Ti6A14V is a well-known ‘Difficult to Cut’ material in the aerospace industry. Ti6Al4V shows strain hardening, poor thermal conductivity and chemical reactivity at elevated temperatures, which implies low machinability. This work presents an experimental investigation of 3D finish milling of Ti6Al4V material by Taguchi design of experiments, having L25 array. The considered process parameters are cutting speed, feed, depth of cut, tool type, coolant type and computer aided manufacturing strategy. The experimentation is conducted on the 3D finish milling process, and the performance in terms of tool life, tool wear and surface integrity were recorded. The fuzzy technique for order of preference by similarity to ideal solution, a multiple-criteria decision-making tool, was applied on experimental responses. The yielded optimum results are derived at minimum cutting speed, moderate depth of cut, feed rate per tooth and collaboration under high concentrated wet lubrication using a PVD-TiAlN cutting tool driven by streamline computer aided manufacturing strategy. In addition, analysis of variance confirms the influential process parameter contribution on the respective performance. Finally, optimised process parameters were applied for the gear bracket finish milling through streamline CAM strategy, which results in minimum flank and crater wear with an average surface roughness of 0.17 microns.

The Ti6Al4V is an eminent material by its high strength, dimensional stability, lower weight and corrosion resistance. Its lower thermal conductivity leads to poor machinability by exhibiting metallurgical alterations. This article discusses the details of dry, wet, cryogenic, minimum quantity lubrication and hybrid cooling methods in the milling of Ti6Al4V. Dry cooling has a worse acute effect on tool life and surface quality by thermal degradation. The widespread high-pressure cooling controls heat dissipation, but cutting tools are affected by chipping and adhesion under long-run milling. In the first instance, cryogenic cooling like liquid nitrogen and liquid carbon dioxide assisted cooling shows excellent tool life and surface integrity; however, excessive uncontrolled chilling and abnormal lubrication affect milling performance. Minimum quantity lubrication with nanoparticles and their combination with multi-wall carbon nanotubes improves the machinability by balanced cooling and lubrication under the concept of green manufacturing engineering. Indirect hybrid cryogenic cooling is a new era in superalloy’s cooling methods for long-run applications. The prime drive of this review is to formulate a bridge between cooling and performance under sustainability concerns and propounds the hybrid nanofluids and indirect hybrid cryogenic cooling being the future of Ti6Al4V milling under the mapping of sustainable scale.