Experimental and numerical study of chip formation in orthogonal cutting of Ti-5553 alloy: the influence of cryogenic, MQL, and high pressure coolant supply

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

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Numerical Study of Bicomponent Droplet Vaporization in a High Pressure Environment

Volume 3: Coal, Biomass and Alternative Fuels; Combustion and Fuels; Oil and Gas Applications; Cycle Innovations ◽

10.1115/96-gt-442 ◽

1996 ◽

Cited By ~ 15

Author(s):

J. Stengele ◽

H.-J. Bauer ◽

S. Wittig

Keyword(s):

High Pressure ◽

High Temperature ◽

Gas Phase ◽

Numerical Study ◽

Droplet Evaporation ◽

Single Component ◽

Vapor Concentration ◽

Diffusion Limit ◽

Evaporation Process ◽

Droplet Vaporization

The understanding of multicomponent droplet evaporation in a high pressure and high temperature gas is of great importance for the design of modern gas turbine combustors, since the different volatilities of the droplet components affect strongly the vapor concentration and, therefore, the ignition and combustion process in the gas phase. Plenty of experimental and numerical research is already done to understand the droplet evaporation process. Until now, most numerical studies were carried out for single component droplets, but there is still lack of knowledge concerning evaporation of multicomponent droplets under supercritical pressures. In the study presented, the Diffusion Limit Model is applied to predict bicomponent droplet vaporization. The calculations are carried out for a stagnant droplet consisting of heptane and dodecane evaporating in a stagnant high pressure and high temperature nitrogen environment. Different temperature and pressure levels are analyzed in order to characterize their influence on the vaporization behavior. The model employed is fully transient in the liquid and the gas phase. It accounts for real gas effects, ambient gas solubility in the liquid phase, high pressure phase equilibrium and variable properties in the droplet and surrounding gas. It is found that for high gas temperatures (T = 2000 K) the evaporation time of the bicomponent droplet decreases with higher pressures, whereas for moderate gas temperatures (T = 800 K) the lifetime of the droplet first increases and then decreases when elevating the pressure. This is comparable to numerical results conducted with single component droplets. Generally, the droplet temperature increases with higher pressures reaching finally the critical mixture temperature of the fuel components. The numerical study shows also that the same tendencies of vapor concentration at the droplet surface and vapor mass flow are observed for different pressures. Additionally, there is almost no influence of the ambient pressure on fuel composition inside the droplet during the evaporation process.

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Evaluation of Performance of Various Coolant Grades When Turning Ti-6Al-4V Alloy With Uncoated Carbide Tools Under High-Pressure Coolant Supplies

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4041778 ◽

2018 ◽

Vol 141 (1) ◽

Cited By ~ 2

Author(s):

Emmanuel O. Ezugwu ◽

Rosemar B. da Silva ◽

John Bonney ◽

Eder S. Costa ◽

Wisley F. Sales ◽

...

Keyword(s):

High Pressure ◽

Failure Modes ◽

Physical Damage ◽

Evaluation Of Performance ◽

Life Tool ◽

Resistance To Oxidation ◽

Tension Properties ◽

Almost All ◽

Coolant Delivery ◽

High Pressure Coolant

This work presents the evaluation of three commercially available coolant grades (dicyclohexylamine-based coolant, a triethanolamine-based coolant, and an ester-based coolant) when machining Ti-6Al-4V alloy with high-pressure coolant delivery. The evaluations were based on tool life, tool failure modes, surface integrity, and chip formation. The dicyclohexylamine-based coolant was the more effective coolant when machining at the highest pressure of 20.3 MPa due to its stability at elevated temperature, whereas the triethanolamine-based coolant performed effectively at a pressure of 11 MPa due to its low surface tension properties. Deterioration of the ester-based coolant was found in almost all coolant pressures due to its low resistance to oxidation. Surfaces generated when machining with all coolants grades were generally acceptable with negligible physical damage.

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