Sustainable Machining of Titanium Alloy Ti-6Al-4V: Experimental Analysis Using Esterified Green Fluids

Abstract

Ti-6Al-4V titanium alloy is widely employed in aerospace, biomedical, defence, automotive, and cryogenic applications due to its superior strength-to-weight ratio, high-temperature stability, and corrosion resistance. Despite these advantages, its machining remains highly challenging, primarily attributed to low thermal conductivity, strong chemical reactivity with cutting tools, and inherent hardness. These characteristics lead to significant heat accumulation at the cutting interface, formation of segmented chips, dynamic cutting forces, accelerated tool wear, and compromised dimensional accuracy. To address these persistent issues, this study proposes the formulation of an eco-friendly, biodegradable cutting fluid derived from esterified Rubber Seed Oil, further enhanced with nano-additive, Molybdenum Disulphide. The proposed cutting fluid is designed to provide superior lubrication, efficient heat dissipation, and reduced friction during machining operations. A comprehensive experimental investigation will be conducted to evaluate the fluid’s performance in lowering cutting temperatures, decreasing cutting forces, and improving surface integrity across varying cutting parameters. Additionally, the study examines its effectiveness in mitigating built-up edge formation and reducing material adhesion on the tool rake face. It is anticipated that the novel green cutting fluid will extend tool life, enhance process stability, and contribute to reduced energy consumption, thereby advancing sustainable manufacturing practices. Overall, the findings are expected to deliver valuable insights into enhancing the machinability of titanium alloys while addressing environmental and performance considerations.