aksahy final ppt.pptx

Optimization of Machining Parameters for
End Milling of Titanium Alloy with Coated
Tungsten Carbide Insert
Presentation on
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

What is End Milling ?
3
Fig. End Milling Process

Indexable End Milling
4

Indexable End Milling
5

Cemented Carbide
Tungsten
Carbide
Titanium
Carbide
Tantalum
Carbide
Cemented
Carbide
Better
Surface
Finish
Faster
machining
Withstand
higher
temperature
Advantages
6

Cemented Carbide Inserts
7
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 al.
Study of Cutting Forces
and Tool wear during End
Milling of TI-6AL-4V Alloy
Titanium
Alloy (Ti-
6Al-4V
alloy)
Cutting
Speed, Feed
Rate
Cutting
Force, Tool
Wear
Maiyar et
al.
Optimization of Machining
Parameters for End Milling of
Inconel 718 Super Alloy Using
Taguchi Based Grey
Relational Analysis
Inconel 718
Super Alloy
Cutting
Speed, Feed
Rate , Depth
of Cut
Surface
Roughness,
Material
Removal
Rate.
Ghani et
al.
Application of Taguchi Method
in the Optimization of End
Milling Parameters
Hardened
Steel AISI
H13
Cutting
Speed, Feed
Rate , Depth
of Cut.
Surface
Finish
Chandra
Nath et al.
Machinability Study and
Process Optimization in Face
Milling of Some Super Alloys
with Indexable Copy Face Mill
Inserts
Inconel
718,
Inconel 625
Cutting
Speed, Feed
Rate
Tool Wear,
Material
Removal
Rate, Cutting
Forces

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

• 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.
12

Work Plan
13
Work Activity
June
2018
July Aug Sep Oct Nov Dec
Jan
2018
Feb Mar Apr May
June
2019
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
Planned Activity 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.
Sr
No
Grade Coating Type Coating Layer
1 K 10 - Uncoated
2 TTMS PVD TiAlN (monolayer)
3 TTMS PVD TiAlN (multilayer)
TiC/TiN
TiCN
TiAlN
Coating
s
Inserts to be used:
16

Tool Material Selection
17
Tool Holder Inserts

Machine Specification and Experimental
Setup
Coolant hoses
Spindle
Insert
Tool holder
Machine set up and Tool assembly
18

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
Machine Specifications
19

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
Parameters
Level 1 Level 2 Level 3
Cutting speed
(m/min)
55 75 95
Feed per tooth
(mm/min)
90 110 130
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
no.
Speed
(RPM)
Feed
(mm/min)
DOC
(mm)
Length of
Tool Travel
Observation
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
(m/min)
Feed Rate
(mm/min)
Depth of
Cut
(mm)
Type of Insert
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 0.75 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
Connecting
Cable
Dynamomet
er
Workpiece

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.

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

Response Parameter
Measurement
44
Infeed Force
Thrust Force

Response Parameter
Measurement
45
 Material Removal Rate
MRR measured in mm³/min.
MRR = width of cut × depth of cut × feed rate
(mm) (mm) (mm/min)

Results and Discussion
46
Sr.
No
.
Cutting
Speed
(m/min
)
Feed
Rate
(mm/min
)
Depth
of Cut
(mm)
Type of
Insert
S/F
Roughn
ess
(µm)
Infeed
Force(N
)
Thrust
Force(
N)
MRR
(mm3/m
in)
1 55 90 0.5 Uncoated 0.51 46.597 48.434 540
2 55 90 0.75 Monolaye
r
0.31 52.216 74.762 945
3 55 90 1 Multilayer 0.78 77.442 92.773 1350
4 55 110 0.5 Monolaye
r
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 1.06 103.18 179.91
4
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 Monolaye
r
0.35 80.636 97.837 1820

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

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

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

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
Rate
54

ANOVA For Material Removal
Rate
55
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.

Thank You
57

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