Evaluation of specific cutting energy, tool wear, and surface roughness in dry turning of titanium grade 3 alloy

Titanium-based alloys find their applications in aerospace, automotive, and food-processing industries owing to their high corrosion resistance and strength-to-weight ratio. Due to its high industrial importance and superior machining characteristics, titanium alloys are being extensively used worldwide. This specific project is related to analyze the variations in output responses like surface roughness, specific cutting energy, and tool wear rate by changing machining parameters like cutting speed, feed rate, and depth of cut for commercially pure titanium grade 3 alloy. Three levels of cutting speed (75 m/min, 100 m/min, 125 m/min), feed rate (0.16 mm/rev, 0.2 mm/rev, 0.24 mm/rev), and depth of cut (0.8 mm, 1.2 mm, 1.6 mm) were chosen for the experimentation. L9 orthogonal array (TAGUCHI DOE) was chosen for the design of experiments. The best and worst conditions for each of the individual output responses were identified, and it was seen that the SCE can be saved by up to 34.78%, surface roughness can be decreased by 44%, and R can be decreased by 17.74% if the conditions are chosen wisely when these are our required parameters individually. The results showed that cutting speed had the highest contribution ratio for specific cutting energy and tool wear rate, whereas feed rate had the highest contribution ratio for surface roughness. Regression analysis was done for developing empirical models which proved to be highly accurate when validated against experimental results.