Comparative solutions for optimizing the cutting parameters when turning titanium alloy Ti-6Al-4V

Abstract

This paper introduces some traditional and modern cutting parameters optimization (CPO) methods, specifically applied for the Ti-6Al-4V alloy, the most common material in the Ti-alloys, that also belong to the group of typically difficult-to-machine materials. The single and multi-objective optimization models have been mathematically rigorously built, using the reliable experimental data set according to the full factorial model. Five optimization methods were used for comparison. They give quite similar and realistic solutions. The average value of the calculated results only deviates (0.2 ÷ 2.3)% from the confirmation test. In the case study, the economic benefit from optimization is significant, the machining cost is only 56% of the average value of the experimental options; the cost for cutting tools accounting for about (17 ÷ 45)%, which cannot be ignored as in the case of conventional structural steel. Similar results can be predicted for the materials in the same group, such as stainless steel, Ni, or Co-based alloys.