Performance Evaluation of Uncoated and Coated Carbide Tools When End Milling of Titanium Alloy using Response Surface Methodology

Mohruni, Amrifan Saladin (2008) Performance Evaluation of Uncoated and Coated Carbide Tools When End Milling of Titanium Alloy using Response Surface Methodology. PhD thesis, Universiti Teknologi Malaysia.

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    Titanium alloys are being constituted in modern aerospace structure, marine, automotive and chemical industry due to their strength-to-weight ratio, excellent corrosion and fracture resistance and low modulus of elasticity. However, titanium and its alloys are considered very difficult-to-machine material due to its highly chemical reactivity and tendency to weld to the cutting tool. These result in edge chipping and rapid tool failure. Although in the past, many studies had been carried out to predict the tool performance during end milling operation in terms of primary machining parameters, the effect of tool geometry was not taken into consideration. Therefore, an effort has been made in this research to evaluate the influence of tool geometry (radial rake angle), feed and cutting speed when end milling titanium alloy, Ti-6Al-4V. Machining trials were performed under flood condition with a constant axial and radial depth of cut. The cutting tools used were uncoated solid carbide tools grade K30 and coated with a physical vapor deposition (PVD) TiAlN and Supernitride. Tool performance of the above mentioned tools were investigated under various cutting conditions, while the surface roughness of the milled parts and cutting forces were measured. The performance of cutting tools was described using response surface methodology. It was found that, the cutting speed, feed rate and radial rake angle have a significant effect on various responses investigated such as tool life, surface roughness and cutting forces. The developed mathematical models were validated statistically using analysis of variances (ANOVA), which can be used for predicting the optimum cutting conditions within the limits of the actors investigated. In general, coated solid carbide tools performed better than the uncoated tools when end milling Ti-6Al-4V.

    Item Type: Thesis (PhD)
    Subjects: T Technology > TJ Mechanical engineering and machinery
    T Technology > TS Manufactures
    Divisions: Faculty of Engineering > Department of Mechanical Engineering
    Depositing User: Dipl.-Ing. Ir. PhD. Amrifan Saladin Mohruni
    Date Deposited: 07 Mar 2017 14:59
    Last Modified: 07 Mar 2017 14:59

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