Investigation of effect on machinability and tool wear of cutting parameters in milling of Ti-6Al-4V alloy

Ti-6Al-4V alloy has increased its use in aeronautics, chemistry and medical applications owing to various properties such as low hardness, high strength and excellent corrosion resistance. However, these properties complicate the machining of Ti-6Al-4V alloy. Therefore, in this study, the effect of cutting parameters on milling zone and cutting tools were investigated by the hard carbide (WC) and TiN coated HSS end mills with 8 mm diameters of Ti-6Al-4V alloy in milling. The following parameters were chosen in milling experiments: cutting speeds 5, 10 and 15 m/min, feed rates 0.05, 0.075 and 0.1 mm/rev and depth of cut 2mm. Also, cutting fluids were not used in the experiments. As a result of the experimental study, it was seen that cutting speed, feed rate and type of cutting tool important had significant effects on cutting force, tool wear, surface roughness, burr height and channel deviation. In both cutting tools, it was seen that as cutting speed increased, the cutting forces, surface roughness and burr heights reduced; on the other hand, as the feed rate increased, cutting forces surface roughness and burr heights increased. Tool wear increased with increasing of the both cutting speed and the feed rate. It was observed that a value close to the nominal size was obtained in channel deviations with the increasing of feed rate compared to cutting speed. It was seen that deviation in the milling channel input was higher than that of its output. For all results, optimum results were obtained from hard carbide (WC) end mills in the milling Ti-6Al-4V alloy.