Energy Efficient Machining of Titanium Alloys by Controlling Cutting Temperature and Vibration

In this paper, a new approach is proposed to predict optimal machining conditions for most energy-efficient machining of Ti6Al4 V. First an analytical cutting force model is implemented to predict the cutting forces and cutting power, followed by the temperature prediction to estimate the cutting temperature. Then based on the cutting temperature and stability lobes, the energy-efficient machining conditions are obtained. Thereafter experiments were performed to verify the simulation results by measuring forces with force gauges and cutting temperature using the tool-work thermocouple method. The case study shows that the proposed approach provides more stable cutting conditions as well as longer tool life using optimal cutting conditions by controlling vibration and the cutting temperature.