OPTIMIZATION OF PROCESS PARAMETERS IN DRY AND WET MACHINING OF TI-6AL-4V ELI USING TAGUCHI METHOD

This paper reports the optimization of process parameters such as cutting speed (m/min), feed (mm/rev), depth of cut(mm) and nose radius (mm) in Dry and Wet machining using Taguchi method. Cutting fluids in machining operations help to remove the heat generated during cutting, to achieve better tool life and surface finish and to facilitate the flushing of chips. The machining without the use of any cutting fluid is becoming increasingly important due to concern regarding safety and environmental legalization. In addition it reduce 17% of manufacturing costs by not using cutting fluids. However in Dry machining operations, the friction and adhesion between chip and tool tend to be higher, which causes higher temperatures, higher wear rates and shorter tool life . This problem can overcome by using PVD coated TiAlN cutting tool. PVD - TiAlN coated carbide tools are used frequently in metal cutting process due to the higher hardness, wear resistance and chemical stability. In addition it improves tool life and machining performance. The work piece material is Ti-6Al-4V ELI which is most widely used in bio-medical applications due to its high strength to weight ratio and exceptional corrosion resistance. The cost of titanium still remain high cost but longer service life counter balance the production cost. If the work piece material is machined by Dry machining the production cost will be reduced further without affecting the quality parameters .Experiment was conducted on Dry and Wet machining with identical cutting parameters . The main output monitored was the surface roughness.