DefinePK

Abstract

Titanium and aluminium alloys are ubiquitously used in aerospace, automobile, chemical and medical applications due to their innate and characteristic properties of high strength to weight ratio, specific strength at elevated temperatures, corrosion and chemical resistance, creep and fatigue strength etc. Manufacture of accurate precision components from titanium alloys is a daunting task as the alloys are difficult to cut material due to the ingrained microscopic as well as macroscopic qualities such as low thermal conductivity, low modulus of rigidity, work hardening, high chemical reactivity with tool, built-up edge formation etc. during machining processes. Turning is one of the most widely used manufacturing techniques for producing circular shape from irregular shape in the real time industry applications and there are a large number of parameters to be investigated in this process. Predictions of important process variables of turning such as temperature, cutting forces and stress distributions play significant role on designing turning process parameter and optimizing cutting conditions. Therefore finite element deform 3d (FEA) and simulation comes as a handy tool to calculate and analyse the tool wear rate which in turn helps us save time and also leads to less material wastage. The tool bit base metal used is tungsten carbide over which a coating of three different materials namely Ti, Al2O3 and TiCN has been applied. Four factors that are -material, federate, speed, and depth of cut were taken into considerations at three different levels to get nine experiments which was then optimized by taguchi method to infer and analyse the best suitable parameter and condition for least amount of tool wear during turning operation.