Performance Analysis of Solid and Hollow End Mills Under Hybrid Nano Flood Coolant in Milling of Titanium Alloy-5

• Published in: Journal of the Institution of Engineers (India) Series C Vol. 105; no. 5; pp. 1233 - 1245
• Main Authors: Patil, Amit S., Sunnapwar, V. K., Bhole, K. S., Ingle, S. V., Singh, Deepak
• Format: Journal Article
• Language: English
• Published: New Delhi Springer India 2024; Springer Nature B.V
• Subjects: Aerospace Technology and Astronautics; Aircraft performance; CAM; Carbide tools; Computer aided manufacturing; Context; Coolants; Corrosion resistance; Cutting resistance; Cutting tool materials; Cutting tool paths; Cutting tools; Cutting wear; Engineering; External pressure; Industrial and Production Engineering; Mechanical Engineering; Milling (machining); Nozzle flow; Original Contribution; Shearing; Spindles; Surface layers; Surface properties; Thermal conductivity; Titanium alloys; Titanium base alloys; Tool life; Tool wear; Hybrid nano flood coolant; Hollow cutting tool; Surface quality; Ti6Al4V; Milling; Tool life
• ISSN: 2250-0545; 2250-0553
• DOI: 10.1007/s40032-024-01080-w

Machining of Ti6Al4V is most challenging when looking towards the cutting tool performance in the context of surface quality, spindle load, and tool health. It is a popular material for the Aircraft, Automobile, and Bio-implant industries have of its pervasiveness in high strength, good corrosive resistance, and adaptive formability. The cutting tools’ wear, like Crater and Flank, is inherent during the milling of Ti6Al4V due to poor thermal conductivity and thermo-chemical affinity with cutting tool material. This experimental analysis carried out by using Solid and Hollow End Mills of Carbide-PVD TiAlN and HSS-TiN coated under a hybrid nano flood coolant environment. The 2.5D profile is milled at a 2 mm constant axial depth of cut following the Cavity tool path by tracing the periphery of the cavity shape with corner smoothing; by mines of Computer Aided Machining strategy. Cutting tool performance is observed in terms of Cutting tool wear, Spindle load, and Surface Quality of the machined portion. The novel hollow cutting tools reveal adequate performance in Ti6Al4V shearing, securing better tool life and giving rise to smooth surface texture. Also, diminished spindle loads were observed owing to the high volume of Hybrid Nano Flood Coolant at the cutting zone through the hollow portion and supporting with external nozzle flow with immense pressure. The balanced Lubri-Cooling and increased cutting tool surface area improve the thermal health of the cutting tool during milling. Carbide Hollow cutting tools elaborate the successive performance in the decided context than Solid cutting tools.