Sustainable milling of Ti-6Al-4 V super alloy using AlCrN and TiAlN coated tools

Abstract

Majority of the heat energy generated during the metal removal processes disperses with the help of cutting fluids, which possess numerous challenges to environment and mankind. Dry machining with the help of coated tools is a sustainable alternative to eliminate the cutting fluids. The present work investigates the influence of AlCrN and TiAlN coating during the end milling of high-performance Ti-6Al-4 V super alloy. Experiments were also performed at high-speed condition where coated tools were employed in dry condition and uncoated tools in the presence of cutting fluid. For both the conditions, force, tool wear, surface roughness and surface morphology were investigated. The resultant force generated by the AlCrN and TiAlN coated tool under dry condition is comparable to that of uncoated tool under wet condition. It is observed that the chipping of cutting is the major mode of failure of cutting tool. This was evident while machining with uncoated tool under low-speed condition. AlCrN coated tool gave better surface finish when compared to TiAlN coated tool. At various operating conditions, various defects such as redeposition of material, side flow, presence of black spot were observed.