Investigation of micro turning process parameters for titanium alloy using response surface methodology

Abstract The trend of miniaturizing engineering components represents a significant advancement in technology, enabling the production of small, precise parts that are essential in contemporary life. Titanium alloy has become a well-known material in contemporary applications due to its low density and high strength, along with its excellent heat resistance. As a result, it is widely utilized in aerospace and gas turbine industries. This article presents a novel study aimed at investigating the machining effects of titanium alloy through the optimization of micro-turning process parameters, focusing on tool wear and surface roughness. The study indicates that the primary factors influencing reactions are cutting speed and feed rate. The analysis of numerical and graphical methods aims to determine the optimal process parameters. The gathered results indicate that optimal tool wear and surface roughness are achieved simultaneously at 0.149 mm and 0.691 μm, respectively, with cutting parameters set at 3035 rpm for cutting speed, 7.5 μm/rev for feed, and a depth of cut of 15 μm, resulting in 89% desirability. This approach enhances output and surface quality while minimizing machining costs. A confirmation experiment is conducted and analyzed for the purpose of comparative study, focusing on residual error. The analysis through Scanning Electron Microscopy indicates that the medium order cutting conditions yield superior performance while addressing conflicting objectives, resulting in a smoother surface topography.