The aerospace, biomedical, and automotive sectors extensively utilize titanium alloys due to their remarkable strength-to-weight ratio, resistance to corrosion, and high-temperature performance. However, because of their high cutting forces and poor thermal conductivity, they result in quick tool wear and decreased machining efficiency. Machining Ti-alloys presents considerable hurdles on conventional machine, so this study is made for intermittent machining of Ti-alloys, and it also compares the performance of two different cutting tools. The study looks at critical performance metrics under different input conditions, such as material removal rate, surface roughness, and tool wear. A pilot study was carried out to select the machining parameter. The best cutting parameters for enhanced machining performance were identified, and predictive models were developed using the RSM-based statistical technique. The results show that machining using cryogenically treated tools achieved an average Material Removal Rate (MRR) of 2341.97 mm3/min, representing a 7.2% improvement over the 2186.41 mm3/min observed with untreated tools. Tool Wear Rate (TWR) also decreased by 9.7%, from 0.72 mm3/min for untreated tools to 0.65 mm3/min for treated tools, indicating enhanced wear resistance and prolonged tool life. Additionally, the average surface roughness (SR) was reduced by 6.7%, from 0.45 µm to 0.42 µm, demonstrating better surface integrity.

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A Comparative Performance Evaluation During Intermittent Machining of Ti-Alloy Using RSM

  • Mithun Kumar,
  • P. Sudhakar Rao

摘要

The aerospace, biomedical, and automotive sectors extensively utilize titanium alloys due to their remarkable strength-to-weight ratio, resistance to corrosion, and high-temperature performance. However, because of their high cutting forces and poor thermal conductivity, they result in quick tool wear and decreased machining efficiency. Machining Ti-alloys presents considerable hurdles on conventional machine, so this study is made for intermittent machining of Ti-alloys, and it also compares the performance of two different cutting tools. The study looks at critical performance metrics under different input conditions, such as material removal rate, surface roughness, and tool wear. A pilot study was carried out to select the machining parameter. The best cutting parameters for enhanced machining performance were identified, and predictive models were developed using the RSM-based statistical technique. The results show that machining using cryogenically treated tools achieved an average Material Removal Rate (MRR) of 2341.97 mm3/min, representing a 7.2% improvement over the 2186.41 mm3/min observed with untreated tools. Tool Wear Rate (TWR) also decreased by 9.7%, from 0.72 mm3/min for untreated tools to 0.65 mm3/min for treated tools, indicating enhanced wear resistance and prolonged tool life. Additionally, the average surface roughness (SR) was reduced by 6.7%, from 0.45 µm to 0.42 µm, demonstrating better surface integrity.