Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for...

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Bibliographic Details
Published in:Materials 2019-11, Vol.12 (22), p.3749
Main Authors: Abbas, Adel T., Sharma, Neeraj, Anwar, Saqib, Hashmi, Faraz H., Jamil, Muhammad, Hegab, Hussien
Format: Article
Language:English
Subjects:
Aerospace industry
Biomedical materials
Corrosion resistance
Cutting parameters
Cutting speed
Cutting tools
Decision making
Experiments
Feed rate
High speed machining
Machine tools
Material removal rate (machining)
Multiple objective analysis
Optimization
Optimization techniques
Productivity
Strength to weight ratio
Surface properties
Surface roughness
Swarm intelligence
Titanium alloys
Titanium base alloys
Tool wear
Variables
Wear mechanisms
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Summary:Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma12223749