Optimization of Machining Parameters for End Milling of Titanium Alloy

Presentation on
Optimization of Machining Parameters for End

Milling of Titanium Alloy with Coated Tungsten
Carbide Insert
By
Akshay Mahavir Koruche
SY MTech Production
PRN No: 2017MTEMEPR010
Under Guidance of
Prof. Sharad V. Gaikwad
Dept. of Mechanical Engineering
Walchand College of Engineering, Sangli
(An Autonomous Institute)
Contents
2
 Introduction
 Literature Review
 Scope
 Objectives
 Methodology
 Work Plan
 Experimental Work
 Trial Experiments
 Process Parameters Selection and DOE
 Result and Discussion
 References Walchand College of Engineering, Sangli
What is End Milling ?
3
Fig. End Milling Process

Indexable End Milling
4

Indexable End Milling
5 Walchand College of Engineering, Sangli

Cemented Carbide
Tungsten Carbide
Titanium Carbide
Withstand
higher
Faster temperature
Cemented Tantalum Carbide machining
Carbide
Better
Surface
Finish
Advantages
Cemented Carbide Inserts
Carbide is more expensive per unit than

other typical tool materials, and it is more
brittle, making it susceptible to chipping
and breaking.
To offset these problems, the carbide
cutting tip itself is often in the form of a
small insert for a larger tipped tool whose
shank is made of another material, usually
carbon tool steel.
This gives the benefit of using carbide at
the cutting interface without the high cost
and brittleness of making the entire tool
out of carbide.
Literature Review
8 Author Name of Paper Material Parameters Response
Variable
Sadham et Study of Cutting Forces Titanium Cutting Speed, Cutting Force,

al. and Tool wear during End Alloy (Ti- Feed Rate Tool Wear
Milling of TI-6AL-4V Alloy 6Al-4V
alloy)
Maiyar et Optimization of Machining Inconel 718 Cutting Speed, Surface

al. Parameters for End Milling of Super Alloy Feed Rate , Roughness,
Inconel 718 Super Alloy Using Depth of Cut Material
Taguchi Based Grey Relational Removal Rate.
Analysis
Ghani et al. Application of Taguchi Method Hardened Cutting Speed, Surface Finish
in the Optimization of End Steel AISI Feed Rate ,
Milling Parameters H13 Depth of Cut.
Chandra Machinability Study and Inconel 718, Cutting Speed, Tool Wear,
Nath et al. Process Optimization in Face Inconel 625 Feed Rate Material
Milling of Some Super Alloys Removal Rate,
with Indexable Copy Face Mill Cutting Forces
Inserts Walchand College of Engineering, Sangli
Scope of Project Work
9
 Titanium alloy posses very good material properties which

makes it popular in aerospace industry. Due to its low thermal
conductivity and high chemical reactivity, it is considered as a
difficult to machine material.
 Indexable end milling is one of the most widely used metal
removal processes because of its ability to remove material
faster with a good surface quality.
 From the literature it was found that there is scope to perform
indexable end milling on titanium alloy for optimization of
process parameters.

Objectives
10
 To identify the effect of different process parameters

affecting milling operation on response variables.
 Design of experiments by using optimization method.
 To conduct experiments as per optimization technique
under selected process parameters.
 Analysis of experimental result for response variables.
 Optimization and validation of experimental results.

Methodology
11
 To study and identify the research gap for indexable end

milling on titanium alloy.
 Literature survey of the various process parameters and
optimization techniques used for determining the

required response parameters.
 Analyze the techniques used for measuring different
response variables and checking the availability for it.

 To study optimization method for parameter design and
optimization of selected process parameters that are to

be considered in the project.
 To identify the factors affecting indexable end milling
operation.
• Manufacturing or purchasing tooling, purchasing
material and other required components to perform
experiment.
• Selection of level of process parameters to determine
the design of experiments.
• Perform DOE to identify the number of experiments
to be carried out for determining the optimum
parameters.
• To analyze the experimental results to decide the
optimum process parameters and the influence of each
process parameter on the process.
• Report writing.

Work Plan June Jan June
Work Activity July Aug Sep Oct Nov Dec Feb Mar Apr May
2018 2018 2019

13 Problem identification

Literature Review

Selection of process
parameters

Design of
Experiments

Trial Experiments

Experiment using
DOE

Analysis and
Determination of
optimum parameters

Validation and
Confirmation of
Results

Preparation of draft
for Journals and
Conferences

Report writing WalchandPlanned
CollegeActivity
of Engineering, Sangli Completed

Activity
Experimental Work
14
Material Selection
Titanium alloy (Ti-6Al-4V)
 High strength to weight ratio
 High tensile strength and Toughness at high Temp.
 Extraordinary corrosion resistance
Cons:
Low thermal conductivity
High chemical reactivity Applications :
• Aerospace industries
• Medical devices
• Expensive sports cars
Difficult to Machine
Material Selection
15
Ti-6Al-4V alloy grade 5:

200 × 80 × 8.5 mm
Number of Slabs
Required : 2

Tool Material Selection
Tungsten carbide inserts
tungsten carbide is one of the hardest materials in existence and
substantially harder than titanium.
It comes with various coatings for better machinability.
Inserts to be used:
TiC/
Sr Grade Coating Type Coating Layer TiN
No
1 K 10 - Uncoated
Coatings TiCN
2 TTMS PVD TiAlN (monolayer)
3 TTMS PVD TiAlN (multilayer) TiAlN

Tool Material Selection
17
Tool Holder Inserts

Machine Specification and Experimental Setup
Spindle Coolant hoses
Insert
Tool holder
Machine set up and Tool assembly

Machine Specifications
Machine name MAXMILL PLUS +
Machine Travels Maximum travel: X- 600 mm, Y- 450mm, Z- 500mm

Work table size- X-700 mm, Y- 420 mm
Max. table load – 350 kg
Axes motor power 1.48/1.48/3.77 KW
Programmable feed rate – 0-10 m/min
Guide ways – LM guides size 35 mm
Travel accuracy Position accuracy: 0.01 mm

Repeatability: 0.005µm
Control System Siemens 828D
Spindle Spindle taper – BT 4

Distance spindle nose table - 80-580
Spindle to column – 480 mm
Spindle speed range - 100-8000 rpm
Spindle motor power-12.5 KW

PROCESS PARAMETERS SELECTION AND
DOE
20
Parameters affecting the milling operation

Process Parameters
21
 Feed Rate ( 90 to 130 mm/min)

 Cutting Speed ( 55 to 95 m/min)
 Depth of cut (0.5 to 1 mm)
 Insert coating (Uncoated, TiAlN
Monolayer, TiAlN Multilayer )

Response Variables
22
 Cutting Force
 Surface Roughness
 Material Removal Rate

Design of Experiments
23
Process Level 1 Level 2 Level 3

Parameters
Cutting speed 55 75 95
(m/min)
Feed per tooth 90 110 130

(mm/min)
Depth of cut (mm) 0.5 0.75 1
Insert Coating Uncoated TiN Monolayer TiAlN Multilayer
Process parameters and their levels

Trial Experiment
24

Trial Experiment
25
Workpiece before Machining

Trial Experiment
26
Machining of Workpiece
Trial Experiment
27
Workpiece after Machining

Trial Experiment
28

Trial Experiment Results
29
Trial Speed Feed DOC Length of Tool Observation

no. (RPM) (mm/min) (mm) Travel
Tool
Wear
1 500 80 0.1 80 No
2 700 80 0.2 60 No
3 1000 80 0.3 40 No
4 1300 80 0.45 25 No
5 1500 110 0.55 25 No
6 1700 110 0.65 25 No
7 1900 110 0.7 25 No
8 2100 110 0.8 25 No
9 2300 130 0.9 25 No
10 2500 130 1 25 No
Trial Experiment
30
Workpiece after trial Experiments

Orthogonal Array for Experimentation
31
Sr. No. Cutting Speed Feed Rate Depth of Type of Insert

(m/min) (mm/min) Cut
(mm)
1 55 90 0.5 Uncoated
2 55 90 0.75 Monolayer
3 55 90 1 Multilayer
4 55 110 0.5 Monolayer
5 55 110 0.75 Multilayer
6 55 110 1 Uncoated
8 55 130 0.75 Uncoated
9 55 130 1 Monolayer
10 75 90 0.5 Uncoated
11 75 90 College of Engineering,
Walchand 0.75 Sangli Monolayer
Orthogonal Array for Experimentation
32
13 75 110 0.5 Monolayer
15 75 110 1 Uncoated
17 75 130 0.75 Uncoated
19 95 90 0.5 Uncoated
20 95 90 0.75 Monolayer
22 95 110 0.5 Monolayer
24 95 110 1 Uncoated
26 95 130 0.75 Uncoated
Pre-processing
33

Pre-processing
34

Dynamometer Mounting
35

Type of Inserts
36
Uncoated
TiAlN
Monolayer
TiAlN
Multilayer
Experimental Setup
37
Cutting Insert
Workpiece
Connecting
Dynamometer Cable

End Milling Operation
38

39

40

41

Response Parameter Measurement
42
 Surface Roughness
 Taylor Hobson Surface
Roughness Tester .
 values Measured in µm.
 length of probe travel
8mm.

43
 Force Measurement
 Kistler Type 9257BA
 Quartz dynamometer for
measuring the three
orthogonal components of
a force.
 Measurements are taken
in N.

44
Infeed Force
Thrust Force

45
 Material Removal Rate
MRR = width of cut × depth of cut × feed rate

(mm) (mm) (mm/min)
MRR measured in mm³/min.

Results and Discussion
Sr. Cutting
46 Feed Depth Type of S/F Infeed Thrust MRR
No. Speed Rate of Cut Insert Roughne Force(N Force(N (mm3/m
(m/min) (mm/min (mm) ss (µm) ) ) in)
)
1 55 90 0.5 Uncoated 0.51 46.597 48.434 540
2 55 90 0.75 Monolayer 0.31 52.216 74.762 945
3 55 90 1 Multilayer 0.78 77.442 92.773 1350
4 55 110 0.5 Monolayer 0.24 47.693 49.019 770
5 55 110 0.75 Multilayer 0.46 52.090 68.835 1237.5
6 55 110 1 Uncoated 1.06 103.18 179.914 1320
7 55 130 0.5 Multilayer 0.41 43.324 46.434 975
8 55 130 0.75 Uncoated 0.97 69.87 80.451 1170
9 55 130 1 Monolayer 0.35 80.636 97.837 1820
10 75 90 0.5 Uncoated 0.38 40.783 72.858 540
11 75 90 0.75 Monolayer 0.34 52.157 93.785 945
12 75 90 1 Multilayer 0.54 68.894 101.223 1350
Results and Discussion
47
13 75 110 0.5 Monolayer 0.12 52.168 74.791 770
14 75 110 0.75 Multilayer 0.4 54.848 90.275 1237.5
15 75 110 1 Uncoated 1.12 105.953 216.542 1320
16 75 130 0.5 Multilayer 0.3 42.852 70.912 975
17 75 130 0.75 Uncoated 1.06 167.027 97.348 1170
18 75 130 1 Monolayer 0.51 80.207 168.191 1820
19 95 90 0.5 Uncoated 0.3 29.769 51.217 540
20 95 90 0.75 Monolayer 0.4 40.866 75.243 945
21 95 90 1 Multilayer 0.54 57.204 104.515 1350
22 95 110 0.5 Monolayer 0.23 19.5731 53.413 770
23 95 110 0.75 Multilayer 0.27 55.231 70.650 1237.5
24 95 110 1 Uncoated 1.22 65.729 143.718 1320
25 95 130 0.5 Multilayer 0.2 17.481 48.675 975
26 95 130 0.75 Uncoated 0.88 53.806 83.156 1170
27 95 130 1 Monolayer 0.46 61.004 108.319 1820
ANOVA For S/F Roughness
48
Main Effects Plot for SN ratios Main Effects Plot for Means
Data Means Data Means
cutting speed(m/min) feed rate(mm/min) depth of cut (mm) type of inserts cutting speed(m/min) feed rate(mm/min) depth of cut (mm) type of inserts
0.9
11
10 0.8
Mean of SN ratios
Mean of Means
8 0.7
7
0.6
6
5 0.5
4
0.4
3
2
0.3
Signal-to-noise: Smaller is better

ANOVA For S/F Roughness
49
Source DF Contribution F-Value P-Value
cutting speed(m/min) 2 0.75 % 0.49 0.622
feed rate(mm/min) 2 3.04 % 1.98 0.167
depth of cut (mm) 2 33.08 % 21.56 0.000
type of inserts 2 49.32 % 32.15 0.000
Error 18 13.81 %
Total 26 100 %

ANOVA For Infeed Force
50
80
-31
-32
Mean of SN ratios
70
Mean of Means
-33
-34
60
-35
-36 50
-37
40
-38

ANOVA For Infeed Force
51
feed rate(mm/min) 2 3.99 % 4.90 0.020
depth of cut (mm) 2 63.12 % 77.55 0.000
type of inserts 2 7.23 % 8.89 0.002
Error 18 7.33 %
Total 26 100 %

ANOVA For Thrust Force
52
140
-35
130
-36
Mean of SN ratios
120
-37
Mean of Means
110
-38
100
-39
90
-40
80
-41
70
-42
60
-43
50

ANOVA For Thrust Force
53
feed rate(mm/min) 2 6.66 % 4.82 0.021
depth of cut (mm) 2 61.41 % 44.45 0.000
type of inserts 2 9.66 % 6.99 0.006
Error 18 12.43 %
Total 26 100 %

ANOVA For Material Removal
54
Rate
64
1500
63 1400
Mean of SN ratios
62 1300
Mean of Means
61 1200
1100
60
1000
59
900
58
800
57
700
Signal-to-noise: Larger is better

ANOVA For Material Removal
55
Rate
feed rate(mm/min) 2 19.29 % 77.08 0.000
depth of cut (mm) 2 73.06 % 292.00 0.000
type of inserts 2 5.40 % 21.59 0.000
Error 18 2.25 %
Total 26 100 %

References
56
 S Sadham.S, Rakesh.N, Nissaantha Kumar.N, Krishnaraj.V, “ Study of Cutting Forces

and Tool wear during End Milling of TI-6AL-4V Alloy ”, International Journal of
Mechanical And Production Engineering, Volume 3,2015, Pages 1287–1300.
 L M Maiyara, Dr.R.Ramanujamb, K.Venkatesan, Dr.J.Jeraldd, “Optimization of
machining parameters for end milling of Inconel 718 super alloy using taguchi based
grey relational analysis”, International Conference on design and manufacturing,
Volume 64, 2013,Pages 1276 – 1282.
 J.A. Ghani, I.A. Choudhury, H.H. Hassan, “Application of Taguchi method in the
optimization of end milling parameters”, Journal of Materials Processing Technology
84–92, Volume 145, 2004, Pages 84-92.
 Tassn Rong Lin, “Experimental design and performance analysis of TiN coated
carbide tool in face milling stainless steel”, Journal of materials processing
technology, Volume 127, 2002, Pages 1-7.

57
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Optimization of Machining Parameters for End Milling of Titanium Alloy

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Presentation on

Optimization of Machining Parameters for End

Fig. End Milling Process

Walchand College of Engineering, Sangli

5 Walchand College of Engineering, Sangli

Carbide is more expensive per unit than

Sadham et Study of Cutting Forces Titanium Cutting Speed, Cutting Force,

Maiyar et Optimization of Machining Inconel 718 Cutting Speed, Surface

 Titanium alloy posses very good material properties which

Walchand College of Engineering, Sangli

 To identify the effect of different process parameters

Walchand College of Engineering, Sangli

 To study and identify the research gap for indexable end

optimization techniques used for determining the

response variables and checking the availability for it.

optimization of selected process parameters that are to

12 Walchand College of Engineering, Sangli

Ti-6Al-4V alloy grade 5:

Walchand College of Engineering, Sangli

2 TTMS PVD TiAlN (monolayer)

3 TTMS PVD TiAlN (multilayer) TiAlN

16 Walchand College of Engineering, Sangli

Tool Holder Inserts

Walchand College of Engineering, Sangli

Spindle Coolant hoses

Machine set up and Tool assembly

Machine Travels Maximum travel: X- 600 mm, Y- 450mm, Z- 500mm

Travel accuracy Position accuracy: 0.01 mm

Spindle Spindle taper – BT 4

19 Walchand College of Engineering, Sangli

Parameters affecting the milling operation

 Feed Rate ( 90 to 130 mm/min)

 Depth of cut (0.5 to 1 mm)

 Insert coating (Uncoated, TiAlN

Monolayer, TiAlN Multilayer )

Walchand College of Engineering, Sangli

 Material Removal Rate

Walchand College of Engineering, Sangli

Process Level 1 Level 2 Level 3

Feed per tooth 90 110 130

Depth of cut (mm) 0.5 0.75 1

Insert Coating Uncoated TiN Monolayer TiAlN Multilayer

Process parameters and their levels

Walchand College of Engineering, Sangli

Workpiece before Machining

Workpiece after Machining

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Trial Speed Feed DOC Length of Tool Observation

Workpiece after trial Experiments

Sr. No. Cutting Speed Feed Rate Depth of Type of Insert

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli

Walchand College of Engineering, Sangli