In the present paper, the Inconel alloy's heat-based machining has been conducted to analyse this influence on surface integrity. The pre-heating softens the workpiece, which indeed reduces the yield strength to make machining easier. However, the impact of pre-heating on residual stress required more focus, which indeed has an impact on fatigue life, so the experiments conducted with different cutting conditions such as speed, cutting tool, feed rate, and depth of cut with reducing of residual stress and surface roughness. The experimental results are compared with simulation results performed using ABAQUS/Explicit, which are acceptable. The optimal parameters determined using grey relational analysis (GRA) optimisation approach are TiN coated tool, speed 50 m/min, feed 0.11 mm/rev, depth of cut 0.3 mm, and pre-heating temperature 600 degrees C. From the obtained optimum parameters, the experiment has been carried out to validate the result. From ANOVA, it is identified that the pre-heating temperature is the top influential factor among all the factors.

The aim and objective of the project work is the modeling of control surface which has complex three dimensional aerodynamic profiles using solid works software, performing analysis of the model with the imposed loads and boundary conditions using ANSYS to estimate the maximum stress and deflection. The material used for this component is titanium alloy (Ti-6Al-4V) which has good properties like resistance to corrosion, high strength to weight ratio, which are mostly needed for aerospace vehicles. The actual dimensions of control surface are 350×225×20. The model of the control surface is scaled to 1:2 for manufacturing using Proe/Manufacturing module, the part programmes are generated and are transferred to the specific machine through DNC system.Control surface is probably the most commonly used form of missile control, particularly for long range airto-air missiles and surface-to-air missiles. The primary reason for this application is because tail provides excellent maneuverability at high angles of attack.Deckel E3LV CNC milling machine has been used for manufacturing the control surface. Development of 3D model using solid works then it is transferred to PROE software for generating error-free tool path and checking the tool path using simulation. Post processing of CL (cutter location) Data file to generate CNC part program, transferring the same to the respective machine tool via DNC system from CAM workstation and manufacturing of the control surface. Co-ordinate measuring machine (CMM) is used for the inspection of features, as the control surface is having complex three-dimensional aerodynamic profile. On this machine, every dimension of the control surface has been inspected and found that the dimensions are within the design considerations of the given design.