Analysis of Wiper Tool Failure and Surface Roughness in Turning of Bio-compatible Ti-6Al-4V ELI Alloy

Ti-6Al4V ELI alloy machining is a challenging task for the manufacturers because of their poor thermal conductivity, lower elastic modulus, and highly reactive at elevated temperatures. Therefore, the selection of machining parameters for this alloy is highly critical and sophisticated. To accomplish this objective, L-16 (3 factors and their 4 levels) Taguchi design is utilized to conduct the turning experiments using wiper geometry CVD-coated carbide tool under the dry environment. Application of wiper geometry cutting tool for the machining of ELI grade Ti-alloys is a novel concept as no work reported yet to use of it for machining of ELI grade of Ti-alloys. Also, high-speed machining itself a novel task for machining of Ti-alloys. Therefore, the current work selected the wiper geometry tool for machining Ti-6Al4V ELI alloys. Further, the crucial responses like flank wear (VBc), surface roughness (Ra), workpiece temperature (Tw), and material removal rate (MRR) are analyzed. Ra is found to be under control as the maximum value lies within 1 mu m, but simultaneously flank wear and workpiece temperature are relatively larger in magnitude. However, an advanced sunflower optimization (SFO) algorithm is implemented to get the appropriate response value at optimum values of input parameters. From SFO, global optimum value for VBc, Ra, Tw, and MRR is found as 0.139 mm, 0.414 mu m, 113.28 degrees C, and 46.72 g/min, respectively, while local best optimum values of input terms t, s, and v are found as 0.3071 mm, 0.0579 mm/rev, and 81.73 (m/min) respectively. Additionally, a novel modeling technique, namely multiple adaptive neuro-fuzzy inference system (MANFIS), is implemented to predict the responses and found to be very accurate and effective as root mean square error for model VBc, Ra, Tw, and MRR is found to be 0.64%, 0.15%, 0.54%, and 2.47%, respectively.