Development of a model for the optimization of energy consumption during the milling operation of titanium alloy (Ti6Al4V)

Abstract The quest for improvement in the cost effectiveness, environmental friendliness and the energy efficiency during the machining process of titanium alloy has necessitated the use of numerical and physical experimentations for the optimization of energy consumption. The Response Surface Methodology (RSM) was employed for the numerical experimentation with the process parameters in the following range; cutting speed (250–270 mm/min), feed rate (0.05–030 mm) and axial depth of cut (0.50–3.0 mm). The physical experiments were investigated using a DMU80monoBLOCK Deckel Maho 5-axis CNC milling machine with a spindle speed of 1800 rpm. A mill cutter (SF550: HRC 40-HRC 50) was employed for the cutting operation while a KISTLER dynamometer (9257A 8-Channel Summation of Type 5001A Multichannel Amplifier) with the data acquisition system was used for the cutting force measurement. Using the 2FI model, the statistical analysis of the results obtained produced a mathematical model which correlates the process parameters as a function of the specific cutting energy. The results obtained show that the specific cutting energy, cutting speed and depth of cut increases with a decrease in feed rate. The findings of this work will assist manufacturers in the energy optimization and conservation during the machining operation of titanium alloy.