Experimental Evaluation of Surface Roughness, Burr Formation, and Tool Wear during Micro-Milling of Titanium Grade 9 (Ti-3Al-2.5V) Using Statistical Evaluation Methods

Author:

Khan Muhammad Ayyaz1ORCID,Khan Muhammad Ali12ORCID,Aziz Shahid34ORCID,Faraz Muhammad Iftikhar5,Tahir Abdul Malik26,Jaffery Syed Husain Imran1,Jung Dong-Won7ORCID

Affiliation:

1. School of Mechanical and Manufacturing Engineering (SMME), National University of Sciences and Technology (NUST), Islamabad 44000, Pakistan

2. Department of Mechanical Engineering, College of Electrical and Mechanical Engineering (CEME), National University of Sciences and Technology (NUST), Islamabad 44000, Pakistan

3. Department of Mechanical Engineering, Jeju National University, 102 Jejudaehak-ro, Jeju-si 63243, Republic of Korea

4. Institute of Basic Sciences, Jeju National University, 102 Jejudaehak-ro, Jeju-si 63243, Republic of Korea

5. Department of Mechanical Engineering, College of Engineering, King Faisal University, Al-Ahsa 31982, Saudi Arabia

6. Department of Engineering Management, College of Electrical and Mechanical Engineering (CEME), National University of Sciences and Technology (NUST), Islamabad 44000, Pakistan

7. Faculty of Applied Energy System, Major of Mechanical Engineering, Jeju National University, 102 Jejudaehak-ro, Jeju-si 63243, Republic of Korea

Abstract

Titanium grade 9 (Ti-3Al-2.5V) stands out as a preferred material in various industrial applications because of its suitable properties. Its applications span diverse sectors, including precision manufacturing, where it is utilized to produce honeycomb structures for advanced aeronautics, as well as for certain biomedical components. In parallel, micro-milling has gained widespread utilization across medical, aerospace, and electronic industries due to the increasing demand for miniature products in these domains. This current research study aims to explore the impact of various micro-milling process parameters—specifically, feed rate, cutting speed, and depth of cut—on the surface quality, burr formation, and tool flank wear of titanium grade 9. Research findings reveal that the feed rate plays a major role in influencing surface roughness (contribution ratio (CR): 62.96%) and burr formation (CR: 55.20%). Similarly, cutting speed and depth of cut significantly affect surface roughness, contributing 20.32% and 9.27%, respectively, but are insignificant factors for burr width. Tool flank wear is primarily influenced by cutting speed (CR: 54.02%), with feed rate contributing 33.18%. Additionally, the feed rate and cutting speed are significant factors in determining the length of the burr, with contribution ratios of 77.70% and 7.77%, respectively. Confirmatory tests conducted at optimum parameters selected from the main effects plot validated the experimental results.

Publisher

MDPI AG

Subject

Fluid Flow and Transfer Processes,Computer Science Applications,Process Chemistry and Technology,General Engineering,Instrumentation,General Materials Science

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