Optimization of Machining Parameters for Vibration-Assisted Turning of Ti6Al4V Alloy Using Analysis of Variance

Abstract

In this study, Taguchi-based analysis of variance (ANOVA) is adopted for optimization of lower-frequency vibration-assisted turning (LVAT) process parameters such as cutting speed, frequency, amplitude, and feed rate. Machining parameters are analyzed by evaluating maximum cutting force and tensile maximum circumferential residual stress (MCRS) in VAT of Ti6Al4V alloy. Finite element simulations are performed in ABAQUS according to L27 orthogonal array to find the optimum condition for maximum cutting force and MCRS (tensile). Results show that the vibrating parameters, frequency, and amplitude are most significant for maximum cutting force and MCRS (tensile), respectively. The optimum condition is obtained at 30 m/min of cutting speed, 150 μm of amplitude, 600 Hz of frequency, and 0.05 mm/rev of feed rate for cutting force while the optimum condition for MCRS (tensile) is 45 m/min of cutting speed, 50 μm of amplitude, 200 Hz of frequency, and 0.15 mm/rev of feed rate.