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Materials
Volume 12
Issue 22
10.3390/ma12223749
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Article

Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

by
Adel T. Abbas
1,*,
Neeraj Sharma
2,
Saqib Anwar
3,
Faraz H. Hashmi
1,
Muhammad Jamil
4 and
Hussien Hegab
5
1
Department of Mechanical Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia
2
Department of Mechanical Engineering, Maharishi Markandeshwar (Deemed to be University), Mullana 133207, India
3
Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia
4
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
5
Mechanical Design and Production Engineering Department, Cairo University, Giza 12613, Egypt
*
Author to whom correspondence should be addressed.
Materials 2019, 12(22), 3749; https://doi.org/10.3390/ma12223749
Received: 22 October 2019 / Revised: 4 November 2019 / Accepted: 11 November 2019 / Published: 14 November 2019
(This article belongs to the Section Manufacturing Processes and Systems)
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Abstract

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective. View Full-Text
Keywords: high speed machining; titanium alloys; surface roughness; productivity; optimization high speed machining; titanium alloys; surface roughness; productivity; optimization
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited
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MDPI and ACS Style

Abbas, A.T.; Sharma, N.; Anwar, S.; Hashmi, F.H.; Jamil, M.; Hegab, H. Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V. Materials 2019, 12, 3749. https://doi.org/10.3390/ma12223749

AMA Style

Abbas AT, Sharma N, Anwar S, Hashmi FH, Jamil M, Hegab H. Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V. Materials. 2019; 12(22):3749. https://doi.org/10.3390/ma12223749

Chicago/Turabian Style

Abbas, Adel T., Neeraj Sharma, Saqib Anwar, Faraz H. Hashmi, Muhammad Jamil, and Hussien Hegab. 2019. "Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V" Materials 12, no. 22: 3749. https://doi.org/10.3390/ma12223749

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