Analysis of Cutting Forces and Tool Wear during Micro milling of Ti-6Al-4V at low machining speed By Ammir Rashid Supervisor Dr Mushtaq Khan Design and

Abstract

In this research milling tests were carried out in order to analyze the influence of different parameters of machining such as feed rate, cutting speed, depth of cut and type of tool being used on cutting forces and wear of cutting inserts while micro milling the Ti-alloy (Ti-6Al-4V) using uncoated, AlTiN coated and multi coated (AlTiN and SiN coating) tungsten carbide end mill cutters. The results were analyzed through Statistical technique ANOVA in order to govern the key process variables. Consequences show that depth of cut is most leading factor in cutting forces (44.45% contribution ratio) and cutting speed is most substantial factor in wear of cutting inserts (67.59%) Feed rate and depth of cut had slight influence upon wear of the tool with the contribution of 5.29% and 3.85% respectively. It is observed that multi coated tool undergoes least cutting forces and wear in comparison to other two cutting inserts while micro milling Ti-alloy at low-speed machining setup.