Improving material removal rate in macro electrolyte jet machining of TC4 titanium alloy through back-migrating jet channel

2021 ◽  
Vol 71 ◽  
pp. 489-500
Author(s):  
Minglu Wang ◽  
Ningsong Qu
Keyword(s):  
Titanium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Tc4 Titanium Alloy ◽  
Electrolyte Jet

Experimental Investigation of Abrasive Waterjet Machining of Titanium Graphite Laminates

2016 ◽  
Vol 10 (3) ◽  
pp. 392-400 ◽  
Author(s):  
M. Ramulu ◽  
◽  
Vara Isvilanonda ◽  
Rishi Pahuja ◽  
Mohamed Hashish ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Titanium Alloy ◽  
High Temperature ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Material System ◽  
Operating Variables

High temperature Fiber Metal Laminate – Titanium/Graphite (Ti/Gr) is an advanced material system, developed to meet the high temperature requirements in aerospace applications. High specific strength and stiffness of composite core along with its protection from aggressive environment by tough titanium alloy sheets qualify FMLs for a promising alternative material where metallic and composites overcome each other's limitations. However, industrial employability of this three phase system is often limited by the machining challenges posed by the difference in material removal mechanisms of Titanium alloy, PIXA thermoplastic polyimide resin and graphite fibers. An experimental investigation was conducted to evaluate the machinability of 1 mm thick Ti/Gr laminate sheets through Abrasive Waterjet (AWJ) machining process in terms of kerf characteristics and material removal rate. The parametric influence of AWJ operating variables on machining performance was studied by systematically measuring operating variables (traverse speed and Abrasive flow rate) using fully crossed Design of experiment (DOE) scheme, and statistically analyzing using ANOVA (Analysis of variance) technique. Empirical models were developed to quantify these effects and predict the influence of process parameters on material removal rate, kerf taper, entry damage width and overcut in straight cutting of Ti/Gr sheets.

Statistical analysis of material removal rate and surface roughness in electrical discharge turning of titanium alloy (Ti-6Al-4V)

2016 ◽  
Vol 232 (9) ◽  
pp. 1603-1614 ◽  
Author(s):  
Vikas Gohil ◽  
Yogesh M Puri
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Peak Current ◽  
Pulse On Time

Electrical discharge turning is a unique form of electrical discharge machining process, which is being especially developed to generate cylindrical forms and helical profiles on the difficult-to-machine materials at both macro and micro levels. A precise submerged rotating spindle as a work holding system was designed and added to a conventional electrical discharge machine to rotate the workpiece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating workpiece; thus, mirror image of the tool is formed on the circumference of the workpiece. The machining performance of electrical discharge turning process is defined and influenced by its machining parameters, which directly affects the quality of the machined component. This study presents an investigation on the effects of the machining parameters, namely, pulse-on time, peak current, gap voltage, spindle speed and flushing pressure, on the material removal rate (MRR) and surface roughness (Ra) in electrical discharge turning of titanium alloy Ti-6Al-4V. This has been done by means of Taguchi’s design of experiment technique. Analysis of variance as well as regression analysis is performed on the experimental data. The signal-to-noise ratio analysis is employed to find the optimal condition. The experimental results indicate that peak current, gap voltage and pulse-on time are the most significant influencing parameters that contribute more than 90% to material removal rate. In the context of Ra, peak current and pulse-on time come up with more than 82% of contribution. Finally, the obtained predicted optimal results were verified experimentally. It was shown that the error values are all less than 6%, confirming the feasibility and effectiveness of the adopted approach.

Multi-Response Optimization of CNC WEDM Process Parameters for Machining Titanium Alloy Ti 6AI-4V Using Response Surface Methodology (RSM)

2014 ◽  
Vol 541-542 ◽  
pp. 354-358 ◽  
Author(s):  
C. Nandakumar ◽  
B. Mohan
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Titanium Alloy ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Response Optimization ◽  
Wedm Process

This research deals with the multi-response optimization of CNC WEDM process parameters for machining titanium alloy Ti 6AI-4V using Response Surface Methodology (RSM) to achieve higher Material Removal Rate (MRR) and lower surface roughness (Ra). The process parameters of CNC WEDM namely pulse-on time (TON), pulse-off time (TOFF) and wire feed rate (WF) were optimized to study the responses in terms of material removal rate and surface roughness. The surface plot and the contour plots were generated between the process parameters and the responses using MINITAB software. The results show that the Response surface methodology (RSM) is a powerful tool for providing experimental diagrams and statistical-mathematical models to perform the experiments appropriately and economically.

Powder Mixed Micro Electro Discharge Milling of Titanium Alloy: Investigation of Material Removal Rate

2011 ◽  
Vol 383-390 ◽  
pp. 1759-1763 ◽  
Author(s):  
Mohammad Yeakub Ali ◽  
Nur Atiqah Binti Abdul Rahman ◽  
Erniyati Binti Mohamad Aris
Keyword(s):  
Titanium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Dielectric Fluid ◽  
Optimum Level ◽  
Machining Parameters ◽  
Micro Edm ◽  
Discharge Energy ◽  
Powder Concentration

This paper presents effects of silicon carbide (SiC) powder in dielectric fluid of micro EDM on material removal rate (MRR). The aim is to identify the optimum level of SiC powder concentration and other micro EDM parameter for higher MRR. The work material was titanium alloy (Ti-6Al-4V) machined with tungsten carbide (WC) electrode by varying two machining parameters SiC powder concentrations and discharge energy. By using two factor four level factorial design of experiment, sixteen experiments were conducted. Data were analyzed by Design Expert® software. In this experimental investigation, maximum MRR of 7.3 µg/min was obtained for 24.75 g/l SiC powder concentration and 56.77 µJ discharge energy. The analysis of variance revealed that the SiC powder concentration in dielectric fluid on micro EDM has significant influence on MRR Ti-6Al-4V titanium alloy.

Effect of Insert Style in Milling of Titanium Alloy (TC18)

2012 ◽  
Vol 159 ◽  
pp. 99-103
Author(s):  
Pei Pei Zhang ◽  
Zi Dong Yin ◽  
Xue Yan
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Material Removal Rate ◽  
Modulus Of Elasticity ◽  
Material Removal ◽  
Removal Rate ◽  
Chemical Reactivity ◽  
Machining Parameters ◽  
The Poor ◽  
Low Modulus

Titanium alloy (TC18) is new style alloy (α+β). It possesses better performances than common titanium alloy. However, Titanium alloy (TC18) is still classified as difficult-to-machine materials for their poor machinability, which is attributed to relatively low modulus of elasticity, strong alloying tendency or chemical reactivity with cutting materials at higher temperatures and low conductivity of heat generated by the cutting action. Due to the poor machinability of the alloys, selecting of insert style is crucial for tool life and material removal rate. In this work, milling tests, using three kinds of inserts (KC522M, YD201 and SANDVIK 4240), were carried out on this kind of titanium alloy (TC18). The results of tests show that the material removal rate of insert KC522M is the highest, but its tool life is shorter compared with insert SANDVIK 4240. The material removal rate and tool life of insert YD201 do not draw the attention because both of them are relatively low. The abrasion speed of insert SANDVIK 4240 is slow and the efficiency is high, so it is ideal for machining titanium alloy (TC18). In addition, the optimal machining parameters of insert SANDVIK 4240 for milling titanium alloy (TC18) were also given in this paper.

scholarly journals A New Cutting Tool Design for Cryogenic Machining of Ti–6Al–4V Titanium Alloy

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 477 ◽  
Author(s):  
Alborz Shokrani ◽  
Stephen Newman
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Tool Life ◽  
Material Removal Rate ◽  
Surface Integrity ◽  
Material Removal ◽  
Cutting Tool ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cryogenic Machining

Titanium alloys are extensively used in aerospace and medical industries. About 15% of modern civil aircrafts are made from titanium alloys. Ti–6Al–4V, the most used titanium alloy, is widely considered a difficult-to-machine material due to short tool life, poor surface integrity, and low productivity during machining. Cryogenic machining using liquid nitrogen (LN2) has shown promising advantages in increasing tool life and material removal rate whilst improving surface integrity. However, to date, there is no study on cutting tool geometry and its performance relationship in cryogenic machining. This paper presents the first investigation on various cutting tool geometries for cryogenic end milling of Ti–6Al–4V alloy. The investigations revealed that a 14° rake angle and a 10° primary clearance angle are the most suitable geometries for cryogenic machining. The effect of cutting speed on tool life was also studied. The analysis indicated that 110 m/min cutting speed yields the longest tool life of 91 min whilst allowing for up to 83% increased productivity when machining Ti–6Al–4V. Overall the research shows significant impact in machining performance of Ti–6Al–4V with much higher material removal rate.

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