Title: Experimental analysis of Ti-6Al-4V drilling: tool wear monitoring and parametric characterisation

Authors: Khalid Hussain Hashmi; Muhammad Shahid Khalil

Addresses: University of Engineering and Technology Taxila, 47050, Pakistan ' University of Engineering and Technology Taxila, 47050, Pakistan

Abstract: Titanium is a renowned metal in modern industry. However, titanium machining poses significant challenges globally, since hole making shares 40%-60% material removal in aerospace structural components. Therefore, optimising drilling parameters is crucial for economic viability and efficient production. This study focuses on drilling Ti-6Al-4V alloy using Ti-Al-N-coated tungsten carbide inserts. The objective includes measuring tool wear, life, surface roughness, accuracy, circularity, and metallurgical effects under various cutting conditions until tool failure. Lowest surface roughness (14% lower) is achieved at 1,600 rpm compared to 1,200 rpm. Minimum circularity error (56.5%) occurs at 1,200 rpm, 240 mm/min, while the maximum found at 1,200 rpm, 480 mm/min. The smallest hole size deviation (0.13%) is observed at 1,600 rpm, 320 mm/min. Crack failure occurs at 1,200 rpm, 240 mm/min, while wear failure is observed in other combinations. Optimal conditions are 1,600 rpm and 320 mm/min, but trade-offs may be necessary based on specific requirements.

Keywords: TTi-6Al-4V drilling; tool wear monitoring; parametric characterisation; titanium alloy; drilling parameters.

DOI: 10.1504/IJMMM.2023.136025

International Journal of Machining and Machinability of Materials, 2023 Vol.25 No.3/4, pp.354 - 374

Received: 13 Mar 2023
Accepted: 04 Jun 2023
Published online: 12 Jan 2024 *

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