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Procedia CIRP 00 (2018) 000–000
ScienceDirect
Procedia CIRP 00 (2018) 000–000 www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
Procedia CIRP 00 (2017)
Procedia CIRP 000–000
79 (2019) 79–84
www.elsevier.com/locate/procedia

12th
12thCIRP
CIRPConference
Conferenceon
onIntelligent
IntelligentComputation
ComputationininManufacturing
ManufacturingEngineering,
Engineering,18-20
CIRPJuly
ICME2018,
'18
12th CIRP Conference on Intelligent Computation in Manufacturing
Gulf of Naples, Italy Engineering, CIRP ICME '18
Analysis of the surface
28th CIRP roughness of titanium
Design Conference, May 2018,pieces obtained by turning
Nantes, France
Analysis of the surface roughness of titanium pieces obtained by turning
A new methodology tousing using
different
analyze cooling systems
the functional
different and physical architecture of
cooling systems
existingEva
products for
M. Rubio* ,a
,a
an assembly
, Alfonso Bericua aa,oriented
Beatriz de product
Agustina aa,family
Marta M.identification
Marín aa
Eva M. Rubio* , Alfonso Bericua , Beatriz de Agustina , Marta M. Marín
a
Department of Manufacturing Engineering, Industrial Engineering School, Universidad Nacional de Educacióna distancia (UNED), C/ Juan del Rosal nº 12,
a Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Department of Manufacturing Engineering, Industrial EngineeringE28040-Madrid, SpainNacional de Educacióna distancia (UNED), C/ Juan del Rosal nº 12,
School, Universidad
E28040-Madrid, Spain
* Corresponding
Écoleauthor. Tel.:Supérieure
Nationale +34 91 398d’Arts
82 26;etfax: +34 91
Métiers, 398et64
Arts 60. E-mail
Métiers address:
ParisTech, erubio@ind.uned.es
LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding author. Tel.: +34 91 398 82 26; fax: +34 91 398 64 60. E-mail address: erubio@ind.uned.es

* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

Abstract
Abstract
The present paper shows an experimental study about the surface roughness of Ti6Al4V titanium alloy bars obtained by turning under low-
Abstract
The present paper
performance cuttingshows an experimental
conditions. The designstudy about the surface
of experiments (DOE)roughness
used in the of work
Ti6Al4Vis a titanium
full factorialalloywith
bars all
obtained
factorsby turning as
identified under low-
possible
performance
sources cutting conditions.
of variation of the surface The roughness.
design of experiments
Namely: depth (DOE) usedfeed
of cut, in the work
rate, is a full
spindle factorial
speed, type with all factors
of tool, type ofidentified as possible
cooling system and
Insources
today’sofbusiness
measurement variationenvironment,
location.ofThe
theanalysis
surfacethe of
trend towards
roughness.
variance moreasproduct
isNamely:
used depth variety
method oftocut, and
feedcustomization
analyze rate,
the spindle
data. isspeed,
unbroken.
The statistical type Due to
of tool,
analysis this
shows,typedevelopment,
asofmain
cooling thethat
needfeed
system
results, of
and
agile
rate, and
measurementreconfigurable
spindle location.
speed, production
andThe analysis systems
measurement oflocation
varianceemerged
are usedto as
cope
is influence onwith
method various
the to analyze
surface products
the data.
roughness and
Theproduct
while families.
statistical
the type the To
analysis
of design
shows,
cooling andmain
as
system optimize production
andresults,
the typethat
of feed
tool
systems
rate,
are not as
spindlewell
factors as toand
speed, choose theroughness
measurement
influencing the optimal product
location are matches,
influence
independently; product analysis
on influence
their the surface methods
onroughness
the surfaceareroughness
whileneeded.
the type Indeed,themost
isofonly of the
cooling
produced known
system
through methods
andtheir
the type aim to
of tool
interactions
analyze
are not
with a product
thefactors or one product
spindleinfluencing
speed. Asthe family on
roughness the
conclusions, the physical
independently; level. Different
their influence
best combinations product families,
on the parameters
of the cutting however,
surface roughness may
to achieve differ
is only largely
produced
concrete in terms
through
surface of the number and
their interactions
roughness have been
nature
with theof components.
selected. spindle speed.This
As fact impedes an
conclusions, theefficient comparisonofand
best combinations thechoice
cuttingofparameters
appropriatetoproduct
achievefamily combinations
concrete for the production
surface roughness have been
system.
2018AThe
selected.
© new methodology
Authors. is proposed
Published by Elsevierto analyze
B.V. existing products in view of their functional and physical architecture. The aim is to cluster
these
© productsunder
in new assembly
Publishedoriented product families for the optimization
12th CIRPofConference
existing assembly lines and the creation inof future reconfigurable
© 2018
2019 The
Peer-review
assembly The Authors.
Authors.
systems.
responsibility
Published
Based on Datum
by
of Elsevier
by Elsevier
Flow
B.V.
the scientific
B.V.the
Chain,
committee
physical
of the
structure of the products is
on Intelligent
analyzed.
Computation
Functional subassemblies
Manufacturing
are identified, and
Peer-review
Engineering.
Peer-review underresponsibility
under responsibilityofofthethescientific
scientific committee of of
thethe 12th CIRP Conference on Intelligent Computation in Manufacturing
aEngineering.
functional analysis is performed. Moreover, acommittee
hybrid functional 12thandCIRP Conference
physical on Intelligent
architecture Computation
graph (HyFPAG) isinthe
Manufacturing
output whichEngineering.
depicts the
similarity
Keywords:between productair;
Cold compressed families
Cutting;byLubrication
providingand design
coolingsupport
systems;toTitanium
both, production system
alloys; Turning; vortexplanners
tube and product designers. An illustrative
example
Keywords:of Cold
a nail-clipper
compressedisair;
used to explain
Cutting; the proposed
Lubrication methodology.
and cooling An industrial
systems; Titanium case study
alloys; Turning; vortexon two product families of steering columns of
tube
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 28th CIRP
1. Introduction Design Conference
machining 2018.
[5][7][8][21-31], the minimum quantity of
1. Introduction machining
lubricant (MQL) [5][7][8][21-31],
system [5][25][30,33] the minimum quantity air
or cold compressed of
Keywords: Assembly; Design method; Family identification lubricant (MQL) system [5][25][30,33] or cold compressed air
The temperature is the main factor and origin of the (CCA) [28][34-37].
The temperature
problems in interfaceispiece-tool
the mainduring factortheand origin of
machining of the (CCA)
This[28][34-37].
work is an experimental study to analyze the
problems in interface
titanium alloys [1-9]. piece-tool
Then, it isduring the machining
necessary to control oforthe to This work
possibilities is an experimental
of carrying out repair turning study to analyze
operations, on partsthe
titanium
balance alloys
the
1. Introduction heat [1-9]. Then,
generated it
duringis necessary
the cutting to control
process and or to
the possibilities
of titanium of carrying
alloy out
Ti6Al4Vrepair turning
using
of the product range and characteristics manufactured and/or operations,
more on parts
sustainable
balance
dissipationtheofheat
thegenerated
same [2][6-8].duringIf thethe cutting process exceeds
heat generated and the of titaniumin thisalloy
lubrication/cooling
assembled Ti6Al4V
systems.
system. In thisSuch using
context, themore
operations sustainable
consist in
main challenge in
dissipation
theDue to ofthe
heat removed, the same
an [2][6-8].
fastundesirable
development Ifsituation
the heat generated
in occurs in theexceeds
the domain active
of lubrication/cooling
machining under systems.
low-performance Such operations
cutting
modelling and analysis is now not only to cope with single consist
conditions (lowin
communication and an ongoing trend of digitizationactive
the heat
cutting removed,
area ending, an undesirable
finally, with situation
congestion occursand in the
subsequent
and machining
depths of under
cut, low-performance
cutting speed, and cutting
feed
products, a limited product range or existing product families, conditions
rate) in order (lowto
cutting
premature area
digitalization, ending,
wear finally,
or failure
manufacturing of thewith congestion
cutting
enterprises tool and subsequent
are[1,2][8-15].
facing important depths
eliminate of cut,
small cutting
defects orspeed,
cracks and
in thefeed
pieces
but also to be able to analyze and to compare products to definerate) in
getting,order
further, to
premature
To lower wear
the or failure
temperature of the
andcutting
challenges in today’s market environments: acutting
frictiontool
in [1,2][8-15].
the zone,
continuing eliminate
that the small
parts defects
meet to or
the cracks in
requirementsthe pieces
of
new product families. It can be observed that classical existing getting,
surface further,
roughness
tendency towards reduction of product development timeszone,
To
cutting lower
fluids the temperature
have been and
used friction in
traditionally. the cutting
But these are
and that thefamilies
established
product parts meet
in the to theThis
aredesign.
regrouped requirements
commonof
is function
in surface
oftoclients inroughness
do so or complex
features.
cutting
highly fluids
polluting, have been
generate used
high traditionally.
economic costs
shortened product lifecycles. In addition, there is an increasing But
in these
machiningare However, assembly oriented product families are hardlycomplex
established
aeronautical in the
and design.
aerospace This is
parts common
for which to do
thereso in
are noto spare
find.
highly
processespolluting,
[16,17] generate
and can high
be noteconomic
adequate
demand of customization, being at the same time in a global costs
when in machining
using certain aeronautical
On the product family level, products differ mainlynoinspare
parts in stock, and aerospace
mainly, due toparts
the for
high which
costs there
thereof.are
Therefore,two
processes
cutting
competition [16,17]
speeds and can
with(above 60 be
competitors not
m/min) adequate
all over because when using
This certain
the cutting
the world. fluids
trend, parts in stock, mainly,
it is necessary
main to know
characteristics: (i)duetheto
the the high
best
number of costs
cutting thereof.and
parameters
components Therefore,
to(ii)
repair
the
cutting
evaporate speeds
and do(above
not 60
favor m/min)
the heat because
dissipation
which is inducing the development from macro to micro the cutting
[18-20]. fluids it is of
them
type necessary
soon asto
ascomponents know
possible, the best can
so they
(e.g. mechanical, cutting
again parameters to repair
be functional.
electrical, electronical).
evaporate
Then, and
it is do not
necessaryfavor tothe heat
analyze dissipation
the
markets, results in diminished lot sizes due to augmenting [18-20].
possibility of using themTheasneed
soonmethodologies
Classical asreduce
to possible, soconsidering
costs they can again
(in particular, be functional.
the
mainly associated costs
single products
Then, it is necessary tosystems analyze cheaper,
the possibility of using
other lubrication/cooling
product varieties (high-volume to low-volume production) [1]. environmental or solitary, already existing product families analyze costs
to Thecutting
the need tofluids)
reducealongcosts with
(in particular,
the great the associated
awareness with the
the
other lubrication/cooling
respectful andthis
effective at systems
high cutting cheaper,
speeds, environmental
such as: dry to the cutting fluids)
environment of the along
last with
few thedecades
great awareness
has with that
done the
To cope with augmenting variety as well as to be able to product structure on a physical level (components level) which
respectful and effective at high cutting speeds, such as: dry environment of the last few decades has done that
identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and
production
2212-8271 ©system,
2017 The it is important
Authors. Publishedtobyhave a precise
Elsevier B.V. knowledge comparison of different product families. Addressing this
Peer-review
2212-8271 ©under
2017responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
Peer-review under responsibility of the scientific committee of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
2212-8271©©2017
2212-8271 2019The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V. B.V.
Peer-reviewunder
Peer-review underresponsibility
responsibility
of of
thethe scientific
scientific committee
committee of the
of the 28th12th
CIRPCIRP Conference
Design on 2018.
Conference Intelligent Computation in Manufacturing Engineering.
10.1016/j.procir.2019.02.015
80 Eva M. Rubio et al. / Procedia CIRP 79 (2019) 79–84
E. Rubio et al./ Procedia CIRP 00 (2018) 000–000

investigations look for more sustainable manufacturing protocols to calculate the cutting parameters values and to
processes. In this case, it is going to make a comparative study registry data and observations of the machining process.
of three types of cooling systems less aggressive to the - Turning tests. In these tests, workpieces are mechanized
environment than those traditionally used in the machining of under certain conditions of feed rate, cutting speed, depth of
titanium alloys. Specifically, they are going to perform tests: cut, types of tool and types of cooling system.
in dry, with minimum quantity of lubrication (MQL) and with - Monitoring processes. In order to get graphic documents
cold compressed air that can be analyzed after the process, all the turning tests
For this purpose, a number of tests are conducted following described before are photographed and recorded by video and
a full factorial design of experiments (DOE) by varying the both the chips obtained and tools used are photographed with
type of tool, the type of cooling system, the cutting conditions a camera of high resolution.
Output variables measurement. Measurements of the
(depth of cut, cutting speed, and feed rate) and the
surface roughness, vibrations, forces, and roundness have
measurement location. The surface roughness is measured, in
been taken.
terms of average roughness, Ra, for every test. The analysis of
Statistical analysis of the data. Thus, data obtained are
variance (ANOVA) method is used in the treatment of the data treated with statistical techniques according to the design of
to determine the influence of each factor and their interactions experiments used.
on the surface finish. Conclusions. Some conclusions are established from the
results obtained in the statistical analysis.
2. Methodology
Table 1. Factors, levels and designations.
The methodology includes the next activities: Factor Levels Designation
Pre-experimental planning. Factors, levels and ranges, Depth of cut, d 1 d1
Feed rate, f 2 f1, f2
along with response variables are set up. Spindle speed, N 2 N1, N2
Experimental design. At this stage, according with the main Type of tool, T 3 T1, T2, T3
goals established in each case and the available resources, the Type of cooling system, Q 3 Q1, Q2, Q3
best design of experiments is selected. The goal is to analyze Measurement location, L 3 L1, L2, L3
the variability of surface roughness of Ti6Al4V titanium alloy
Table 2. Set of experiments.
pieces obtained by turning with different types of tools and No. Feed Spindle Type of Type of cooling Measurement
under different cutting and lubrication/cooling conditions so 1 f1
rate, f N1
speed, N T1
tool, T Q1
system, Q L1 L2 L L3
location,
2 f2 N1 T1 Q1 L1 L2 L3
that the potential influential factors to include in the design 3 f1 N2 T1 Q1 L1 L2 L3
have been identified as: depth of cut, d, feed rate, f, spindle 4 f2 N2 T1 Q1 L1 L2 L3
speed, N, type of tool, T, type of cooling system, Q, and 5 f1 N1 T1 Q2 L1 L2 L3
6 f2 N1 T1 Q2 L1 L2 L3
measurement location, L. 7 f1 N2 T1 Q2 L1 L2 L3
Their levels are fixed taking into account the next criteria: 8 f2 N2 T1 Q2 L1 L2 L3
9 f1 N1 T1 Q3 L1 L2 L3
- First, the study is focused in analyzing the surface 10 f2 N1 T1 Q3 L1 L2 L3
roughness of the Ti6Al4V titanium alloy pieces obtained by 11 f1 N2 T1 Q3 L1 L2 L3
turning. Then, the factors: type of tool, T, type of cooling 12 f2 N2 T1 Q3 L1 L2 L3
13 f1 N1 T2 Q1 L1 L2 L3
system, Q, and measurement location, L, are considered 14 f2 N1 T2 Q1 L1 L2 L3
critical in this study and, therefore, three levels of each one 15 f1 N2 T2 Q1 L1 L2 L3
16 f2 N2 T2 Q1 L1 L2 L3
should be studied. 17 f1 N1 T2 Q2 L1 L2 L3
- Second, as the study deals with repair operations, in 18 f2 N1 T2 Q2 L1 L2 L3
19 f1 N2 T2 Q2 L1 L2 L3
general, the depth of cut, d, has to be small since; otherwise, 20 f2 N2 T2 Q2 L1 L2 L3
the parts could be out of dimensional tolerances. Then, one 21 f1 N1 T2 Q3 L1 L2 L3
level is enough. 22 f2 N1 T2 Q3 L1 L2 L3
23 f1 N2 T2 Q3 L1 L2 L3
- Third, for the factors feed rate, f, and spindle speed, N, 24 f2 N2 T3 Q3 L1 L2 L3
which are expected to have influence on the study (in 25 f1 N1 T3 Q1 L1 L2 L3
26 f2 N1 T3 Q1 L1 L2 L3
particular the feed rate), two levels for each one are fixed. 27 f1 N2 T3 Q1 L1 L2 L3
From de combination of the considered factors, a full 28 f2 N2 T3 Q1 L1 L2 L3
factorial design with 108 experiments is obtained. This is, the 29 f1 N1 T3 Q2 L1 L2 L3
30 f2 N1 T3 Q2 L1 L2 L3
performing of 36 turning tests with 3 surface roughness 31 f1 N2 T3 Q2 L1 L2 L3
measurements taken in each test. Table 1 shows factors, levels 32 f2 N2 T3 Q2 L1 L2 L3
fixed for them and their designations. Table 2 illustrates this 33 f1 N1 T3 Q3 L1 L2 L3
34 f2 N1 T3 Q3 L1 L2 L3
design with the order of the experiments. 35 f1 N2 T3 Q3 L1 L2 L3
Performing the experiment. As this work is framed within 36 f2 N2 T3 Q3 L1 L2 L3
a study that involves different light alloys, types of machining
operations, different workpieces geometries, types of cutting
3. Applications
tools (geometries and coatings) and cutting conditions, the
experiments are carried out following systematically the next For this study, the workpieces used in the turning tests
steps: were cylindrical bars of titanium alloy Ti6Al4V, whose
- Previous activities to machining process. These activities composition is shown in Table 3, with a diameter of 50 mm
consist on the preparation of the test material and the and a length of 750 mm (useful 600 mm).
 Eva M. Rubio et al. / Procedia CIRP 79 (2019) 79–84 81
E. Rubio et al./ Procedia CIRP 00 (2018) 000–000

Table 3. Composition (mass %) of the titanium alloy Ti6Al4V. Table 4. Cutting parameters of the turning tests.
Al C H Fe N O Others Ti V No. Feed rate, Spindle speed, N Type of tool, T Type of cooling
5.5- 87.725- 3.5- 1 f [mm/r]
0.11 [r]
500 TP100 Dry
system, Q*
≤0.08 ≤0.015 ≤0.40 ≤0.03 ≤0.20 ≤0.30 2 0.20 500 TP100 Dry
6.75 91 4.5
3 0.11 925 TP100 Dry
4 0.20 925 TP100 Dry
Three different types of tools, from SECO manufacturer, with 5 0.11 500 TP100 MQL
identical geometry (Fig. 1) and different titanium nitrure coatings 6 0.20 500 TP100 MQL
7 0.11 925 TP100 MQL
were used. Concretely: TP100 with TiN coating, TP200 with 8 0.20 925 TP100 MQL
TiCN/Al2O3/TiN and TP1000 with TiCN/Al2O3/TiCN/TiN (Fig. 2). 9 0.11 500 TP100 CCA
The machine tool used was a parallel lathe (PINACHO 10 0.20 500 TP100 CCA
11 0.11 925 TP100 CCA
model L- 1/200) equipped with two external lubrication/cooling 12 0.20 925 TP100 CCA
systems: a Minimum Quantity Lubrication system (MQL- 13 0.11 500 TP200 Dry
system) and a Cold Compressed Air system (CCA-system). As 14 0.20 500 TP200 Dry
15 0.11 925 TP200 Dry
MQL-system an ACCULUBE Microlubrication system was 16 0.20 925 TP200 Dry
used and as CCA-system a Cold Air Gun Vortec system based 17 0.11 500 TP200 MQL
18 0.20 500 TP200 MQL
on vortex tube technlogy (Fig. 3). 19 0.11 925 TP200 MQL
The machining tests were made under the cutting 20 0.20 925 TP200 MQL
conditions collected in Table 4. Such cutting conditions have 21 0.11 500 TP200 CCA
22 0.20 500 TP200 CCA
been expressed in units usually employed in manufacturing 23 0.11 925 TP200 CCA
workshop. Although they are not International System units 24 0.20 925 TP1000 CCA
(S.I.), they give a more intuitive idea of the values used. 25 0.11 500 TP1000 Dry
26 0.20 500 TP1000 Dry
Measurements of the surface roughness were made in 27 0.11 925 TP1000 Dry
three different zones separated 200 mm along the workpieces: 28 0.20 925 TP1000 Dry
initial, medium and final, using a surface roughness tester 29 0.11 500 TP1000 MQL
30 0.20 500 TP1000 MQL
Mitutoyo Surftest SJ 401 (Fig. 4). The average roughness Ra, 31 0.11 925 TP1000 MQL
defined as the integral of the absolute value of the departure 32 0.20 925 TP1000 MQL
of the roughness profile from its mean line along a sampling 33 0.11 500 TP1000 CCA
34 0.20 500 TP1000 CCA
length and given by Eq. 1, was used to describe the surface 35 0.11 925 TP1000 CCA
roughness. 36 0.20 925 TP1000 CCA
*
Note: For “Dry” without using cooling system. For “MQL” and “CCA” the
maximum value (in ml/h) that the system provides for each one.
(1)

To observe the machining tests carried out, videos and

photographs of the tools and chips were systematically taken
during the tests using a digital camera of high resolution
(Sony Cibershot DSC-P100). In addition, as the titanium
presents a risk of fire during dry machining, an extinguisher
for fires and a container with dry sand were used. a) b)
Fig. 4. a) Surface roughness tester Mitutoyo Surftest SJ 401, b) Surface
roughness measurement zones along the workpieces: initial, medium and final.

4. Results and dicussions

Surface roughness values obtained in the different
Fig. 1. Tools geometry. experiments are shown in Table 5. An analysis of variance
(ANOVA) is used to check the influence of the different factors
and their interactions on the surface roughness in terms of Ra.
Table 6 shows the results obtained with the ANOVA analysis
after removing those factors that are not statistically influential
on the surface roughness; showing, therefore, only factors and
interactions that are influential on Ra. These are: the feed rate, f,
a) b) c) the spindle speed, N, the interaction between feed rate and
Fig. 2. Tool with coating: a) TiN (TP100), b) TiCN/Al2O3/TiN (TP200), measurement location, f*L, the interaction between feed rate
c) TiCN/Al2O3/TiCN/TiN (TP1000). and spindle speed, f*N, the interaction between spindle speed
and type of cooling system, N*Q, the measurement location, L
and the interaction between spindle speed and type of tool,
N*L; mencioned in order of importance.
Importantly, the type of the cooling system is not a factor
influencing the roughness independently; it has only influence
on the Ra through its interaction with the spindle speed. This
same occurs with the type of tool. Then, the independent factors
a) b)
Fig. 3. a) Detail of the Cold Air Gun Vortec system used as CCA-system;
that have a direct influence to the Ra are: feed rate, f, spindle
b) Detail of the ACCULUBE Microlubrication system used as MQL-system. speed, N and measurement location, L; as it is shown in Fig. 5.
82 Eva M. Rubio et al. / Procedia CIRP 79 (2019) 79–84
E. Rubio et al./ Procedia CIRP 00 (2018) 000–000

Next, the analysis of the results obtained in this study is
going to be focusing in the aeronautical and aerospace
manufacturing fields mentioned above. In these fields, the usual
range of Ra values come given by the Eq. 2. That is, within
class N7 of the ANSI/ASME B46.1-2009 standards [38], but
the dicusion and the conclusions can be interesting as well for
other fields that no have requeriments so strict.
The Fig. 6 reveals that it will be possible to carry out the
repair and maintenance operations of aeronautical and
aerospace parts, using the three types of cooling systems tested
in this study, if the lower spindle speed is used. Namely, for N
= 500 r/min, the lowest values of Ra (around 0.9 µm) are
obtained when the CCA-system is used. At high spindle speed
(925 r/min) the surface roughness is significantly higher for the
three cooling systems tested.
0.8m  Ra  1.6m (2)
Fig.11, c). At such cutting conditions, for all type of tools, the
use of both, CCA-system and MQL-system have improved the
surface roughness, in a larger extent the CCA-system. In
addition, with the use of TP1000 turning under dry conditions
at low feeds and high spindles allow the achievement the lowest
range of Ra, this 0.83 and 1.29 µm Fig.12.a).
The analysis of these graphics also reveals that only at low
feed rates and spindle speeds with all types of tool and cooling
conditions, the surface roughness decreased significally as the
turning processes progressed under dry conditions with the
TP200 from 2.42 to 0.95 µm (Fig.11.a)). At the rest of the
cutting combinations the surface roughness aumented. This
behaviour could indicate that at such conditions the turning
tests are more stable.
Based on the analysis of the cube graphics, according to the
aeronautical and aeospace surface requeriments, the selection of
the most improved cutting parameters are collected in the Table 7.

Nevertheless, in this study, due to the high hardness of the Table 5. Surface roughness results.
tested titanium alloy, the use of CCA-system at higher spindle Feed Spindle Type of
Ra
speeds could have substantially incremented the cutting forces Type of Measurement
No rate, f speed, N cooling
tool, T location, L [m]
generating a premature tool wear and, consequently, a [mm/r] [r] system, Q
L1 L2 L3
detriment of the surface quality is achieved. In particular, 1 0,11 500 TP100 Dry 1.23 1.84 1.03
surface roughness values (higher than 1.8 µm) are reached, that 2 0,20 500 TP100 Dry 2.21 1.05 1.2
exceed the aeronautical quality requirements that were 3 0,11 925 TP100 Dry 1.26 1.73 1.13
4 0,20 925 TP100 Dry 1.79 2.24 3.3
mentioned before. Therefore, for such applications, with the use 5 0,11 500 TP100 MQL 1.22 1.74 1.55
of CCA-system the spindle speed seems to have to be limited to 6 0,20 500 TP100 MQL 3.43 1.83 1.88
a certain value. 7 0,11 925 TP100 MQL 1.67 2.15 2.05
With respect to the interaction of spindle speed and feed 8 0,20 925 TP100 MQL 1.84 2.92 4.36
9 0,11 500 TP100 CCA 1.31 2.32 1.11
rate, f*N, (Fig. 7), at low spindle speeds the use of feed rates of 10 0,20 500 TP100 CCA 2.98 3.83 4.93
both low and high values, allowed a desirable range of surface 11 0,11 925 TP100 CCA 0.99 1.26 1.21
roughness, between 0.8 and 1.6 µm, as long as the spindle 12 0,20 925 TP100 CCA 1.16 1.55 3.88
13 0,11 500 TP200 Dry 1.18 1.04 1.18
speed was maintained at 500 r/min.
14 0,20 500 TP200 Dry 1.65 1.49 2.41
Although, taking into account the interaction of feed rate 15 0,11 925 TP200 Dry 1.22 0.85 1.77
and measurement location, f*L, (Fig. 8, a)), at high feed rates of 16 0,20 925 TP200 Dry 4.03 7.42 13.53
0.2 mm/r, the surface roughness obtained on the final 17 0,11 500 TP200 MQL 1.22 1.13 0.79
18 0,20 500 TP200 MQL 1.8 2.18 1.82
measurement location, L3, is significantly higher than those 19 0,11 925 TP200 MQL 1.18 0.78 1.36
obtained at low feed rates of 0.11 mm/r. Regarding the 20 0,20 925 TP200 MQL 1.67 0.82 2.82
interaction of spindle speed and measurement location (Fig.8, 21 0,11 500 TP200 CCA 1.11 1.67 1.31
b)), similar results are obtained. This fact could indicate the 22 0,20 500 TP200 CCA 1.52 1.6 1.24
23 0,11 925 TP200 CCA 2.65 0.48 2.06
longer is the workpiece for machining, it is necessary to set 24 0,20 925 TP1000 CCA 1.9 1.98 3.81
lower feed rates and spindle speeds, for obtaining lower 25 0,11 500 TP1000 Dry 1.43 1.02 0.92
surface roughness. 26 0,20 500 TP1000 Dry 2.09 2.17 1.07
From the analysis of the interaction of spindle speed and 27 0,11 925 TP1000 Dry 2.67 1.75 3.32
28 0,20 925 TP1000 Dry 1.76 2.53 9
type of tool, it is remarkable, on one hand, that the lower values 29 0,11 500 TP1000 MQL 1.99 1.01 0.92
of surface roughness were obtained with the use of TP100 at 30 0,20 500 TP1000 MQL 1.83 2.39 1.28
low spindle speeds. Then, for aeronautical and aerospace 31 0,11 925 TP1000 MQL 2.76 0.62 1.06
applications, it is possible to use the three types of tool at low 32 0,20 925 TP1000 MQL 2.5 3.83 7.99
33 0,11 500 TP1000 CCA 1.35 1.06 0.83
spindle speeds. And, on the other hand, it is remarkable, as 34 0,20 500 TP1000 CCA 2.16 2.04 1.01
well, the improved behaviour of the tool TP1000 at high 35 0,11 925 TP1000 CCA 1.12 0.91 1.76
spindle speeds of 925 r/min compared to the other types of 36 0,20 925 TP1000 CCA 2.48 6.47 6.28
tools employed, TP100 and TP200, being the opposite at low
Table 6. Results obtained by the ANOVA analysis of Ra
spindle speeds of 500 r/min. Sum of
Finally, the influence of the different cooling system on the Source DF Mean Square F-value Pr>F
Square
surface roughness obtained with each tool was analysed by the Feed rate, f 63.2808 1 63.2808 35.05 0.0000
Spindle speed, N 29.0682 1 29.0682 16.10 0.0001
use of cube graphics (Fig. 10, Fig. 11 and Fig. 12) plotted from
Measurement location, L 13.1841 1 13.1841 7.30 0.0081
the estimated values of surface roughnes. f*N 15.9544 1 15.9544 8.84 0.0037
The analysis of these graphics shows, first, the lowest f*L 17.2187 1 17.2187 9.54 0.0026
ranges of values of Ra were reached with the TP100 and TP200 N*T 9.7682 1 9.7682 5.41 0.0221
tools and CCA-system at low feed rates and spindle speeds; N*Q 14.616 1 14.616 8.10 0.0054
N*L 23.6557 1 23.6557 13.10 0.0005
concretely, ranges between 0.53 and 1.24 µm, and 0.23 and Total error 178.74 99
1.30 µm, respectively, as it can be seen in Fig.10, c) and in Error corr 365.486 107
 Eva M. Rubio et al. / Procedia CIRP 79 (2019) 79–84 83
E. Rubio et al./ Procedia CIRP 00 (2018) 000–000

Fig. 10. Cube plot of Ra versus the feed rate, spindle speed and measurement
location with the cooling system: a) Dry, b) MQL and c) CCA obtained with
TP100 tools.

Fig. 5. Chart of the influential factors: a) Feed rate, b) Spindle speed and
c) Measurement location, on Ra.

Fig. 11. Cube plot of Ra versus the feed rate, spindle speed and
measurement zone with the cooling system: a) Dry, b) MQL and c) CCA
obtained with TP200 tools.

Fig. 6. Chart of the influential interaction between the cooling system and Fig. 12. Cube plot of Ra versus the feed rate, spindle speed and measurement
cutting speed on Ra. zone with the cooling system: a) Dry, b) MQL and c) CCA obtained with
TP1000 tools.

Table 7 selection of the most improved cutting parameters according to the

aeronautical and aeospace surface requeriments.
Feed rate, f [mm/r] Spindle speed, N [mm/r] Cooling system, Q
TP100 0.11 500 MQL
0.11 500 CCA
TP200 0.11 925 Dry
0.11 500 CCA
TP1000 0.11 925 Dry
0.11 925 MQL
0.11 500 CCA
Fig. 7. Chart of the influential interaction between the feed rate and
cutting speed on Ra.
5. Conclusions
This paper presents an experimental study to analyze the
surface roughness reached in pieces of Ti6Al4V titanium alloy
obtained by turning under low-performance cutting conditions
own of the repair and maintenance operations. To carry out
the study, a design of experiments was established. Namely,
factors identified as possible sources of variation of the
surface roughness are the following: depth of cut, feed rate,
spindle speed, type of tool, type of cooling system and
measurement location. Data were analyzed by means of the
analysis of variance (ANOVA) method. Results obtained with
it allowed establishing the following conclusions:
Fig. 8. Chart of the influential interactions between: a) Feed rate and Factors that have a direct influence on the surface
Measurement location and b) Spindle speed and Measurement location,
on Ra. roughness are: feed rate, spindle speed, and measurement
location. The type of the cooling system and the type of tool
are not factors influencing the roughness independently; they
have only influence on the Ra through their interactions with
the spindle speed.
The three types of cooling systems tested in this study can
be used to carry out repair and maintenance operations of
aeronautical and aerospace parts, using low spindle speed.
The lowest values of Ra (around 0.9 µm) are obtained at this
low spindle speed (500 r/min) when the CCA-system is used.
With respect to the interaction of the spindle speed and the
feed rate, as long as the spindle speed was maintained at 500
Fig. 9. Chart of the influential interaction between the spindle speed and
type of tool on Ra. r/min, the use of feed rates of both low and high values,
84 Eva M. Rubio et al. / Procedia CIRP 79 (2019) 79–84
E. Rubio et al./ Procedia CIRP 00 (2018) 000–000
allowed a desirable range of surface roughness, between 0.8
and 1.6 µm.
The longer is the workpiece to repair or maintain, the
lower should be the feed rates and the spindle speeds to
obtain lower surface roughness.
For aeronautical and aerospace applications, it is possible
to use the three tested types of tool in this study (TP100,
TP200 and TP1000), as long as, low spindle speeds are used.
Finally, a selection of the best cutting parameters
combinations to achieve usual aeronautical and aeospace
surface roughness requeriments are established.
Acknowledgments
The authors thank to the Research Group of the UNED
“Industrial Production and Manufacturing Engineering
(IPME)” the given support during the development of this
work, and funding of Spanish Ministry of Science and
Innovation (Project DPI2014-58007-R) and of the Industrial
Engineering School-UNED (Project REF2017-ICF05) to
carry it out.
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