Titanium Alloy Grade 5 (Ti6Al4V) is a strong, lightweight, corrosion-resistant, and highly recommended material for various Aerospace components. The machining efficiency during milling is poor due to a lack of proper cooling and lubrication. Also, Ti6Al4V’s sensitive metallurgy will affect the Material Removal Rate and Tool wear. The selection of shearing process parameters and proper cooling method is a crucial success in machining Ti6Al4V. The article explains the experimental investigation of open pocket milling under various cooling methods and shearing parameters through the Taguchi Design of Experiments. The L9 orthogonal array combines cutting speed, feed, Depth of Cut, and Cooling methods in a systematic way. The investigation was conducted through Cavity milling Computer-Aided Machining strategy with PVD-TiN coated insert. The experimental results wear measured in terms of Average Surface Roughness, Flank, and Crater Wear. Investigation proves that Nano Hybrid Flood Coolant + Cryogenic Air releases adequate lubrication and cooling. Consecutively reduction in the cutting tool wear is measured by scanning electron microscopy. The effective combination of process parameters viz. cutting speed=60 m/min, feed rate=0.19 mm/rev, axial depth of cut=0.35 mm under Nano Hybrid Flood Coolant + Cryogenic Air is delving by Grey Relational Approach.
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