force is directly
related to shearing stress of the machined material that
undergoes influence of heat generated with the rise of cut-
ting speed.
Fig. 4 shows the effect of the feed rate (f) and depth of
cut (ap) on the turning forces. The lower levels of feed
rate (f) and lower levels of depth of cut (ap) contributed
to a decrease of the passive force, feed force, and cutting
force. As previously mentioned, the lower values of depth
of cut possibly influence the decreasing of the material
removal rate. Similarly, the decrease of the feed rate
promoted a smaller amount of material deformation
and the volume of material removed was also reduced.
This implies that a lower volume of material removed
decreased the shearing rate, facilitating the cut and
improving chip formation.
The turning forces observed during machining of the
titanium were similar to the forces obtained in machining
of steel [9]. However, the optimal combination that mini-
mized the turning forces was different because of the low
energy consumed during the process. Bhushan [5] and
Hanafi et al. [12] reported that the minimum value of
power consumption was achieved in smallest values of
cutting speed. Negrete [18] concluded that the highest
values of feed rate and depth of cut decreased the energy
accumulated necessary to perform the operation.
3.2. Surface quality
The results in Table 4 indicate that the individual fac-
tors and their interactions significantly affected the surface
 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237 231

Passive
(a) (a’) 0.22 Force [N]
0.2 < 130
130 – 140
0.18 140 – 150
180

ƒ [mm/rev]
150 – 160
0.16 160 – 170
Fp [N] 160 170 – 180
0.14 > 180
140 0.25
0.2 0.12
120 0.15 ƒ [mm/rev] 0.1
00.11 0.2 0.3 0.1
0..4 0.08
Aap [mm]
0.15 0.2 0.25 0.3 0.35 0.4 0.45
ap [mm]
Ap [mm]
(b) Feed (b’)
0.22
Force [N]
0.2 < 70
70 – 80
0.18 80 – 90
ƒ [mm/rev]

90 – 100
0.16 100 – 110
110 – 120 120
0.14 > 120
Ff [N]
0.12 100
0.25
0.1 80 0..2
0.08 0.15 ƒ [mm/rev]
0.1 0.2 0.3 0.1
0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.4
app [[m
A mmm]]
Ap
ap [[mm]
mm]

Cutting
(c) (c’) 0.22 Force [N]
0.2 < 100
100 – 150
300 0.18 150 – 200
ƒ [mm/rev]

200 – 250
0.16 > 250
Fc [N] 200
0.14
0.25 0.12
100 0.2
0.1 5 ƒ [mm/rev] 0.1
00.1 0.2 0 .3 0 .1
0.08
0 .4
Aap [mm]
0.15 0.2 0.25 0.3 0.35 0.4 0.45
Ap
ap [mm]
[mm]
Fig. 4. Surface and contour for interaction feed rate (f) vs. depth of cut (ap) on the passive force (a–a0 ), feed force (b–b0 ) and cutting force (c–c0 ).

finish of workpieces in Ra and Rz pattern. The significance
and the influence of the interactions can be predicted by
the response surface models, which are capable to define
the most relevant factor that affected the response. In this
way, some authors reported that the response surface
methodology is a better tool for optimization compared
to Taguchi’s technique [1,18].
The feed rate (f) was the factor that most influenced
surface roughness in Ra and Rz with a contribution of
98.68% and 96.55%, respectively. Similarly, the feed rate
was the most relevant factor that affected the passive force
showing a good relationship with the surface quality. The
passive force can be related with the elastic recovery of
the workpiece during the metal cutting, and consequently
has a relevant influence in surface finish and dimensional
tolerances. The change of feed rate allows an increase of
the passive force, which generates an increase in the
regenerative vibrations and promotes a variation of the
surface quality.
Ruibin and Wu [21] found similar results where the
feed rate and depth of cut have great influence on surface
roughness. According to the authors, the surface roughness
increases slightly with the increasing of depth of cut.
Moreover, the surface roughness decrease with the
increase of spindle speed or the increase of the cutting
speed. This can occur because the feed rate has a strictly
relationship with nose radius where the decrease of feed
rate, without change the nose radius of tool, provides a
great improve of surface roughness, because in some situ-
ations an overlapping phenomenon can occur and reduce
the crests generated with displacement of the tool.
A graphic representation of the models obtained by
RSM is exhibited in Figs. 5–7. Fig. 5 exhibits the effect
of the depth of cut (ap) vs. the cutting speed (Vc) on the
232 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237

0.45 Ra [µm]
(a) (a’) < 1.6
0.4 1.6 – 1.7
1.7 – 1.8
1.8 – 1.9
2 .25 0.35 1.9 – 2.0

ap [mm]
2.0 – 2.1
2 0.3 2.1 – 2.2
Ra [µm]
> 2.2
1.75 0.25
0.4
1.5 0.3
50
50 0.2 A
app[[m
mmm]] 0.2
6070 80 0 .1
0.15
Vc [m/min]
55 60 65 70 75 80 85
Vc [m/min]
(b) 0.45 Rz [µm]
< 7
(b’)
0.4 7 – 8
8 – 9
9 – 10
0.35 10 – 11
ap [mm]

> 11 12
0.3

0.25 Rz [µm] 10

0.2 8 0.4
0.3
0.15 50 0.2 A
app[[m
mmm]]
6070
55 60 65 70 75 80 85 800 0.1
Vc [m/min] Vc [m/min]

Fig. 5. Surface and contour for interaction cutting speed (Vc) vs. depth of cut (ap) on the surface quality Ra (a–a0 ) and Rz (b–b0 ).

Ra
(a) (a’) 0.22 [µm]
< 1
0.2
1 – 2
0.18 2 – 3
5.5
ƒ [mm/rev]

3 – 4
0.16 4 – 5
Ra [µm] 4 > 5
0.14
2.5 0.25
0 .2 0.12
1 0.15 ƒ [mm/rev]
50 0.1
60 0.1
70 80 0.08
Vc [m/min]
55 60 65 70 75 80 85

Rz [µm]
Vc [m/min]
(b) 0.22 < 8 (b’)
0.2 8 – 12
12 – 16
0.18 16 – 20
ƒ [mm/rev]

20 – 24
0.16 > 24
24
0.14
0.12 Rz [µm] 18

0.1 12 0.25
6 0.2
0.08
0.1 5 ƒ [mm/rev]
50 60 70 0.1
55 60 65 70 75 80 85
80
Vc [m/min] Vc [m/min]

Fig. 6. Surface and contour for interaction cutting speed (Vc) vs. feed rate (f) on the surface quality Ra (a–a0 ) and Rz (b–b0 ).
 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237 233

Ra
(a) (a’) 0.22 [µm]
0.2 < 1
1 – 2
5.5 0.18 2 – 3

ƒ [mm/rev]
3 – 4
4 0.16 4 – 5
Ra [µm] > 5
0.14
2.5 0.25
0.2 0.12
1
0.15 ƒ [mm/rev] 0.1
0.1 0.2 0.1
0.3 0.4 0.08
ap [mm]
0.15 0.2 0.25 0.3 0.35 0.4 0.45
ap [mm]
(b) 0.22 Rz [µm]
< 4
0.2 4 – 6 (b’)
6 – 8
0.18 8 – 10
ƒ [mm/rev]

10 – 12
0.16 12 – 14
14 – 16 20
0.14 16 – 18
0.12 18 – 20 Rz [µm] 15
> 20
10 0.25
0.1
5 0.2
0.08 0.15 ƒ [mm/rev]
0.1 0.2 0.3 0.1
0.15 0.2 0.25 0.3 0.35 0.4 0.45 0 .4
ap [mm]
ap [mm]

Fig. 7. Surface and contour for interaction feed rate (f) vs. depth of cut (ap) on the surface quality Ra (a–a0 ) and Rz (b–b0 ).

surface roughness of Ra (Fig. 5a–a0 ) and Rz (Fig. 5b–b0 ). The
high values of cutting speed caused a decrease in surface
roughness. When low depth of cut and higher level of cut-
ting speed were used, the best surface quality was
observed. However, in some cases, the increase in cutting
speed provided worst surface quality and consequently a
poor finish because an increase in the feed rate occurred
simultaneously, which can generate higher temperatures
and higher pressures during the cutting process, as can
be seen in Fig. 6.
Sargade et al. [23] affirm that lower surface roughness
values are obtained with high cutting speeds because
lower cutting forces are generated. According to the
authors, the increase of cutting speed improves the surface
quality because less heat is dissipated to the workpiece.
Fig. 6 shows the relationship feed rate vs. cutting speed
on surface roughness. The 3D response surface and contour
plots show that surface roughness showed higher values
with the increase of the feed rate. The reason for that
resides in the increase of vibration and thermal effects pro-
vided by the increase in feed rate contributing to a higher
surface roughness. This behavior can be intensified by the
increase of the cutting speed, which increases the elastic
deflection, and consequently, increases the passive force,
generating higher regenerative vibrations.
Fig. 7 presents the effect of feed rate and depth of cut on
surface quality. As previously mentioned, the increase of
the feed rate and the depth of cut generate a rise in the
turning forces. This situation occurs due to the increase
in the areas of the primary and secondary shear planes.
From Fig. 7, it is can be seen that a similar trend was
observed for surface roughness. This implies that the
decreasing in turning forces promoted better surface qual-
ity in the Ti–6Al–4V alloy. In this way, the best surface
quality was obtained when the lowest values of depth of
cut and feed rate were used. This effect can be related with
the lower volume of material removed by the decrease of
the feed rate and depth of cut, which decreases the plastic
deformation and the chip formation rate, facilitating the
cut with lower passive force.
3.3. Corrosion behavior
The micrographs of Ti–6Al–4V alloy samples are shown
in Fig. 8 after attack with 2% hydrofluoric acid (HF) and 10%
nitrite acid (HNO3) for 5 s. The samples exhibited similar
microstructures. Fig. 8 shows a homogenous structure
with the presence of grains with defined contours, evi-
dencing the a-phase (lighter) and b-phase (darker).
The potentiostatic polarization curves in an aerated
simulated body fluid solution (SBF) at 37 °C, after the turn-
ing with different machining parameters, are shown in
Fig. 9. The electrochemical tests exhibit the same general
features for all different machined surfaces. Lower oscilla-
tions of the current density in the electrochemical curves
were related to the re-passivation of micro sized pits and
the formation of the passive film. It can be noted that this
situation was more significant for the condition with cut-
ting speed of 60 m/min, feed rate 0.2 mm/rev, and depth
of cut of 0.4 mm.
The anodic region shows the formation of the passive
layer over all surfaces, spontaneously. The first region in
234 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237

Fig. 8. Optical microscope images of Ti–6Al–4V with 200 (a) e 500 (b).

1.5

Vc: 60 m/min f: 0.1 mm/rev Ap: 0.2 mm

1
Potential (V) ECS

Vc: 60 m/min f: 0.1 mm/rev Ap: 0.4 mm

Vc: 60 m/min f: 0.2 mm/rev Ap: 0.2 mm
Vc: 60 m/min f: 0.2 mm/rev Ap: 0.4 mm

0.5

-0.5
-9 -8 -7 -6 -5
10 10 10 10 10
Log J (mA/cm²)

1.5

Vc: 80 m/min f: 0.1 mm/rev Ap: 0.2 mm

Vc: 80 m/min f: 0.1 mm/rev Ap: 0.4 mm
1
Potential (V) ECS

Vc: 80 m/min f: 0.2 mm/rev Ap: 0.2 mm

Vc: 80 m/min f: 0.2 mm/rev Ap: 0.4 mm

0.5

-0.5
-8 -7 -6 -5
10 10 10 10

Log J (mA/cm²)

Fig. 9. Polarization curves of Ti–6Al–4V alloy at different cutting parameters.

the range of 0.22 V to 0.28 V exhibited passive current the passive layer more quickly. Hacisalihoglu et al. [11]
densities lesser than the currents with more positive also demonstrated similar polarization curves of titanium
potentials, for example, above 0.5 V, as shown in Table 6. alloys in SBF solution.
The ratio of the current densities between the first and sec- Table 6 shows the electrochemical results from the
ond anodic passive regions were near 10 or higher [2]. It polarization curves. From Table 6, it can be seen that the
was also noticed that the lower level of depth of cut corrosion potential ECORR of the different machined sur-
(0.2 mm) and feed rate (0.1 mm/rev) presented a lower faces was slightly similar. However, the corrosion potential
corrosion current density, independent of the cutting for the high level of depth of cut (0.4 mm) was more posi-
speed investigated. This behavior suggests that the lower tive. Furthermore, the corrosion current densities Icorr con-
levels for depth of cut and feed rate showed a higher bio- firmed lower corrosion rates for lower feed rate and depth
compatibility in body environment with the formation of of cut. It can be noted more clearly that due to the use of
 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237 235

Table 6
Polarization results in aerated SBF solution at 37 °C of Ti–6Al–4V.

Cutting parameters Corrosion behavior

Vc (m/min) f (mm/rev) ap (mm) ECORR (V) (ECS) Icorr (A/cm2) j (A/cm2) 0.5 V above ECORR j (A/cm2) 1 V above ECORR
60 0.1 0.2 0.27945 7.2E09 6.62E06 7.69E06
60 0.1 0.4 0.28815 1.68E08 5.74E06 7.62E06
60 0.2 0.2 0.2245 2.23E09 6.56E06 9.02E06
60 0.2 0.4 0.21625 1.38E07 4.43E06 6.62E06
80 0.1 0.2 0.23676 2.09E08 5.28E06 1.05E05
80 0.1 0.4 0.18628 4.08E08 3.76E06 5.01E06
80 0.2 0.2 0.26419 1.32E08 5.25E06 7.38E06
80 0.2 0.4 0.26825 4.79E08 5.14E06 7.21E06

1.5

1 Vc: 60 m/min f: 0.1 mm/rev Ap: 0.2 mm

Potential (V) ECS

Vc: 80 m/min f: 0.1 mm/rev Ap: 0.2 mm

Polished surface

0.5

-0.5

-1 -9 -8 -7 -6 -5
10 10 10 10 10

Log J (mA/cm²)

Fig. 10. Polarization curves of Ti–6Al–4V alloy on polished and machined surfaces.

lower cutting speed (60 m/min) a higher passivation the machined surface can provided a satisfactory surface
rate occurred when compared to higher cutting speed quality for biomedical devices if the correct parameters
(80 m/min). are selected.
However, the behavior of different cutting speeds was
quite similar, showing that the most relevant factors for 3.4. Multi response optimization using desirability function
the passivation rate were the depth of cut and the feed rate analysis
parameters. As previously showed, the best surface finish
was obtained with lower levels of depth of cut and feed The analysis using the desirability function uses an
rate, which demonstrates the influence on the corrosion optimization technique that provides a method to obtain
behavior. In this way, surface quality demonstrated a con- the maximum value of fitness to identify the optimal solu-
siderable contribution to passivation rate, which suggests tion [24]. This approach starts with multiple solutions and
that the passivation rate of the rough surface was lower its analysis is based on the algorithm with reduced gradi-
than the smooth surface. It can be affirmed that the ent [15]. Derringer and Suich [8] planned the desirability
smooth machined surface increases the passivation rate analysis, which specified three types of individual fitness
by reducing surface area, which occurs due to the electro- functions: lower is best, higher is best, and nominal is best.
chemical reactions. Williamson et al. [30] and Jabbaripour The desirability function scales range between 0 and 1.
et al. [13] also concluded that the surface morphology pre- Solutions with desirability values closer to 1 establish the
sents an essential role in determining the corrosion behav- optimal combination for the predicted response. Therefore,
ior in titanium alloys. the best result in this work can be considered where the
Fig. 10 represents the fluctuation of electrochemical responses; surface roughness, turning forces, and the cor-
measurements for polished and machined surfaces, which rosion current densities correspond to the desirability
presented lower corrosion current density. The morphol- function ‘smaller values is best’ scenario. The mathemati-
ogy effect of the surface on the corrosion behavior is clearly cal forms of the desirability function of ‘the smaller the
noted in Fig. 10. In this way, the surface quality is strongly better’ and the composite desirability can be found in Sait
related to the biocompatibility of the titanium alloy, con- et al. [22,24].
firmed in Fig. 9. It can be noted that the small oscillations Table 7 exhibits the results obtained from the desirabil-
of the current density was more evident for polished ity functions. The levels of cutting parameters that pro-
surface, which suggests a higher passivation rate for the vided a solution with desirability values close to 1 were
polished surface with smooth characteristic. However, considered the optimal solution. Furthermore, this solution
machined surface with cutting speed of 60 m/min exhib- predicted the lowest values of surface roughness, passive
ited a lower corrosion current density. This implies that force, feed force, cutting force, and corrosion current
236 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237

Table 7 on the turning responses. Moreover, the analysis of vari-

Desirability results for multi response optimization. ance demonstrated that the feed rate was the most rele-
Solution Vc (m/min) ap (mm) f (mm/rev) Composite vant factor on the surface roughness and passive force.
desirability Ra and Rz were influenced by the feed rate with contribu-
1 85.7987 0.131821 0.0659104 0.99903 tion of 98.98% and 96.55%, respectively. Whereas the pas-
2 53.1821 0.131821 0.0659104 0.99903 sive force (Fp) was affected by feed rate with 94.54%.
3 86.8179 0.131821 0.0659104 0.99069 Additionally, this analysis also shows that the depth of
4 53.1821 0.131821 0.0659104 0.99069
5 86.8179 0.131821 0.0659104 0.9833
cut and feed rate have significant influence on the feed
6 53.1821 0.131821 0.0659104 0.9833 force (Ff) and cutting force (Ff). The feed force (Ff) and
7 86.8179 0.131821 0.0659104 0.97236 the cutting force (Fc) were strongly affected by the depth
8 53.1821 0.131821 0.0659104 0.97027 of cut (82.19%) and feed rate (16.13%). Furthermore, the
9 82.1963 0.219387 0.0693401 0.96116
cutting speed demonstrated a small influence on all the
10 58.5513 0.214833 0.0675957 0.96049
responses analyzed.
The corrosion behavior was evaluated in function of the
density (Icorr), among all the solutions obtained. The same turning parameters. The passivation rate of the titanium
weights and importance were used for all responses. The alloy was related to a minimum error with high surface
minimum predicted values for all responses were set as quality. The surface roughness defines the quality of the
the goal. The optimization was carried out for a combina- workpiece and it was very important in determining the
tion of goals. From the analysis of results, the optimization corrosion behavior. In this way, the feed rate and depth
predicted values were 0.768 lm and 4.4577 lm for the Ra of cut showed that they were the most significant factors
and Rz model. Regarding the turning forces, the optimal for minimizing the corrosion rate in Ti–6Al–4V alloy. The
values were 127.891 N, 74.4126 N and 101.922 N for the lower levels of the feed rate and depth of cut decreased
passive force, feed force and cutting force, respectively. the turning forces. On the other hand, the highest cutting
Finally, the corrosion behavior values were 1.9E09 A/cm2, speed provided a decrease on the passive force, feed force,
for corrosion current density (Icorr). and cutting force. Similarly, the best surface quality was
The optimization of the multi responses in machining achieved using the highest cutting speed and the lowest
processes, in some cases involves the worsening of one feed rate and depth of cut.
response and simultaneous improvement of another r. The analysis using the desirability function showed val-
However, in the experimental trials performed for this ues of fitness closer to 1, indicating this is a suitable tech-
work the response variables showed a similar trend, which nique to predict the responses with reliable results for
states the desirability solution close to 1. In this way, the surface roughness, turning forces, and corrosion behavior.
surface quality and the forces required in the turning Therefore, the optimal results for minimizing surface qual-
process achieved the optimal cutting parameters. Further- ity, turning forces, and corrosion current density (Icorr)
more, this optimization method also included the corro- were achieved with feed rate of 0.07 mm/rev and depth
sion behavior of the titanium alloy, so this involves a vital of cut 0.13 mm. The cutting speed had no significant effect
benefit for biomedicine and prostheses development. This in the responses, thus the value can be used in the range of
condition is important to improve the turning process, in 53.18 m/min or 85.79 m/min.
order to improve the quality of the manufacturing technol- The anodic region of the polarization curves showed the
ogy of biomedical devices for restoring function to the formation of a passive layer over all machined surfaces
human body. independent of the cutting parameters. This situation indi-
The initial settings and the predicted responses to the cates that the ionic composition of the SBF solution
desirability function were compared to estimate the effec- allowed the formation of passive layer stable with low
tiveness of the method. The surface roughness decreased in presence of pits on the machined Ti–6Al–4V alloy surface.
5.46% and 11.9% for Ra and Rz, respectively. In the same Furthermore, the high concentration of titanium and the
way, the passive force, feed force and cutting force were homogeneous microstructure of Ti–6Al–4V alloy surface
also reduced to 7.85%, 6.42%, and 14.22%, respectively. justify the satisfactory corrosion performance of the
Regarding the corrosion behavior, the corrosion current machined surfaces in a simulated body fluid environment.
density was minimized by 18.789% when the operating
parameters obtained by optimization method were used. Acknowledgments

The authors would like to thank the Brazilian Research

4. Conclusions
In this study, the Response Surface Method (RSM) and
desirability function were used to investigate and optimize
the influence of the cutting parameters on the surface
roughness, turning forces, and the biocompatibility of
Ti–6Al–4V alloy. Based on these results, the following
conclusions are possible.
The 3D surface and contour plots of RSM could help
visualize and evaluate the effect of the cutting parameters
Agency (CNPq) and the Minas Gerais Research Agency
(FAPEMIG) for the financial support.
References
[1] A. Aggarwal, H. Singh, P. Kumar, M. Singh, Optimizing power
consumption for CNC turned parts using response surface
methodology and Taguchi’s technique – a comparative analysis, J.
Mater. Process. Technol. 200 (2008) 373–384.
[2] A.P.R. Alves, F.A. Santana, L.A.A. Rosa, S.A. Cursino, E.N. Codaro, A
study on corrosion resistance of the Ti–10Mo experimental alloy
 S.L.M. Ribeiro Filho et al. / Measurement 88 (2016) 223–237
after different processing methods, Mater. Sci. Eng.: C 24 (2004)
693–696.
[3] H. Aouici, M.A. Yallese, K. Chaoui, T. Mabrouki, J.F. Rigal, Analysis of
surface roughness and cutting force components in hard turning
with CBN tool: prediction model and cutting conditions
optimization, Measurement 45 (2012) 344–353.
[4] E.M. Arruda, L.C. Brandão, S.L.M. Ribeiro Filho, J.A. Oliveira,
Integrated optimization using mixture design to confirm the
finishing of AISI P20 using different cutting strategies and ball nose
end mills, Measurement 47 (54–63) (2014) 2014.
[5] R.K. Bhushan, Optimization of cutting parameters for minimizing
power consumption and maximizing tool life during machining of Al
alloy SiC particle composites, J. Clean. Prod. 39 (2013) 242–254.
[6] Q. Chen, G. Thouas, Metallic implant biomaterials, Mater. Sci. Eng.: R:
Rep. 87 (2015) 1–57.
[7] B. Davoodi, B. Eskandari, Tool wear mechanisms and mulit-response
optimization of tool life and volume of material removed in turning
of N-155 iron–nickel-base superalloy using RSM, Measurement 68
(2015) 286–294.
[8] G. Derringer, R. Suich, Simultaneous optimization of several response
variables, J. Qual. Technol. 12 (4) (1980) 214–219.
[9] E.O. Ezugwu, Z.M. Wang, Titanium alloys and their machinability – a
review, J. Mater. Process Technol. 68 (1997) 262–274.
[10] J. Gravier, V. Vignal, S.B. Bissey, Influence of residual stress, surface
roughness and crystallographic texture induced by machining on the
ion behaviour of copper in salt-fog atmosphere, Corros. Sci. 61
(2012) 162–170.
[11] I. Hacisalihoglu, A. Samancioglu, F. Yildiz, G. Purcek, A. Alsaran,
Tribocorrosion properties of different type titanium alloys in
simulated body fluid, Wear 332–333 (2015) 679–686.
[12] I. Hanafi, A. Khamlichi, F.C. Mata, E. Almansa, A. Jabbouri,
Optimization of cutting conditions for sustainable machining of
PEEK-CF30 using TiN tools, J. Clean. Prod. 33 (2012) 1–9.
[13] B. Jabbaripour, M.H. Sadeghi, M.R. Shabgard, H. Faraji, Investigating
surface roughness, material removal rate and corrosion resistance in
PMEDM of c-TiAl intermetallic, J. Manuf. Process. 15 (2015) 56–68.
[14] R. Kumar, S. Chauhan, Study on surface roughness measurement for
turning of Al 7075/10/SiCp and Al 7075 hybrid composites by using
response surface methodology (RSM) and artificial neural
networking (ANN), Measurement 65 (2015) 166–180.
[15] K. Maji, D.K. Pratihar, A.K. Nath, Experimental investigations and
statistical analysis of pulsed laser bending of AISI 304 stainless steel
sheet, Opt. Laser Technol. 49 (2013) 18–27.
[16] R. Muhammad, S.H. Mohammad, A. Maurotto, C. Siemers, A. Roy, V.
V. Silberschmidt, Analysis of a free machining a + b titanium alloy
using conventional and ultrasonically assisted turning, J. Mater.
Process. Technol. 214 (2014) 906–915.
[17] D.C. Montgomery, Design and analysis of experiments, sixtha ed.,
John Wiley & Sons Inc., Arizona, 2005.
237
[18] C.C. Negrete, Optimization of cutting parameters using Response
Surface Method for minimizing energy consumption and
maximizing cutting quality in turning of AISI 6061 T6 aluminum, J.
Clean. Prod. 91 (2015) 109–117.
[19] M. Prakash, S. Shekhar, A.P. Moon, K. Mondal, Effect of machining
configuration on the corrosion of mild steel, J. Mater. Process.
Technol. 219 (2015) 70–83.
[20] W.B. Rashid, S. Goel, X. Luo, J.M. Ritchie, The development of a
surface defect machining method for hard turning processes, Wear
302 (2013) 1124–1135.
[21] X. Ruibin, H. Wu, Study on cutting mechanism of Ti6Al4V in ultra-
precision machining, Int. J. Adv. Manuf. Technol. (2016) 1–7.
[22] A.N. Sait, S. Aravindan, A.N. Haq, Optimization of machining
parameters of glass–fibre-reinforce plastics analysis using Taguchi
technique, Int. J. Adv. Manuf. Technol. 43 (2009) 581–589.
[23] V.G. Sargade, S.R. Nipanikar, S.M. Meshram, Analysis of surface
roughness and cutting force during turning of Ti–6Al–4V ELI in dry
environment, Int. J. Ind. Eng. Comput. 7 (2016) 257–266.
[24] M. Sarikaya, A. Güllü, Taguchi design and response surface
methodology based analysis of machining parameters in CNC
turning under MQL, J. Clean. Prod. 65 (2014) 604–616.
[25] A. Shokrani, V. Dhokia, S. Newman, Investigation of the effects of
cryogenic machining on surface integrity in CNC end milling of Ti–
6Al–4V titanium alloy, J. Manuf. Process. 21 (2016) 172–179.
[26] R.B. Silva, A.R. Machado, E.O. Ezugwu, J. Bonney, W.F. Sales, Tool life
and wear mechanisms in high speed machining of Ti–6Al–4V alloy
with PCD tools under various coolant pressures, J. Mater. Process.
Technol. 213 (2013) 1459–1464.
[27] S.P. Silva, S.L.M. Ribeiro Filho, L.C. Brandão, Particle swarm
optimization for achieving the minimum profile error in honing
process, Precis. Eng. 38 (2014) 759–768.
[28] S. Sun, M. Brandt, M.S. Dargusch, Characteristics of cutting forces
and chip formation in machining of titanium alloys, Int. J. Mach.
Tools Manuf. 49 (2009) 561–568.
[29] M.C. Shaw, Metal Cutting Principles, Oxford University Press, 2005,
p. 651.
[30] R.S. Williamson, J. Disegi, A.V. Janorkar, J.A. Griggs, M.D. Roach, Effect
of duty cycle on the crystallinity, pore size, surface roughness and
corrosion resistance of the anodized surface on titanium, Surf. Coat.
Technol. 277 (2015) 278–288.
[31] J. Xie, M.J. Luo, K.K. Wu, L.F. Yang, D.H. Li, Experimental study on
cutting temperature and cutting force in dry turning of titanium
alloy using a non-coated micro-grooved tool, Int. J. Mach. Tools
Manuf. 73 (2013) 25–36.
[32] J. Yan, L. Li, Multi-objective optimization of milling parameters – the
trade-offs between energy, production rate and cutting quality, J.
Clean. Prod. 52 (2013) 462–471.