One of the biggest challenges in precision micro-machining of titanium alloys is the tool
wear as titanium is characterised as a “difficult to cut” material. Tool coatings provide
a promising solution for the problem of tool wear while offering a low cost high value
machining route.
This project aims to explore the design of engineering material systems along with
machining parameters to guide the choice of tool coating while machining biomedical
grade Ti-6Al-4V. The overarching aim is to identify a low cost tooling such as WC coated
with the right coating composition together with the appropriate machining parameters.
The research methodology applied to work towards this aim employs a design of experimental approach using the Taguchi method such that the spindle speed, feed rate and
coating would be varied.
Both qualitative and quantitative analysis of the machining process was carried out to
qualify the machining performance. During the machining trials, data was gathered and
analysed to study the effect of cutting parameters on the specific cutting energy, material
removal rate and surface roughness.PhD in Manufacturin
