Scientific Research and Essays Vol. 5(11), pp.

1284-1293, 4 June, 2010

Available online at http://www.academicjournals.org/SRE
ISSN 1992-2248 ©2010 Academic Journals

Full Length Research Paper

Effect of cutting parameters on the surface roughness

of titanium alloys using end milling process
Khairi Yusuf1*, Y. Nukman1, T. M. Yusof1, S. Z. Dawal1, H. Qin Yang1, T. M. I. Mahlia2 and K. F.
Tamrin3
1
Department of Engineering Design and Manufacture, University of Malaya, 50603 Kuala Lumpur, Malaysia.
2
Department of Mechanical Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia.
3
Wolfson School of Mechanical and Manufacturing Engineering, Loughborough University, United Kingdom.
Accepted 4 May, 2010

Titanium alloys have been widely used in industries, especially aerospace industries, due to their good
mechanical and chemical properties. However, machining of titanium alloys involves expensive tooling
cost at the expense of getting good surface roughness. This paper describes a comprehensive study of
end milling of titanium alloys. The study investigated the optimum parameters that could produce
significant good surface roughness whereby reducing tooling cost. It employed the Taguchi design
method to optimize the surface roughness quality in a Computer Numerical Control (CNC) end mills.
The control parameters were spindle speed, feed rate, depth of cut and type of end milling tool. On the
other hand, the noise parameters were coolant pressure and patterns of cut. Then, an orthogonal array
7
of L8 (2 ) and analysis of variance (ANOVA) were carried out to identify the significant factors affecting
the surface roughness. The best parameters were then chosen based on the signal-to-noise ratio (SNR).
The experimental results indicated that the most significant factors affecting the surface roughness of
Titanium alloy during end milling process were primarily the spindle speed of machine, secondly, the
type of end mills tool used, thirdly, the feed rate adopted and lastly, the depth of cut chosen.

Key word: Titanium alloy, surface roughness, tool wear, ends milling, Taguchi method.

INTRODUCTION

Titanium and its alloys are used extensively in aerospace
because of their excellent combination of high specific
strength, which is maintained at elevated temperature,
their fracture resistant characteristics and their
exceptional resistance to corrosion. They are being used
increasingly in other industrial and commercial
application such as petroleum refinery, nuclear reactors,
*Corresponding author. E-mail: khairiyusuf@um.edu.my. Tel:
+60-3-7967-4464. Fax: +60-3-7967-5330.
Abbreviations: CNC, Computer numerical control; Ra,
roughness average; Rms, root-mean-square; Rq, roughness;
Ry or Rmax, maximum peak-to-valley roughness; NPM, noise
performance measure, TPM, target performance measure;
SNR, signal noise ratio; HSS, high speed steel; WC, tungsten
carbide.
surgical implants and marine application (Henriques et
al., 2005). They are also being used extensively for aero-
space industry, mainly in airframe construction, where
maximum ease of formability is desired (Kumar et al.,
2008). However, machining of titanium alloys involves
expensive tooling cost at the expense of getting good
surface roughness.
The machining of titanium and its alloys is generally
cumbersome owing to several inherent properties of the
material. Titanium is very chemically reactive and
therefore, has a tendency to weld to the cutting tool
during machining thus, leading to premature tool failure.
Its low thermal conductivity increases the temperature at
the tool-work interface thus, affecting the tool life
adversely. Additionally, its high strength maintained at
elevated temperature further impairs the machinability
(Ezugwu and Wang, 1997).
Machining of titanium alloys at higher cutting speed will
cause rapid chipping at the cutting edge which leads to

Figure 1. Titanium alloys surface features
observed using a 100× microscope objective.
catastrophic failure of the insert. A higher cutting speed
also result in rapid cratering and/or plastic deformation of
the cutting edge. The rapid tool failure and chipping at the
cutting edge has resulted in poor surface finish of the
machined surface. Since titanium alloys are generally
used for a component, which requires the greatest reliabi-
lity, therefore the surface integrity must be maintained
(Che-Haron and Jawaid, 2005). Several researches have
been conducted to find the way of machining titanium
alloys to get a good significant surface roughness. Zoya
and Krishnamurty (1998) used a cubic boron nitride
(CBN) tool in the machining of titanium alloys. The
machining performance was assessed by monitoring
process indicators such as the cutting temperature and
the cutting force. Ezugwu (2004) investigated high speed
machining of aero-engine alloys. Titanium alloys were
developed in order to satisfy the need for a class of
strong and lightweight materials for aircraft engine and
airframe manufacture. It was concluded that machining of
aero-engine alloys, including titanium alloys; generate
high temperatures at the cutting edge which impair the
performance of various cutting tool materials. Che-Haron
and Jawaid (2005) investigated the effect of machining
on surface integrity of titanium alloys. The experiment
was carried out under dry cutting conditions. It was con-
cluded that straight cemented carbides are suitable for
use in machining titanium alloy 64. Zhang et al. (2007)
conducted the research of surface roughness optimiza-
tion in an end-milling operation using the Taguchi design
method.
Unfortunately, it was not applied to titanium alloys.
Stressing on the Taguchi method dominated the
investigation. Kumar et al. (2008) investigated the
characteristics of titanium using ultrasonic machining.
Experiment has been conducted to assess the effect of
three factors-tool material. It was concluded that the sur-
face roughness of the machined surface has been found
to depend on grit size of the slurry used. Ginta et al.
(2009) developed a surface roughness models in end
milling titanium alloy using uncoated tungsten carbide
inserts.
They suggested using uncoated WC-Co inserts under
dry conditions for titanium alloys end-milling. The next
work depicted in this paper is an investigation of the
cutting parameters effect of end milling of titanium alloys.
The end milling can produce the flat surface and the
rotation of cutter is perpendicular to the work piece of
Yusuf et al. 1285
titanium alloys. In this study, the Taguchi method is used.
The investigation included optimization of the cutting
conditions of end milling in order to produce good surface
roughness. By obtaining the gain value, minimum tooling
costs for titanium alloys can be predicted.
MATERIALS AND METHODS
Titanium alloys
This research used titanium alloys of Ti-6Al-4V which has alpha ( )
– beta ( ) as stabilizers. As a typical + - type alloy, it becomes
the most widely used alloys of titanium since it has good specific
strength and corrosion resistance (Gu et al., 2001). However, it
generally contains impurity elements that affect its thermo-
mechanical properties. The microstructure of this alloy is strongly
influenced by the processing history and heat treatment (Figure 1).
Alpha-beta alloys are heat treatable and most are weldable (Zao et
al., 1999). Typical properties include:
- Strength level are medium to high
- High temperature creep strength is not as good as most alpha
alloys
- Cold forming may be limited but hot forming qualities are normally
good
- Many alloys can be super-plastically formed
Milling process
Titanium alloys which is widely used especially in aircraft industry
have special characteristics as mentioned above. The main limiting
factor in designing aircraft structures that involves dynamic loading
is the fatigue property of the materials which is related to the
surface quality. Therefore, the importance of surface integrity in
titanium alloys milling process should be in consideration.
The milling process used in this study is flat end milling process
that can produce a flat surface. The rotation of cutter is per-pen-
dicular to the work piece of titanium alloys. The flat end milling with
the multiple flute end mills solid tool is used since the center cutting
end teeth alloys allows these end mills to drill into work piece to
start a machining operation (Gill et al., (2006)). The advantage of
this multiple flute is that it can produce better surface roughness
compared to the other two flutes and three flutes of end mills.
Surface roughness evaluation
There are various simple surface roughness amplitude parameters
used in industry, such as roughness average (Ra), root-mean-
square (rms) roughness (Rq), and maximum peak-to-valley rough-
ness (Ry or Rmax), etc (Joseph and John, 2001). Since Ra and Rq
are the most widely used surface parameters in industry, Ra was
selected to express the surface roughness in this study. The
average roughness (Ra) is the area between the roughness profile
and its mean line, or the integral of the absolute value of the
roughness profile height over the evaluation length (Figure 2). The
Ra is specified by the following equation:
L
1
Ra = Y ( x) dx ( m) (1)
L0
Machining parameter
To improve the quality of surface roughness of titanium alloys and
1286 Sci. Res. Essays

Cut off length

Figure 2. Surface roughness profile (Chen and Yang, 2001).

processes with minimum cost and time constraints, the Taguchi
parameter design techniques are applied in design of experiment
(DOE). Minimum surface roughness average (Ra) was carried out
since the value represents better or improved surface roughness.
Therefore, a smaller-the-better method is implemented in this
experiment (Mori, (1990)).
The controllable parameters are selected because of their
potential effects on surface roughness performance in end milling
operations. The parameters are the cutting speed denoted as (A),
the feed rate denoted as (B), the depth of cut denoted as (C) and
the type of end mills tool denoted as (D).
By applying cutting speed, feed rate, depth of cut and type of end
mills tool as control factors and used them to measure responses
for surface roughness, signal-to-noise ratio can be calculated to
determine the optimum cutting condition (Lou MS et al., (1998)).
Since surface cutting speed is linearly correlated to feed rate, the
control variable of cutting speed was specified as spindle speed.
The spindle speed and feed rate is calculated as
1000.v
S=
π .D
FR = N .F .S
Where S = Spindle speed (rpm) D = Tool diameter (mm)
FR = Feedrate (mm/min) N = Number of flutes F = Feed (m/tooth)
Taguchi method and analysis of variant
to suitable four columns. Since only four controllable factors and
two levels are considered, the suitable of orthogonal array in this
research is L8 (27). The L8 (27) means eight trials or experiments
must be done and seven factors each has two different levels
(Table 2). The target performance measure (TPM) is essentially a
measure of the mean response. It is used to identify control factors
that largely affect the mean, and not the variability. These factors
are called target control factors. It can use target control factors to
adjust the mean response.
For noise performance measure (NPM) is essentially a measure
of the variation in response. It is used to identify control factors that
largely affect variation and not the mean. These factors are called
variability control factors. It can use variability control factors to
minimize variation. For NPM, signal noise ratio (SNR) is used as
usual. Then, the analysis of variance (ANOVA) is done by an own
created program using C language.
The calculation for TPM and NPM are:
TPM = y= Y / n (4)
Smaller-the-better for NPM:
(2)
= -10 log10 ( 2
+ y 2) (5)
(3)
Where Y = Surface roughness n = Number of result = Sample
variance.
After selection of the best four parameters, the predicted method is
used to predict the value and to check whether the experiment
value is closer to predicted value. Formulation of predicted value is:

The uncontrollable (Noise) factors are one of the important
attributes of Taguchi parameter design which is considered in the
analysis (Table 1). Coolant pressure (X) is one of the noise factors
to study. The purpose is to know whether the low or high coolant
pressure is the significant factor to affect the milling of titanium
alloys performance. In order to know whether the positive-x-
direction or positive-y-direction of cut gives significant effects to
cutting operation, the pattern of cut (Y) is another noise factor used
in this study.
Among those seven control factors, only four control factors are
selected, therefore, each of the four control factors must be assign
Ypredicted = y + (Aopt - y ) + (Bopt - y ) + (Copt - y ) (6)
After the optimal levels of all the control factors are identified, the
last step is conducting the confirmation run. The combination of the
optimal levels of all the factors should produce the optimal
magnitude of surface roughness (the smallest Ra). This conclusion
must be further supported through the confirmation runs. Ten trials
cut under the optimal parameter setup in the study for the purpose
of confirmation run, before checking the tool performance.
Comparison of the performance between tungsten carbide (WC)
and high speed steel (HSS) has formula as
 Yusuf et al. 1287

Table 1. Parameters, codes and level values used in orthogonal array.

Parameter Code Level 1 Level 2

Control factors
Spindle speed (rpm) A 2546 2865
Feed rate (mm/min) B 815 917
Depth of cut (mm) C 0.4 0.6
Type of end mills tool (Ø5 mm, 4-flute, flat end) D Tungsten carbide (WC) High speed steel (HSS)

Noise factors
Coolant pressure (pipe) X Low (1) High (2)
Pattern of cut Y +x-direction +y-direction

Response variable
Surface roughness, Ra ( m) - - -

Table 2. New L8 (27) orthogonal array effects.

Columns 1 2 3 4 5 6 7
Effects A B AxB D AxD BxD AxBxD
New effects A B - C - - D

2 RESULT AND DISCUSSION

MSD = (σ 2 + y ) (7)
η optimun −η before
Gain = 1 − 0.5 3
(8)
EXPERIMENTAL SET UP
To improve the quality of surface roughness of titanium alloys and
processes with minimum cost and time constraints, the parameter
design techniques are applied in Design of experiment (DOE).
Figure 3 shows the vertical end milling operation. The 4-flute of end
mills tool with diameter 5 mm is chosen and mounted by solid
collect.
Then Cincinnati Milacron computer numerical control (CNC) vertical
milling machine is set up. The work piece of titanium alloys is
clamped tightly against the solid jaws by soft plastic hammer to
withstand the cutting force and reduce the vibration. Then the
programming code by machine control unit (MCU) is written.
After completing the cutting operation, the air sprayer is used to
blow out the coolant oil and some wasted chips around the work
piece. The solid jaws and solid collets are opened to remove work
piece and end mills tool respectively. The optical microscope is
used to observe the feature of end mills tool and surface roughness
feature of work piece.
The tool was not changed every time of machining, but mea-
surement of the tool wear was done every time the cutting process
finish. The tool wear is measured by optical microscope equipped
with measurement software and the surface roughness is
measured by perthometer. In order to get accurate result, three
measurements were taken and averaged as shown in Figure 4.
Measurement values collected was saved in Microsoft excel file
(Version 2007) for further analysis and discussion.
In this study, the measurement is done for surface rough-
ness and tool wear. The TPM and NPM are calculated
using equation (4) and equation (5) as shown in Table 3.
The analysis of variance (ANOVA) is shown in Tables 4
and 5. The most significant factors of Rho% are factor A
(spindle speed), factor D (type of end mills tool), and
factor B (feed rate). The least significant factor is factor C
(depth of cut). Spindle speed is largely affecting the
surface roughness quality and also largely affects the tool
life. Both tables show the good result, because the Rho%
values for each factor A, factor B, factor C and factor D in
TPM ANOVA and NPM ANOVA are almost same. There-
fore, both noise factors (coolant pressure and pattern of
cut) are not significantly affected by the surface rough-
ness quality and also the tool life. The pooled error of
Rho% for both TPM (20.079%) and NPM (16.429%) are
considered lower, which means the running of this
experiment is good enough. Figures 5 and 6 show the
comparison between the factors A in TPM and NPM
response.
Smaller values of surface roughness and higher value
of the signal noise ratio at A2 lead to choose the spindle
speed at level 2 which is 2865 rpm. Since smaller values
of surface roughness are desired and higher signal noise
ratio values indicate the good performance the following
factors are selected. That are B2 (917 mm/min feed rate
at level 2), C1 (0.4 mm depth of cut at level 1) and D1
(tungsten carbide at level 1). It concluded that the best
parameters are A2, B2, C1, and D1. The best four
1288 Sci. Res. Essays
Figure 3. Procedure to setup the experiment.
Figure 4. Three spots for taking surface roughness measurements.
parameters which are selected are: A2, B2, C1, and D1.
Four factors in TPM and NPM are not conflicted, because
best four factors selected from TPM and NPM are same.
A factor that affects both the mean and variance must be
used very carefully. However, such a factor allows some
flexibility in balancing target require-ments. From Table 6,
it can be seen that the predicted values for target
performance measure (TPM) as 1.475 m and noise
performance measure (NPM) as -3.432 dB are closer to
experiment values from Table 3. The experiment values
are 1.470 m and -3.228 dB. It shows that the research is
done correctly. With this prediction, it can be concluded
that the machine produced the best surface roughness
(Ra = 1.470 m) within the range of specified cutting
conditions and the best four parameters are located at
trial 7 of experiment (Table 3).
The optimal levels for the controllable factors were
spindle speed 2865 rpm, feed rate 917 mm/min, depth of
cut 0.4 mm and type of end mills tool is tungsten carbide
(WC). In term of the experimental results, since there was
no noise factors can significantly affect the end milling
performance, any level for noise factors can be chosen.
The noise factors in confirmation run are high coolant
pressure and cutting in positive-x-direction. Table 7
shows the results of the confirmation running. Compared
with the experimental results in Table 3, the mean
surface roughness of the 10 confirmation samples 1.441
µm (Table 7), which was very close to the smallest value
 Yusuf et al. 1289

Table 3. Results of experiment orthogonal array L8 (27)

X 1 2 1 2
Y 1 2 1 2
No. exp. A B C D N1 ( m) N2 ( m) N3 ( m) N4 ( m) TPM ( m) NPM (dB)
1 1 1 1 1 1.867 1.855 1.849 1.852 1.856 -5.370
2 1 1 2 2 2.029 2.022 2.062 2.020 2.033 -6.164
3 1 2 1 2 1.961 1.956 1.974 1.978 1.967 -5.878
4 1 2 2 1 1.713 1.703 1.714 1.704 1.708 -4.652
5 2 1 1 2 1.662 1.644 1.665 1.656 1.657 -4.386
6 2 1 2 1 1.758 1.767 1.732 1.755 1.753 -4.877
7 2 2 1 1 1.470 1.445 1.442 1.443 1.450 -3.228
8 2 2 2 2 1.704 1.709 1.708 1.708 1.708 -4.647
Average 1.767 -4.900
N1, N2, N3, N4: Results of surface roughness
X: Coolant pressure Y: Pattern of cut

Table 4. Target performance measure (TPM) response.

Source Pool Sq DOF Mq F-ratio Sq' Rho%

A - 0.497 1 0.497 80.116 0.491 51.245
B - 0.109 1 0.109 17.487 0.102 10.679
C Yes 0.037 1 0.037 – – –
D - 0.179 1 0.179 28.784 0.172 17.996
Error Yes 0.137 27 0.005 – – –
Pooled Error - 0.174 28 0.006 1.000 0.192 20.079
St - 0.958 31 0.031 – 0.958 100.000
Mean - 99.865 1 – – – –
ST - 100.823 32 – – – –

Table 5. Noise performance measure (NPM) response.

Source Pool Sq DOF Mq F-ratio Sq' Rho%

A - 3.034 1 3.034 96.005 3.003 50.348
B - 0.716 1 0.716 22.656 0.684 11.477
C - 0.273 1 0.273 0.273 0.242 4.052
D - 1.087 1 1.087 34.390 1.055 17.695
Error Yes 0.853 27 0.032 – – –
Pooled Error - 0.853 27 0.032 1.000 0.980 16.429
St - 5.964 31 0.192 – 5.964 100.000
Mean - 192.109 1 – – – –
ST - 198.072 32 – – – –

1.442 µm of surface roughness in Table 3 and also the
predicted value (1.475 µm) in Table 6. The confirmation
run indicated that the selection of the optimal levels for all
the parameters produced the best surface roughness. In
order to study the performances of tungsten carbide to
reduce tooling cost, the confirmation running for high
speed steel (HSS) is created to compare the confirmation
running for tungsten carbide (WC). From the Table 3, it
can be seen that the best surface roughness for HSS is
located at trial 5. The best parameters at trial 5 are A2
(spindle speed, 2865 rpm), B1 (feed rate, 815 mm/min),
C1 (depth of cut, 0.4 mm) and D2 (high speed steel,
HSS). Noise factors are not significant factors, so just
select any level of noise factors. Ten trials of cut are
running and mean of three readings are collected in
Table 7. Comparison of the performance between WC
1290 Sci. Res. Essays

Figure 5. Target performance measure (TPM) response.

Figure 6. Noise performance measure (NPM) response.

Table 6. Predicted value.

Source Use TPM ( m) NPM (dB)

A A2 1.642 -4.285
B B2 1.708 -4.601
C C1 1.733 -4.716
D D1 1.692 -4.532
Predicted value 1.475 -3.432
 Yusuf et al. 1291

Table 7. Confirmation running for tungsten carbide (WC).

WC Surface roughness, Ra (µm)

Exp. 1 2 3 Average
1 1.416 1.436 1.458 1.437
2 1.434 1.443 1.504 1.460
3 1.445 1.441 1.471 1.452
4 1.388 1.438 1.451 1.426
5 1.472 1.478 1.408 1.453
6 1.451 1.378 1.428 1.419
7 1.351 1.453 1.438 1.414
8 1.457 1.470 1.432 1.453
9 1.458 1.454 1.433 1.448
10 1.432 1.442 1.467 1.447
Average 1.441

Table 8. Confirmation running for WC and HSS.

Number HSS WC Improve Unit

1 1.654 1.437 0.217 µm
2 1.681 1.460 0.220 µm
3 1.675 1.452 0.223 µm
4 1.654 1.426 0.228 µm
5 1.638 1.453 0.185 µm
6 1.661 1.419 0.242 µm
7 1.656 1.414 0.242 µm
8 1.664 1.453 0.211 µm
9 1.656 1.448 0.207 µm
10 1.639 1.447 0.192 µm
Mean 1.658 1.441 0.217 µm
Variance, 0.014 0.016 0.002 µm
Mean standard deviation, MSD 2.748 2.076 0.672 (µm)²
Signal noise ratio, (SNR) -4.390 -3.173 1.217 dB
Gaining - 24.5 - %

and HSS is shown in confirmation table (Table 8).
The gain in loss reduction is improved by using the
WC. The SNR of WC is higher than SNR of HSS; there-
fore selection of the WC can produce the better surface
roughness and reducing the tooling cost of 24.5%. Since
the WC has better physical and mechanical properties
than HSS, therefore the tool wear length for HSS end
mills tool should be longer than WC end mills tool. The
measurement of the length for both is done under optical
microscope by using software measurement. Figure 7
shows the length of the tool wear of HSS and Figure 8
shows the length of the tool wear of WC after end milling
process.
They can obviously be compared that the length of tool
wear of HSS is longer than the length of tool wear of WC
(the difference is 1210.19 m). Observation of the micro
structure of titanium alloys material, tungsten carbide
(WC) and high speed steel (HSS) reveal characteristics
that have a tremendous influence on their technological
utility. Some of the features that contribute to the strength
of material and tool, and virtually all of the features that
initiate mechanical failure are resolved by optical
microscopy. Thus, preparation of optical microscopy
specimens, their observation using optical microscopes,
and interpretation of photographs taken with optical
microscopes (micrographs) play a vital role to understand
the origin of material and tool properties.
Conclusion
The experimental results indicate the most significant
factors are spindle speed (A), second is type of end mills
tool (D), third is feed rate (B) and forth is depth of cut (C).
In addition, the two noise factors, coolant pressure (X)
and pattern of cut (Y), are not significantly affecting to
1292 Sci. Res. Essays

Figure 7. High speed steel (HSS) tool wear observed using a 100x microscope objective.

Figure 8. Tungsten carbide (WC) tool wear observed using a 100x microscope objective.

surface roughness quality and tool life. The spindle speed
at 2865 rpm (A2), feed rate at 815 mm/min (B2), depth of
cut 0.4 mm (C1) and Tungsten Carbide (D1) are iden-
tified as optimal through Taguchi parameter design were
able to produce the best surface roughness in order to
reduce tooling cost until 24.5%.
Titanium alloys present a unique set of machining
problems. Many of those problems can be alleviated or
eliminated by adhering to the set of guidelines, that are,
performing shallow finish machining pass to remove the
damaged layer, using large volumes of recommended
cutting fluids, using abrasion and heat resistant cutting
tools like coated carbide tool, replacing cutting tools at
the first sign of wear.
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