Effect of process parameters on surface roughness during dry and flood milling of Ti-6A-l4V

Abstract

This study investigated the effect of spindle speed, depth of cut and the milling conditions on the surface roughness of milled Ti6Al4V. Milling was conducted in dry and flood condition while varying spindle speed from 120 to 180 rev/min, depth of cut ranging from 1 to 2 mm as the feed rate was kept constant at 4.6 mm/min. The surface temperature was also measured during milling operation. It was found that during dry milling the surface roughness increased with increment of spindle speed where a maximum surface roughness value of 0.35 μm was recorded at 180 rev/min. During flood milling dry milling, the surface roughness increased with the increase of spindle speed, reaching a maximum of 0.25 μm at 180 rev/min. The depth of cut also had the same impact as spindle speed as it was found that during both dry and flood milling, the surface roughness increased with increment of depth of cut. Flood milling generated smoother milled surface as opposed to dry milling.