Evaluating the effectiveness of various coating layers applied on k-grade cemented carbide cutting tools on machinability of titanium alloy Ti-6Al-4V in high speed end milling

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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The Application of FEA in High-Speed Cutting Tool

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.314-316.1258 ◽

2011 ◽

Vol 314-316 ◽

pp. 1258-1261

Author(s):

Lian Qing Ji ◽

Kun Liu

Keyword(s):

Titanium Alloy ◽

Cutting Force ◽

High Speed ◽

Cutting Tool ◽

Cutting Tools ◽

Cutting Temperature ◽

Material Model ◽

Friction Model ◽

High Speed Cutting ◽

Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools parameters are determined by simulating the influences of cutting temperature, cutting force on the tools parameters using FEA.

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Analysis on Tool Life and Surface Characteristic in Milling Stavax Supreme Material

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.564.475 ◽

2014 ◽

Vol 564 ◽

pp. 475-480

Author(s):

M.F.C. Ibrahim ◽

B.T. Hang Tuah bin Baharudin ◽

Naain Shari

Keyword(s):

Tool Life ◽

High Speed ◽

End Milling ◽

Removal Rate ◽

Cutting Tools ◽

Surface Characteristic ◽

Spindle Speed ◽

Machining Process ◽

Machine Material ◽

Two Parameters

Stavax Supreme material is classified as difficult-to-machine material. The difficulty does not preclude the use of this material, especially in the mold industry. In this experiment, high speed end milling of Stavax Supreme (52 HRC) was investigated using five different types of tool. Performance of the cutting tools was compared with respect to tool life and surface roughness of the workpiece. Machining process was conducted in two parameters where each parameter used different rotation spindle speed and feed rate but same chip per tooth removal rate. The best cutting performance was obtained with TiN and TiCN. TiAlN tool also proved to be suitable for high speed end milling of Stavax Supreme but for finishing process only because fast tool wear in high spindle speed. The Xceed coated tool is more suitable for roughing process only in high spindle speed.

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Surface integrity in high speed end milling of titanium alloy Ti–6Al–4V

Materials Science and Technology ◽

10.1179/026708310x12738371692932 ◽

2011 ◽

Vol 27 (1) ◽

pp. 387-394 ◽

Cited By ~ 34

Author(s):

A. Daymi ◽

M. Boujelbene ◽

A. Ben Amara ◽

E. Bayraktar ◽

D. Katundi

Keyword(s):

Titanium Alloy ◽

Surface Integrity ◽

High Speed ◽

End Milling

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Efficiency Comparison of Cutting Strategies for End Milling Processes Under Feedrate Scheduling

International Journal of Automation Technology ◽

10.20965/ijat.2008.p0377 ◽

2008 ◽

Vol 2 (5) ◽

pp. 377-383 ◽

Cited By ~ 6

Author(s):

Soichi Ibaraki ◽

◽

Atsushi Matsubara ◽

Masanori Murozumi ◽

Keyword(s):

High Speed ◽

Job Shop ◽

End Milling ◽

Cutting Tools ◽

Depth Of Cut ◽

High Speed Cutting ◽

Machining Conditions ◽

Feedrate Scheduling ◽

Major Player ◽

Manufacturing Applications

Technical advances in high-speed machining centers and cutting tools have made high-speed cutting a major player in manufacturing applications, but high-speed cutting provides higher machining efficiency only when machining conditions are appropriately set. In contrast, expert job shop operators often choose a heavy cutting strategy subject to higher depth of cut and a lower feedrate. Feedrate scheduling schemes are widely recognized as practically feasible for optimizing machining conditions in high-speed cutting. We compared the productivity of high-speed milling and heavy milling, assuming that using feedrate scheduling optimizes machining conditions. Possible cutting strategies are interpreted as constraints on cutting conditions or cutting performance, then machining conditions are scheduled optimally to maximize the productivity. A case study illustrates these points.

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Tool Wear and Surface Integrity in High Speed Milling of Forging and Cast TA15 Alloys with Coated Carbide Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.626-627.189 ◽

2009 ◽

Vol 626-627 ◽

pp. 189-194

Author(s):

P. Liu ◽

Jiu Hua Xu ◽

Yu Can Fu

Keyword(s):

Titanium Alloy ◽

Tool Life ◽

Surface Integrity ◽

High Speed ◽

Cutting Tools ◽

High Speed Milling ◽

Alpha Titanium ◽

Series Of Experiments ◽

Coated Carbide ◽

Coated Carbide Tools

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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