An Optimization Strategy To Reduce Surface Roughness, Flank Wear And Tool Vibration In Micro Milling Of TI-6AL-4V Alloy

The present work is aimed to investigate the influence of process parameters namely cutting speed, feed and uncut chip thickness on tool life in micro milling of Ti�6Al-4V alloy. Twenty Seven experiments have been planned as per full factorial
design with three levels of each parameter using carbide end mill cutters. Surface roughness and vibration amplitude are considered as responses to evaluate the tool life and to identify significance of input process parameters. In this study, a non�contact sensor, Laser Doppler Vibrometer (LDV) was used to measure the vibration of tool in terms of Acousto Optic Emission (AOE) signals. A high-speed Fast Fourier Transform (FFT) analyser was used to transform the acousto optic emission signals in to useful signals like vibration amplitude. In the analysis of surface roughness and amplitude of vibration, optimum cutting parameters were found as 5000 r.p.m. of
spindle speed, 40 mm/min of feed rate and 25.6 µm of uncut chip thickness.