Comparison of conventional drilling and helical milling for hole making in Ti6Al4V titanium alloy under sustainable dry condition

Hole drilling in Ti6Al4V titanium alloy is challenging due to its poor machinability resulting from high-temperature strength and low thermal conductivity. Therefore, an evaluation of the helical milling process carried out by comparing thrust force, surface roughness, machining temperature, burr size, hole diametrical accuracy with conventional process. The results indicate advantage terms lower magnitude force. holes generated using displayed a superior finish at axial feed conditions, while higher conditions result chatter tool deformation. Also, absence heat-affected zone (HAZ) under dry indicates work formation without damage. Besides, significant reduction size burrs noted during temperature. Analysis diameter reinforces capability for processing H7 quality holes. Consequently, can be considered sustainable alternative mechanical drilling, considering ability machine conditions.