Publication Date

Spring 2016

Advisor(s) - Committee Chair

Dr. Muhammad Jahan (Director), Dr. Mark Doggett and Dr. Daniel Jackson

Degree Program

Department of Architectural and Manufacturing Sciences

Degree Type

Master of Science

Abstract

Titanium and its alloy (Ti-6Al-4V) are widely used in aerospace industries because of their light weight, high specific strength, and corrosion resistance. This study conducted a comparative experimental analysis of the machinability of Ti-6Al-4V for conventional flood coolant machining and sustainable dry machining. The effect of cutting speed, feed rate, and depth of cut on machining performance has been evaluated for both conditions. The machining time and surface roughness were found to be lower in dry machining compared to flood coolant machining. The tool wear was found to be unpredictable, and no significant difference was observed for dry and coolant machining. In a comparison of all the parameters, sustainable dry machining was found to provide better performance in machining Ti-6Al-4V.

This study also investigated the machinability of Ti-6Al-4V using coated and uncoated tungsten carbide tools under dry conditions. Tool wear is a serious problem in the machining of titanium alloys in dry conditions. Heat dissipation from the toolworkpiece interface a difficult challenge in dry machining, resulting in the alloying of the workpiece to the tool surface. Dry machining with the coated tool was comparatively faster, and resulted in less tool wear than uncoated tools. Using the Titanium aluminum nitride TiAlN coated carbide tool during dry machining provided a smoother surface finish with lower average surface roughness. The conclusion, therefore, is that the tool coating was found to be effective for the dry machining of titanium alloys.

Disciplines

Engineering Mechanics | Engineering Science and Materials | Manufacturing

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