Enhancing Sustainability in Titanium Machining: Simulated and Experimental Insights into PVD & CVD Carbide Inserts Applications

In this article we proposed, an extensive investigation of environmentally friendly methods for machining titanium alloy (Ti–6AL–4V), a vital component of the aerospace and biomedical sectors, is presented. The novelty of the proposed work is to improve sustainability by applying various technologies, particularly carbide inserts made by Physical Vapour Deposition (PVD) and Chemical Vapour Deposition (CVD). These components are essential for increasing machining productivity and reducing environmental impact. Moreover, to optimise the entire process, the experimental inquiry entails a methodical analysis of machining parameters, such as cutting speed, feed rate, and depth of cut. Apart from these we have also provides the superior machining performance with lower energy use and good surface roughness is the novelty of the work. Moreover, this work emphasizes the importance of feed rate, cutting speed, and depth of cut in obtaining greater energy efficiency during titanium alloy machining. PVD and CVD carbide inserts provide consistent performance across a wide range of tools, increasing their dependability and making them attractive options for energy-efficient and environmentally friendly machining methods. Furthermore, compared to CVD-coated inserts, which achieve an optimal surface roughness of 0.232 µm under cutting parameters of 75 mm/min feed rate, 0.035 mm/rev feed, and a 0.5 mm depth of cut, PVD-coated inserts exhibit an optimal surface roughness of 0.258 µm under similar conditions. The consistent performance of both PVD and CVD carbide inserts across a range of tools enhances their reliability and usefulness in green manufacturing applications. The research takes into account the environmental effects of PVD and CVD carbide inserts, in line with the ideas of green manufacturing.