Effect of Tool Nose Radius and Machining Parameters on Cutting Force, Cutting Temperature and Surface Roughness-An Experimental Study of Ti-6Al-4V (ELI)

ATi-6Al-4V Extra Low Interstitial (ELI) possesses superior properties like higher strength to weigh ratio, better corrosion resistance, good fracture toughness etc., because of controlled interstitial element of iron and oxygen. The effects of four cutting parameters namely cutting speed, feed, depth of cut and tool nose radius on responses like cutting temperature, surface roughness and cutting force have been investigated for turning of Ti-6Al-4V (ELI). Total 81 experiments have been performed in dry environment. Mathematical models for cutting temperature, surface roughness and cutting force have been developed from experimental data using Response Surface Methodology. ANOVA test also has been carried out to evaluate contribution of parameters. The developed model is interfaced with Particle Swarm Optimization to minimize responses. The prediction of cutting force by PSO states that minimum cutting force of 7.419 kgf at cutting speed of 315 rpm, feed of 0.0510 mm/rev, depth of cut of 0.5mm and nose radius of 0.4mm. The prediction of surface roughness by PSO states that minimum surface roughness of 0.328μm at cutting speed of 140 rpm, feed of 0.0510 mm/rev, depth of cut of 0.7mm and nose radius of 1.2 mm. Also the minimum cutting temperature has been predicted by PSO as 31.96°C at cutting speed of 140 rpm, feed of 0.0510 mm/rev, depth of cut of 1mm and nose radius of 0.8mm. The confirmation experiments have also been carried out which have measured minimum cutting force of 7 kgf, minimum surface roughness as 0.35μm and cutting temperature of 30°C.