Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions.

Khan, Muhammad Ali; Jaffery, Syed Husain Imran; Khan, Mushtaq; Younas, Muhammad; Butt, Shahid Ikramullah; Ahmad, Riaz; Warsi, Salman Sagheer

Abstract

Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33% whereas specific cutting energy and surface roughness were improved by 10% and 9% respectively by adapting the optimum machining conditions.

Citation

KHAN, M.A., JAFFERY, S.H.I., KHAN, M., YOUNAS, M., BUTT, S.I., AHMAD, R. and WARSI, S.S. 2019. Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions. Mechanical sciences [online], 10(2), pages 561-573. Available from: https://doi.org/10.5194/ms-10-561-2019

• Journal Article Type: Article
• Acceptance Date: Nov 1, 2019
• Online Publication Date: Dec 4, 2019
• Publication Date: Dec 31, 2019
• Deposit Date: Jun 18, 2023
• Publicly Available Date: Jun 26, 2023
• Journal: Mechanical sciences
• Print ISSN: 2191-9151
• Electronic ISSN: 2191-916X
• Publisher: Copernicus Publications
• Peer Reviewed: Peer Reviewed
• Volume: 10
• Issue: 2
• Pages: 561-573
• DOI: https://doi.org/10.5194/ms-10-561-2019
• Keywords: Titanium; Lubricants; Carcinogenic; Health hazards; Liquid nitrogen
• Public URL: https://rgu-repository.worktribe.com/output/1992829