A STUDY ON MACHINING CHARACTERISTICS IN MILLING OF TI-6AL-4V USING EXPERIMENTAL AND FINITE ELEMENT ANALYSIS

Vibrations in cutting tool due to machining condition is one of the most important technological parameter because it can significantly influence on tool wear and life, quality and residual stresses of machined surface and cutting forces. Therefore, it was necessary to study the effect of cutting tool vibrations during the machining. When the work piece was subjected to vibrations during the machining under various cutting conditions, it would cause the relative displacement between tool and work piece, which generated the vibration of the cutting tool. The dynamic phenomena of cutting tool induced by the interaction of an elastic system in the cutting process caused the relative displacement between tool and work piece, which generated the vibration of the cutting tool [1].Vibration of the tool can be a good way to monitor online growth of the tool wear in milling, and therefore, it can be useful for establishing the end of tool life in these operations [2]. Especially, the relative vibrations of cutting tool and work piece causes the poor machined surface roughness, poor dimensional accuracy of the work piece and abnormal tool wear or tool breakage, which lowered down the productivity and increased the cost of production [3]. Therefore, it was necessary to study the effect of cutting tool vibrations during the machining. At present, some experimental measurement methods were used to evaluate the vibration field, including accelerometers and Laser Doppler Vibrometers. Most methods essentially involve processing information such as acoustic emission, tool tip temperature, vibration signatures (acceleration signals), cutting forces and so on. However, acousto-optic emission methods have been recently introduced as a reliable way to detect the vibration amplitudes with non-contact mode to identify the corresponding tool wear [4].