Titanium alloys are frequently utilised in applications that call for high strength at high temperatures as well as excellent mechanical resistance. This alloy has excellent mechanical properties that enable improved performance from titanium alloys. In the current research, Taguchi L25 orthogonal array of experiments were conducted first, and MCDM techniques and ANNOVA were utilised to forecast the influencing machining factors. From MCDM three methods (SAW, VIKOR & TOPSIS) prediction algorithms which rank one for experiment no. 2. Experiment results shows that experiment no. 02 gives optimum/best results in terms of Tool life and surface roughness. While the process parameter has values cutting speed = 80 rpm, Feed rate = 018 rev/mm, Depth of cut = 0.12 mm, and Rake angle = 14 degrees. From ANOVA outcome for surface finish it is noticed that the process parameter rake angle is having Rank 01 for all levels. Thus rake angle is major influencing parameter to achieve a better quality of surface roughness. While in case of flank wear it is crystal clear that the process parameter DOC is having Rank 01 for all levels. Thus DOC is most influencing parameter to achieve lesser flank wear and better quality of tool life.

This study investigates strategies for improving the 3D milling of Titanium Alloy Grade 5 (Ti6Al4V) by optimizing machining parameters and cutting tool engagement techniques. Ti6Al4V presents significant machining challenges due to its low machinability index (20%), which directly impacts manufacturing efficiency. High temperatures during machining, often exceeding 8820C, lead to phase transformations, creating a harder Beta lamellar equiaxed microstructure. This, coupled with the alloy's poor thermal conductivity, results in heat concentration at the cutting tool interface, accelerating thermo-chemical wear and potentially causing catastrophic tool failure. This study explores how controlled cooling methods, coupled with appropriate lubrication, can effectively dissipate heat and flush away chips, mitigating the detrimental effects of high temperatures. Furthermore, the selection of cutting tool materials and coatings with high thermal conductivity and chemical inertness, along with aggressive rake angles and higher relief angles, is examined as methods to improve shearing, minimize smearing, and enhance surface quality. By optimizing these parameters, this study aims to provide manufacturers with practical strategies to overcome the challenges of Ti6Al4V machining, ultimately increasing tool life and overall milling efficiency.

Titanium alloys, such as Ti6Al4V, have become increasingly prevalent in aerospace and biomedical industries owing to their exceptional mechanical properties and corrosion resistance. However, the machining of these alloys presents significant challenges including high tool wear, poor surface finish, and low productivity. This study focused on enhancing the machinability of Ti6Al4V during CNC turning using the Taguchi optimization method. This approach aims to identify the optimal cutting parameters that minimize the surface roughness, flank wear, and crater wear, thereby improving the overall machining performance. This study systematically investigated the influence of various cutting parameters on machining outcomes. The experimental results demonstrate that the Taguchi method effectively determines the optimal process parameters, leading to a significant reduction in surface roughness and tool wear. These findings highlight the potential of the Taguchi optimization technique for achieving improved machinability and sustainability in the machining of Ti6Al4V.

Cutting titanium and titanium alloys are very difficult to machined, hence quite challenging. The metal's mechanical, chemical, and physical characteristics can account for it. The material properties like elevated chemical reactivity with less thermal conductivity make titanium and titanium alloys excellent candidates for use as cutting tool materials. The temperature at a tool's cutting edge rises because of its poor heat conductivity. Additionally, titanium alloys' poor machinability is caused by bad modulus of elasticity and strong strength at elevated temperatures [1–14]. Due to its lower elasticity modulus than steel, titanium exhibits higher "springiness." Under pressure from the tool, thin parts frequently deflect, leading to issues like tolerance, chatter and tool rubbing. The tool should be appropriately formed and the overall system should be highly stiff (very sharp). The total absence of a "built-up edge," which results in a elevated shearing angle, is following crucial characteristic in titanium with titanium alloys (absence of a constant mass of metal ahead of the cutting tool). This increases more bearing loads on each unit area and thin chips contacting a very small portion of cutting tool face. Due to the strong bearing force and friction created by the chip, a very specific portion of the cutting tool becomes extremely hot. Typically, components requiring the highest dependability are made of titanium and titanium alloys, therefore surface properties must be preserved. Surface features of the component, such as surface finish and shape, as well as sub-surface properties, such as residual stress, granular plastic flow direction, and surface defects, have vital impact on machining performance of machined parts (porosity, micro-cracks, etc.). The surface polish and integrity attained following machining determine surface quality of machined parts [1–14]. The Taguchi optimization approach is taken for evaluation and prediction in the research area, which concentrates on the ideal CNC cutting conditions for turning titanium alloy (Ti6Al4V). Cutting velocity (v), feed rate (f), DOC (d), with rake angle (RA) were chosen as input process variables in turning process, while flank wear (Vb), tool life and surface finish (Ra) were taken into consideration as performance evaluation features. For conducting the tests, the Taguchi L25 orthogonal array (OA) experimental design plan was taken into consideration. According to the outcomes of the conformation tests, the Taguchi analysis that revealed the ideal process parameters greatly enhanced the turning performance when machining titanium alloy (Ti6Al4V). The ANOVA findings showed that rake angle and depth of cut significantly affected turning performance in terms of Vb and Ra.