Licensed Under Creative Commons Attribution CC BY Performance Evaluation of Different Tools in Turning of Ti-6Al-4V Alloy Under Different Coolant Condition

Abstract: In any machining operation, a lot of heat is generated due to plastic deformation of work material, friction at the tool-chip interface and friction between the clearance face of the tool and work piece. The friction in machining adversely affects the tool wear and quality of the products produced. Thus, effective control of friction in the cutting zone is essential to ensure less tool wear and good surface quality of the work piece in machining. Cutting fluids have been the conventional choice to deal with this problem. But it shows negative effect on product cost, environment and human health. Later semi-dry i.e., Minimum Quantity Lubrication machining has been tried as a possible alternative to the use of cutting fluid. The usage of coolant in Minimum Quantity Lubrication is typically 100 ml/hr or less. This project work deals the optimization of process parameters for surface roughness in turning of Ti-6Al-4V under different cooling conditions such as dry, flooded and Minimum Quantity Lubrication with different cutting tools such as CVD coated tool, PVD coated tool and Uncoated tools by using Taguchi’s robust design methodology. The results reveal that MQL condition shows minimum surface roughness as compared to dry and flooded conditions. Moderate cutting speed, low feed rate and high depth of cut are found to be optimum conditions. The CVD coated tool out performed compared to uncoated and PVD coated tools. The flank wear behavior is observed with optical images and it observed that the tool wear is less in Minimum Quantity Lubricant as compared to dr