High speed dry end milling of ti-6al-4v alloy towards nano-scale surface roughness

Abstract

The quality of surface finish after machining is one of the most important parameters in ensuring the performance requirements of machined components during assembly. In this study the surface roughness of titanium alloy, Ti-6Al-4V was investigated during high speed end milling under dry condition. Evaluation was conducted using TiAlN+TiN PVD coated carbide tool under different cutting speeds and feed rates. Surface roughness was measured in two directions of feed and stepover. Results showed that increasing cutting speed led to a higher or better surface quality of the machined part. This behaviour was more significant when higher feed rate was employed. In contrast, lower feed rate at higher cutting speed caused appearance of lamellae defect on the machined surface resulting in comparatively poor surface finish. Overall results revealed that the best surface finish with 63nm was obtained when employing cutting conditions of 300m/min and 0.06mm/tooth.