Microstructural analysis of failure progression for coated carbide tools during high-speed milling of Ti-6Al-4V

TA15 (Ti-6.5Al-2Zr-1Mo-1V) is a close alpha titanium alloy strengthened by solid solution with Al and other component. A series of experiments were carried out on normal and high speed milling of TA15. The recommended tools for many years had been the uncoated tungsten carbide grade K. In this work, the tool life of coated carbide tools used in high speed milling of forging and cast titanium alloy was studied. Additionally, the wear mechanism of cutting tools was also discussed. Finally, surface integrity, including surface roughness, metallograph and work hardening, were examined and analyzed. The result shows that the surface quality of forging and cast machined by carbide cutter is similar, but the tool life of carbide in high speed milling of forging TA15 is longer than that in high speed milling of cast TA15.

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Study on the Tool Wear of Coated Carbide Tool in High Speed Milling Titanium Alloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.526 ◽

2014 ◽

Vol 800-801 ◽

pp. 526-530 ◽

Cited By ~ 2

Author(s):

Shu Cai Yang ◽

Yu Hua Zhang ◽

Quan Wan ◽

Jian Jun Chen ◽

Chuang Feng

Keyword(s):

Titanium Alloy ◽

Tool Wear ◽

Tool Life ◽

High Speed ◽

Carbide Tool ◽

High Speed Milling ◽

Coated Carbide Tool ◽

Fluid Environment ◽

Coated Carbide ◽

Coated Carbide Tools

The milling experiments were carried out using TiAlN and PCD coated carbide tools in high speed milling Ti6Al4V to compare and analyze tool wear and tool life of the two kinds of coating carbide tools. In addition, the effect of cooling and lubricating on tool wear is also studied. The results showed that fluid environment is not suitable for milling Ti6Al4V. PCD coating carbide tool can effectively increase the life of tool in high speed milling of Ti6Al4V.

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An Experimental Research of Dry Milling Powder Metallurgy Nickel-Based Superalloy with Coated Carbide Tools

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.500.38 ◽

2012 ◽

Vol 500 ◽

pp. 38-43 ◽

Cited By ~ 1

Author(s):

Yang Qiao ◽

Xiu Li Fu ◽

Xue Feng Yang

Keyword(s):

Powder Metallurgy ◽

Tool Wear ◽

High Speed ◽

Milling Force ◽

High Speed Milling ◽

Nickel Based Superalloy ◽

Milling Temperature ◽

And Control ◽

Coated Carbide ◽

Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This paper presents an experimental study of high speed milling of powder metallurgy nickel-based superalloy with PVD (TiAlN-TiN) coated carbide tools. Experimental measurements of milling temperature and milling force were performed. Then the surface roughness and tool wear were analyzed and discussed under dry machining conditions. The results might be helpful to guiding the selection and design of tool materials and control of tool wear in high speed milling PM nickel-based superalloy.

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The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405416666905 ◽

2016 ◽

Vol 232 (7) ◽

pp. 1273-1286 ◽

Cited By ~ 11

Author(s):

Emel Kuram

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Tool Wear ◽

Cutting Force ◽

High Speed ◽

Cutting Tools ◽

Chip Morphology ◽

High Speed Milling ◽

Ti6al4v Titanium Alloy ◽

Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

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A Study of the Sensitivity of Parameters Affecting Surface Roughness in High Speed Milling Superalloy GH4169

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.711.143 ◽

2013 ◽

Vol 711 ◽

pp. 143-148 ◽

Cited By ~ 1

Author(s):

Wei Wei Liu ◽

Xu Sheng Wan ◽

Xiao Yan Li ◽

Yuan Yu ◽

Dong Fang Wang

Keyword(s):

Surface Roughness ◽

High Speed ◽

Orthogonal Experiment ◽

Relative Sensitivity ◽

Depth Of Cut ◽

High Temperature Alloy ◽

High Speed Milling ◽

Genetic Algorithm Method ◽

Coated Carbide ◽

Carbide Inserts

The orthogonal experiment is processed for high-speed milling superalloy GH4169 with TiAlN coated carbide inserts. The empirical formula of the surface roughness is acquired by using Genetic Algorithm method. On the basis of this formula, studying the absolute sensitivity and relative sensitivity of surface roughness for milling speed, depth of cut and feed; The results showed that in the process of high-speed milling of high-temperature alloy GH4169, Surface roughness is most sensitive to the change of milling feed; change of milling depth take second place and milling speed is the least sensitive.

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Wear and cutting forces in high-speed machining of H13 using physical vapour deposition coated carbide tools

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/95440505x8127 ◽

2005 ◽

Vol 219 (2) ◽

pp. 191-199 ◽

Cited By ~ 7

Author(s):

P T Mativenga ◽

K K B Hon

Keyword(s):

Cutting Forces ◽

High Speed ◽

Vapour Deposition ◽

High Speed Machining ◽

Physical Vapour Deposition ◽

Tin Coatings ◽

Tool Coatings ◽

Process Trends ◽

Coated Carbide ◽

Coated Carbide Tools

This paper reviews the contributions that coatings make in enhancing the cutting performance of carbide tools and, in particular, their application in high-speed machining. It examines flank wear and cutting force process trends that are essential for monitoring tool degradation in automated machining factories. The findings of the investigation into cutting forces over the life cycle of different physical vapour deposition (PVD) tool coatings on micrograin carbide in the high-speed machining of tool steel are presented and related to the existing literature. Cutting tests were carried out at a very high spindle speed, 40000 r/min, and for a predetermined cutting time. Variants of the TiAlN coating, i.e. single- and double-layer and composite coating enhanced with WC/C, were evaluated against the uncoated tool and the TiCN, CrN, and TiN coatings. The paper reflects on the performance of advanced PVD coatings and also presents force trends and suggestions for process monitoring.

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