Influence of Machining Parameters on Surface Roughness in Trochoidal Milling of Ti-6Al-4V via Response Surface Methodology

Nur Aina Farhanah Aziz; Norfauzi Tamin; Kahirol Mohd Salleh; Hairizal Osman; Tun Danish Tun Mohamed Kamarul

doi:10.5614/j.eng.technol.sci.2026.58.5.3

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Nur Aina Farhanah Aziz Faculty of Technical and Vocational Education, Universiti Tun Hussein Onn Malaysia, Parit Raja, Batu Pahat 86400, Johor, , Malaysia
Norfauzi Tamin
norfauzi@uthm.edu.my
a:1:{s:5:"en_US";s:48:"Fakulti Pendidikan Teknikal dan Vokasional, UTHM";}, Malaysia
Kahirol Mohd Salleh Faculty of Technical and Vocational Education, Universiti Tun Hussein Onn Malaysia, Parit Raja, Batu Pahat 86400, Johor, , Malaysia
Hairizal Osman Faculty of Industrial and Manufacturing Technology and Engineering, Universiti Teknikal Malaysia Melaka, Air Keroh, Melaka 75400, , Malaysia
Tun Danish Tun Mohamed Kamarul Resonac Pte Ltd, 2 Pioneer Cres, Singapore 628553, Singapore

Vol. 58 No. 5 (2026): Vol. 58 No. 5(2026): October (In Progress)

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Accepted May 4, 2026

Published August 11, 2026

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Machining of Ti-6Al-4V titanium alloy poses significant challenges, mainly due to its low thermal conductivity and tendency to form a built-up edge (BUE), which can lead to high surface roughness (Ra) and rapid tool wear. In this context, the trochoidal milling strategy emerges as a promising solution, as it can reduce thermal and mechanical loads by using a spiral-shaped tool path with intermittent contact between the tool and Ti-6Al-4V. Therefore, this research aims to evaluate the effectiveness and optimise the machining parameters, specifically, cutting speed (v_c) and feed rate (v_f), when using the trochoidal strategy for machining Ti-6Al-4V, with the primary objective of minimising Ra. The methodology used is Response Surface Methodology (RSM) with a Central Composite Design (CCD) to model the nonlinear relationships among v_c, v_f, and Ra. The experiment was conducted using a 3-axis CNC machining centre with carbide cutting tools. Based on the optimisation results, the optimal parameter combination to minimise Ra is 155 m/min for v_c and 124 mm/min for v_f. Experimental validation tests of the predicted optimal parameters yielded an Ra value of 0.118 μm, with an error of 2.47% relative to the RSM-predicted value, confirming the model’s applicability. In conclusion, this research confirms that targeted parameter optimisation using RSM is highly effective in improving the surface quality of Ti-6Al-4V, further proving the potential of the trochoidal strategy as an efficient method for critical applications in the aerospace and biomedical sectors where surface integrity is a prerequisite.

Aziz, N. A. F., Tamin, N., Salleh, K. M., Osman, H., & Kamarul, T. D. T. M. (2026). Influence of Machining Parameters on Surface Roughness in Trochoidal Milling of Ti-6Al-4V via Response Surface Methodology. Journal of Engineering and Technological Sciences, 58(5), 641–651. https://doi.org/10.5614/j.eng.technol.sci.2026.58.5.3

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