Design-of-experiments application in machining titanium alloys for aerospace structural components

The present investigation is an attempt to study the effect of control factors i.e. the cutting speed, the feed rate, and the titanium alloys on response variables i.e. the cutting force, the feed force and the cutting tool temperature by using the Taguchi techniques. A number of experiments were conducted using the L18 orthogonal array on a CNC vertical machining center. The machining center was configured to act as a lathe with the tool oriented to produce an orthogonal cut. A combined technique using orthogonal array and analysis of variance was employed to investigate the contribution and effects of cutting speed, feed rate and different aerospace grade titanium alloys (Ti6Al4V, Ti54M and Ti10.2.3) on two force components and cutting tool temperature. The results revealed that the feed rate was the most influential factor which affects the cutting and feed forces, while the cutting speed had most significant effect on the cutting tool temperature. Thereafter, optimal control factors were obtained for minimum response variables.