WELCOME TO THE PRESENTATION ON

PREDICTION OF OPTIMAL CUTTING

CONDITIONS IN MILLING OF TI-6AL-4V ALLOY
UNDER DIFFERENT COOLING CONDITIONS
 ANURAG COLLEGE OF ENGINEERING
Aushapur (V), Ghatkesar (M), Medchal (Dist.),T.S - 501 301.

By
Under the guidance of B.RAJASHEKHAR (14PQ1A0307)
Mr. K. SRINIVASULU K.NIKHIL KUMAR (14PQ1A0314)
Associate Professor S.SAI KUMAR (14PQ1A0331)
Dept.of Mechanical Engineering A.GOUD NAIK (15PQ5A0301)
 INTRODUCTION

• IN DRY MACHINING, HIGHER ORDER FRICTION DEVELOPS BETWEEN TOOL AND WORK WHICH LEAD TO
HIGH TEMPERATURES IN THE MACHINING ZONE WHICH LEADS TO TOOL WEAR AND BAD SURFACE
FINISHING.

• IN ORDER TO OPTIMIZE THEM, CUTTING FLUIDS ARE EMPLOYED IN MACHINING WHICH HELPS IN
IMPROVING THE TRIBOLOGICAL CHARACTERISTICS.
 CHOOSING THE RIGHT CUTTING PARAMETERS IS A VITAL
STEP IN MACHINING BECAUSE THE CUTTING
PARAMETERS INFLUENCE ON THE OUTPUT
CHARACTERISTICS OF THE MACHINED PRODUCTS LIKE
SURFACE FINISH, THE TOOLING COST.

 SURFACE FINISH PLAYS MAJOR ROLE IN SERVICE LIFE OF

COMPONENTS, TO ENSURE A GREAT RELIABILITY OF
COMPONENTS.

 THE PRESENT STUDY IS FOCUSED ON THE MACHINING

CHARACTERISTICS OF TITANIUM UNDER DIFFERENT
COOLING CONDITIONS TO IMPROVE SURFACE FINISH
AND REDUCE TOOL WEAR.
 EXPERIMENTAL DETAILS
SELECTION OF CONTROL FACTORS AND LEVELS

• ACCORDING TO TAGUCHI’S ROBUST DESIGN METHOD, THE THREE CONTROL FACTORS SELECTED ARE SPINDLE SPEED
(A), FEED (B), AND DEPTH OF CUT (C). UNCOATED CARBIDE TOOLS ARE USED IN EXPERIMENTATION. THE CONTROL
FACTORS AND THEIR ALTERNATIVE LEVELS ARE LISTED IN TABLE.1.

• SELECTION OF PARTICULAR ORTHOGONAL ARRAY FROM THE STANDARD O.A, DEPENDS ON THE NUMBER OF FACTORS,
LEVELS OF EACH FACTOR AND THE TOTAL DEGREES OF FREEDOM.

• I) NUMBER OF CONTROL FACTORS = 3

• II) MINIMUM NUMBER OF EXPERIMENTS TO BE CONDUCTED = 9.

TABLE 1: CONTROL FACTORS AND LEVELS:
 VERTICAL MILLING MACHINE
MILLING IS THE MACHINING PROCESS OF USING
ROTARY CUTTERS TO REMOVE MATERIAL FROM A WORK PIECE BY
FEEDING THE CUTTER INTO THE WORK PIECE.

SUNRISE UNIVERSAL GEAR HEAD MILLING MACHINE USED FOR

MACHINING TITANIUM ALLOY AT DIFFERENT COOLING
CONDITIONS:

1. DRY

2. SYNTHETIC OIL

3. MINERAL OIL
CUTTING TOOL AND SJ-210 SURFACE ROUGHNESS
TESTER
 1. DRY MACHINING
• ACCORDING TAGUCHI ROBUST DESIGN METHOD, THE L9 (34) ARRAY WERE ASSIGNED TO THE CUTTING SPEED(A),
FEED(B) AND DEPTH OF CUT(C) RESPECTIVELY. INITIALLY 9 SETS OF EXPERIMENTS ARE PERFORMED ACCORDING TO THE
L9 (34) ORTHOGONAL ARRAY.

• EACH SET OF EXPERIMENTS WAS REPEATED TWO TIMES, WITH A TOTAL OF 18 EXPERIMENTS BEING CONDUCTED FOR
INVESTIGATION.

• THE DIFFERENT SETS OF EXPERIMENTS ARE PERFORMED USING MILLING MACHINE, THE MACHINED SURFACE
ROUGHNESS IS MEASURED USING SJ-210 SURFACE ROUGHNESS TESTER AT TWO DIFFERENT POSITIONS ARE SHOWN
IN TABLE 2.
TABLE 2: DATA SUMMARY OF DRY MACHINING (SURFACE
ROUGHNESS) AND S/N RATIO:
 PROCEDURE OF ANALYSIS OF VARIANCE FOR DRY
CONDITION:
1) THE AVERAGE RESPONSE FOR EACH EXPERIMENT:
• THE AVERAGE OF FIRST EXPERIMENT = (2.825+2.820)/2
= 2.8225
2) THE OVERALL EXPERIMENTAL AVERAGE = ̅y = (2.825+2.820+...+2.400)/18
= 3.7213
3) THE TOTAL SUM OF SQUARES (S.T) = (2.8252+2.8202...+2.4002)
= 290.5997
• 4) THE TOTAL SUM OF SQUARES DUE TO MEAN (SM) = n x y̅ 2
= 18 x (3.7213)2
= 249.2653
8.THE F-RATIO (DATA):
THE F-RATIO IS CALCULATED BY DIVIDING THE MEAN SUM OF SQUARES BY THE
ERROR SUM OF SQUARES.
FOR FACTOR A,
FA = (MSSA ÷ MSSE)
= 4.3955/0.4538
= 9.6859

9.THE F-RATIO (TABLE):

THE F-RATIO FROM THE TABLE 3 FOR COMBINATION ARE EXTRACTED IS 95% FOR
ALL FACTORS.
10.THE F-RATIO TEST:

COMPARING THE VALUES OF F-RATIO, THE CALCULATED IS GREATER THAN THE TABULATED F VALUE (FCALCULATED>F0.05,2,11). THIS CONCLUDES THAT THE FACTORS
SELECTED ARE SIGNIFICANT FOR THE PROCESS. THE RESULTS OF THE CALCULATIONS ABOVE ARE USED TO DRAW THE ANALYSIS OF VARIANCE TABULATED IN
TABLE 3.

11.CALCULATION OF PERCENT CONTRIBUTION:

IN ORDER TO CALCULATE PERCENT CONTRIBUTION OF THE VARIOUS SOURCES IN AN ANALYSIS OF VARIANCE WE NEED TO CALCULATE THE PURE SUM OF
SQUARES AND DIVIDE BY THE TOTAL SUM OF SQUARES.

I) FOR FACTOR A:
SSA1 = SSA - (DFA × MSSE)
= 8.7911 - (2 X 0.4538)
= 7.8864
Ρ A = (SSA1/ST) X 100
= (7.8864/41.3473) × 100
= 19.0735 %
• St VALUE TAKEN FROM RESULTS OF ANOVA TABLE.
• 12. POOLING OF LESS SIGNIFICANT FACTORS:
POOLING OF FACTOR A:

POOLED ERROR SUM OF SQUARES (SS (POOLED E)) = SE + SSA

= 4.9918 + 8.7911 = 13.7829 (SE FROM POOLING OF ERROR TABLE:3)

POOLED ERROR DEGREES OF FREEDOM (DF (POOLED E))

=DFE + DFA

=11+2 =13
POOLED ERROR MEAN SUM OF SQUARES (M (POOLED E)) = [SS (POOLED E) ÷ DF (POOLED E)]

= (13.7829/13) = 1.0602

• CONSEQUENTLY, Sq 1 AND PERCENT CONTRIBUTION OF REMAINING FACTORS CHANGES. THE METHOD OF

RECALCULATION IS SIMILAR AS EARLIER MENTIONED.
TABLE-3: BASIC ANALYSIS OF VARIANCE (DRY CONDITION)
TABLE 4: SUMMARY OF S/N RATIOS FOR DRY
CONDITION
 SELECTION OF OPTIMUM SET OF CONDITIONS FOR
DRY MACHINING:
• IN ORDER TO FIND THE OPTIMUM SET OF
CONDITIONS, THE INDIVIDUAL LEVEL
AVERAGES OF S/N RATIOS ARE CALCULATED.
THESE VALUES ARE TABULATED IN BESIDE TABLE.
THE OBJECTIVE IS TO MAXIMIZE THE S/N
RATIO VALUES. THUS, THE OPTIMUM
CONDITIONS CHOSEN ARE A3-B1-C2 AND
THEIR LEVELS ARE SHOWN IN TABLE.
• AS SEEN FROM ANOVA RESULTS, TO MINIMIZE THE SURFACE ROUGHNESS, FEED HAS MAJOR CONTRIBUTION (39.63%)
IN OPTIMIZING THE PERFORMANCE CHARACTERISTIC FOLLOWED BY DEPTH OF CUT AND CUTTING SPEED.

• FURTHER, IT IS ALSO OBSERVED THAT ANOVA HAS RESULTED IN (37.75 %) OF ERROR CONTRIBUTION.

• PREDICTION OF PROCESS AVERAGE FOR OPTIMUM FOR DRY CONDITION:

• PREDICTED = Y + (A1 - Y) + (B1 - Y) + (C1 - Y)

= A1 + B1 + C1 – 2Y

= ((-8.953 - 9.0794 - 8.4616) - (2 × (-10.8174)))

= - 4.8592

• CONFORMATION TEST = -4.4800

 2. FLOODED MACHINING (SYNTHETIC OIL)
• THE EXPERIMENTS ARE CONDUCTED USING L9 (34) ORTHOGONAL ARRAY WITH SYNTHETIC OIL AS COOLANT TO
FOLLOW ABOVE PROCEDURE TO CALCULATE THE OPTIMUM SET OF CONTROL FACTORS FOR SYNTHETIC OIL
CONDITION. THESE VALUES ARE SHOWN BELOW TABLE.

CONTROL FACTOR Speed A Feed B Depth of Cut

OPTIMUM VALUE 405 0.083 0.5

• THUS THE OPTIMUM CONDITIONS CHOSEN ARE A2-B2-C1.

• PREDICTION OF PROCESS AVERAGE FOR OPTIMUM CONDITION:

• PREDICTED VALUE = 8.790

• CONFORMATION TEST = 8.879

WORKING ON SYNTHETIC OIL
 3. FLOODED MACHINING (MINERAL OIL)
• THE EXPERIMENTS ARE CONDUCTED USING L9 (34) ORTHOGONAL ARRAY WITH MINERAL OIL AS COOLANT TO
FOLLOW ABOVE PROCEDURE TO CALCULATE THE OPTIMUM SET OF CONTROL FACTORS FOR SYNTHETIC OIL
CONDITION. THESE VALUES ARE SHOWN BELOW TABLE.

Control Factor SPINDLE SPEED FEED DEPTH OF CUT

(rpm) (mm/rev) (mm)
Optimum Value 725 0.066 0.5

• THUS THE OPTIMUM CONDITIONS CHOSEN ARE A3-B1-C1.

• PREDICTION OF PROCESS AVERAGE FOR OPTIMUM CONDITION:
• PREDICTED VALUE = 7.2684

• CONFORMATION TEST = 7.2324

 RESULTS AND DISCUSSION

• FIGURE 5.1 SHOWS THE VARIATION BETWEEN

CUTTING SPEED AND SURFACE ROUGHNESS
WHEN DEPTH OF CUT IS CONSTANT AND
FEED VARIES. WHEN THE CUTTING SPEED IS
LOW, THE SURFACE ROUGHNESS IS ALSO
LOW FOR MINERAL, SYNTHETIC OIL
CONDITIONS.
• FIGURE 5.2 SHOWS THE VARIATION BETWEEN
FEED RATE AND SURFACE ROUGHNESS WHEN
SPEED IS CONSTANT AND DEPTH OF CUT
VARIES. WHEN THE FEED RATE IS LOW, THE
SURFACE ROUGHNESS IS ALSO LOW FOR
SYNTHETIC OIL CONDITIONS COMPARED TO
THE DRY AND MINERAL CONDITIONS
• FIGURE 5.3 SHOWS THE VARIATION BETWEEN
DEPTH OF CUT AND SURFACE ROUGHNESS
WHEN FEED IS CONSTANT AND SPEED
VARIES. WHEN THE DEPTH OF CUT IS LOW, THE
SURFACE ROUGHNESS IS ALSO LOW FOR
SYNTHETIC OIL CONDITIONS COMPARED TO
THE DRY AND MINERAL OIL CONDITIONS.
 CONCLUSIONS
• BASED ON THE RESULTS OF THE PRESENT EXPERIMENTAL INVESTIGATIONS ON MACHINING TI-6AL-4V ALLOY, THE
FOLLOWING CONCLUSION CAN BE DRAWN:

 THE CUTTING PERFORMANCE ON TI-6AL-4V ALLOY WITH SYNTHETIC OIL SHOWS FAVORABLE AND BETTER
PERFORMANCE COMPARED TO DRY AND MINERAL OIL.

 THE SYNTHETIC OIL AS A CUTTING FLUID IN MACHINING OF TI-6AL-4V ALLOY SHOWS ADVANTAGE IN MINIMIZING
THE SURFACE ROUGHNESS.

 THE ANOVA SHOWS THAT MACHINING OF TI-6AL-4V ALLOY, THE SYNTHETIC OIL IS MORE EFFECTIVE AT MODERATE
CUTTING SPEED, MODERATE DEPTH OF CUT AND LOW FEED COMPARED TO DRY AND MINERAL OIL CONDITIONS, BUT
UNDER MINERAL OIL CONDITION IS EFFECTIVE AT LOW DEPTH OF CUT COMPARED DRY AND SYNTHETIC OIL, WHERE
AS DRY MACHINING SUITABLE ONLY AT LOW FEED RATE AND MODERATE DEPTH OF CUT.
 APPLICATIONS
 AUTOMOTIVE
 AEROSPACE
 MILITARY AIRCRAFT
 MARINE
 MEDICAL