JMS_V3_N2_RP1 Mukund Dutt Sharma Rakesh Sehgal Mohit Pant Journal on Material Science 2347–615X 3 2 1 13 Ti6Al4V Alloy, Machinability, Main Cutting Force, Tool Tip Temperature, Stress, Power Consumption, Average Surface Roughness, Tool Wear To improve the machinability of Titanium ASTM B-348 grade-5 alloy, an attempt has been made to study the effect of machining variables on response parameters which was further validated by literature, SEM (Scanning Electron Microscopy), EDS (Energy Dispersive X-ray Spectroscopy) of tool inserts and chips collected at different conditions. The results reveal that with the increase in feed rate at constant depth of cut, both the main cutting force and the tool tip temperature increase. The dominant wear mechanisms responsible for the crater wear on rake face are adhesion, diffusion wear and chipping at nose of tool insert. Stress or specific cutting force (Kc) decreases with increase in cutting speed from 80 m/min to 140 m/min at all depths of cut with a few exceptions. The power consumption increases with increase in the cutting speed and decrease in depth of cut having maximum value at maximum feed rate, maximum cutting speed and minimum depth of cut. Average surface roughness increases with increase in feed rate and decrease in depth of cut and the peak value of average surface roughness was obtained at 100 m/min cutting speed, because of the presence of severe crater wear. The microscopic analysis of chips indicate the formation of serrated secondary tooth in addition to adiabatic shear bands at different cutting speeds which has significant effect on the main cutting force; thus increasing the tool tip temperature and enhancing the tool wear. July – September 2015 Copyright © 2015 i-manager publications. All rights reserved. i-manager Publications http://www.imanagerpublications.com/Article.aspx?ArticleId=3501