An Experimental Investigation of the High-Speed Milling of VT1–0 Titanium Alloy and Cutting Parameter Optimization Using Numerical Modeling

Karibek Sherov; Zhanara Mussina; Assylbek Kassenov; Ansagan Suleimenov; Tatyana Lub; Nadezhda Kuzminova; Saule Ainabekova; Bakytzhan Donenbayev; Zaure Ibragimova

doi:10.48084/etasr.18550

Authors

Karibek Sherov S. Seifullin Kazakh Agrotechnical Research University, Astana, Kazakhstan
Zhanara Mussina Toraighyrov University, Pavlodar, Kazakhstan
Assylbek Kassenov Toraighyrov University, Pavlodar, Kazakhstan | Kazakh National University of Water Management and Irrigation, Taraz, Kazakhstan
Ansagan Suleimenov Toraighyrov University, Pavlodar, Kazakhstan
Tatyana Lub Toraighyrov University, Pavlodar, Kazakhstan
Nadezhda Kuzminova Karaganda Industrial University, Temirtau, Kazakhstan
Saule Ainabekova Karaganda Industrial University, Temirtau, Kazakhstan
Bakytzhan Donenbayev Abylkas Saginov Karaganda Technical University, Karaganda, Kazakhstan
Zaure Ibragimova M. Auezov South Kazakhstan State University, Shymkent, Kazakhstan

Volume: 16 | Issue: 4 | Pages: 37748-37758 | August 2026 | https://doi.org/10.48084/etasr.18550

Received: 5 March 2026 | Revised: 13 May 2026 and 31 May 2026 | Accepted: 2 June 2026 | Online: 19 June 2026

Corresponding author: Zhanara Mussina

Abstract

This paper presents the results of an experimental study on high-speed milling of the VT1–0 titanium alloy. A solid carbide end mill, MC089, with a diameter of 16 mm, was used as the cutting tool. The results indicated that the influence of the cutting parameters on the machined surface roughness is complex. An increase in spindle speed has a positive effect on surface roughness, whereas an increase in feed rate and depth of cut has a negative effect. The optimal cutting parameters were determined as follows: spindle speed n_sp=4200 rot/min, depth of cut t=1 mm, and feed rate S=4500 mm/min. A numerical modeling methodology was developed to determine the optimal cutting parameters for the same process. A three-dimensional model of the "tool–workpiece" system was developed using KOMPAS-3D and ANSYS Workbench, and the Johnson–Cook material failure model was selected. The contact interaction was defined, and a finite element model was developed. A numerical design of experiments was carried out using a rational planning method with variation of the main machining parameters, including depth of cut, feed rate, and spindle speed. As a result, temperature fields, contact forces, and plastic strain distributions were obtained. In addition, a mathematical model was developed to predict the workpiece temperature as a function of machining parameters. The minimization of the objective function enabled identifying the optimal cutting parameters that ensure minimal thermal impact: depth of cut t = 1 mm, feed rate S = 4500 mm/min, and spindle speed n_sp = 4162 rot/min. Comparison with the experimental results showed a slight discrepancy in the optimal cutting values. The proposed methodology can be used to reduce the cost of conducting physical experiments and improve machining efficiency.

Keywords:

titanium alloys, high-speed milling, end mill, cutting tool wear, surface roughness, numerical modeling, cutting parameters

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