Optimization and Modeling of the Sustainable Manufacturing Process in CNC Turning of Titanium alloy (Ti6Al4V)

Abstract Cutting titanium and titanium alloys are very difficult to machined, hence quite challenging. The metal's mechanical, chemical, and physical characteristics can account for it. The material properties like elevated chemical reactivity with less thermal conductivity make titanium and titanium alloys excellent candidates for use as cutting tool materials. The temperature at a tool's cutting edge rises because of its poor heat conductivity. Additionally, titanium alloys' poor machinability is caused by bad modulus of elasticity and strong strength at elevated temperatures 1–14. Due to its lower elasticity modulus than steel, titanium exhibits higher "springiness." Under pressure from the tool, thin parts frequently deflect, leading to issues like tolerance, chatter and tool rubbing. The tool should be appropriately formed and the overall system should be highly stiff (very sharp). The total absence of a "built-up edge," which results in a elevated shearing angle, is following crucial characteristic in titanium with titanium alloys (absence of a constant mass of metal ahead of the cutting tool). This increases more bearing loads on each unit area and thin chips contacting a very small portion of cutting tool face. Due to the strong bearing force and friction created by the chip, a very specific portion of the cutting tool becomes extremely hot. Typically, components requiring the highest dependability are made of titanium and titanium alloys, therefore surface properties must be preserved. Surface features of the component, such as surface finish and shape, as well as sub-surface properties, such as residual stress, granular plastic flow direction, and surface defects, have vital impact on machining performance of machined parts (porosity, micro-cracks, etc.). The surface polish and integrity attained following machining determine surface quality of machined parts 1–14. The Taguchi optimization approach is taken for evaluation and prediction in the research area, which concentrates on the ideal CNC cutting conditions for turning titanium alloy (Ti6Al4V). Cutting velocity (v), feed rate (f), DOC (d), with rake angle (RA) were chosen as input process variables in turning process, while flank wear (Vb), tool life and surface finish (Ra) were taken into consideration as performance evaluation features. For conducting the tests, the Taguchi L25 orthogonal array (OA) experimental design plan was taken into consideration. According to the outcomes of the conformation tests, the Taguchi analysis that revealed the ideal process parameters greatly enhanced the turning performance when machining titanium alloy (Ti6Al4V). The ANOVA findings showed that rake angle and depth of cut significantly affected turning performance in terms of Vb and Ra.