Volume 8, 2021
|Number of page(s)||13|
|Published online||20 April 2021|
Comparison of conventional drilling and helical milling for hole making in Ti6Al4V titanium alloy under sustainable dry condition
Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal 576 104, Karnataka, India
Accepted: 6 April 2021
Hole drilling in Ti6Al4V titanium alloy is challenging due to its poor machinability resulting from high-temperature strength and low thermal conductivity. Therefore, an evaluation of the helical milling process is carried out by comparing the thrust force, surface roughness, machining temperature, burr size, and hole diametrical accuracy with the conventional drilling process. The results indicate the advantage of the helical milling in terms of the lower magnitude of thrust force. The holes generated using helical milling displayed a superior surface finish at lower axial feed conditions, while higher axial feed conditions result in chatter due to the tool deformation. Also, the absence of a heat-affected zone (HAZ) under dry helical milling conditions indicates the work surface formation without thermal damage. Besides, a significant reduction in the size of the burrs is noted during helical milling due to lower machining temperature. Analysis of the hole diameter reinforces the capability of the helical milling process for processing H7 quality holes. Consequently, helical milling can be considered a sustainable alternative to mechanical drilling, considering its ability to machine quality holes under dry machining conditions.
Key words: Ti6Al4V titanium alloy / helical milling / drilling / force / surface roughness / temperature
© S. Akula et al., Published by EDP Sciences 2021
This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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