A Study on the High Speed Face Milling of Ti-6Al-4V Alloy

Manufacturing ◽  
2002 ◽  
Author(s):  
Balkrishna Rao ◽  
Yung C. Shin
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Experimental Analysis ◽  
High Speed ◽  
Numerical Study ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Face Milling ◽  
Machined Surface ◽  
Element Analysis

This paper is concerned with the experimental and numerical study of the high speed face milling of Ti-6Al-4V titanium alloy. Machining is carried out by uncoated carbide and polycrystalline diamond cutters in the presence of an abundant supply of coolant. Experimental analysis is conducted in terms of cutting forces, chip morphology, surface integrity and tool wear. The experimental analysis is supplemented by simulations from the finite element analysis where needed. The highest cutting speed realized for both the cutting tool materials is 600 sfpm with the diamond cutter operating at feeds lower than that for carbide. Good surface integrity in terms of residual stress and surface finish is achieved under the machining conditions used with limited tool wear. Residual stresses imparted to the machined surface are compressive with the diamond tool yielding higher values and are the most sensitive to feed. Tool wear patterns are described in terms of various cutting conditions.

Investigation of Surface Characteristics and Chip Morphology in High Speed Cutting of Inconel718 Based on SHPB System

2019 ◽  
Author(s):  
Zengqiang Wang ◽  
Zhanfei Zhang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Surface Profile ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting

Abstract High speed cutting (HSC) technology has the characteristics of high material removal rates and high machining precision. In order to study the relationships between chip morphology and machining surface characteristic in high speed cutting of superalloy Inconel718. High-speed orthogonal cutting experiment are carried out by used a high speed cutting device based on split Hopkinson pressure bar (SHPB). The specimen surfaces and collected chips were then detected with optical microscope, scanning electron microscope and three-dimensional surface profile measuring instrument. The results show that within the experimental parameters (cutting speed from 8–16m/s, depth of cut 0.1–0.5mm), the obtained chips are sawtooth chips and periodic micro-ripple appear on the machined surface. With the cutting speed increases, machining surface roughness is decreases from 1.4 to 0.99μm, and the amplitude of periodic ripples also decreases. With the cutting depth increases, the machining surface roughness increases from 0.96 to 5.12μm and surface topography becomes worse. With the increase of cutting speed and depth of cut, the chips are transform from continues sawtooth to sawtooth fragment. By comparing the frequency of surface ripples and sawtooth chips, it is found that they are highly consistent.

scholarly journals Fractal Characteristics of Chip Morphology and Tool Wear in High-Speed Turning of Iron-Based Super Alloy

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 1020
Author(s):  
Xu Zhang ◽  
Guangming Zheng ◽  
Xiang Cheng ◽  
Rufeng Xu ◽  
Guoyong Zhao ◽  
...  
Keyword(s):  
Fractal Dimension ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
Fractal Dimensions ◽  
Chip Morphology ◽  
Color Changes ◽  
Fractal Characteristics ◽  
Iron Based ◽  
Super Alloy

Considering that iron-based super alloy is a kind of difficult-to-cut material, it is easy to produce work hardening and serious tool wear during machining. Therefore, this work aims to explore the chip change characteristics and tool wear mechanism during the processing of iron-based super alloy, calculate the fractal dimensions of chip morphology and tool wear morphology, and use fractals to analyze their change trend. Meanwhile, a new cutting tool with a super ZX coating is used for a high-speed dry turning experiment. The results indicate that the morphology of the chip is saw-tooth, and its color changes gradually, due to the oxidation reaction. The main wear mechanisms of the tool involve abrasive wear, adhesive wear, oxidation wear, coating spalling, microcracking and chipping. The fractal dimension of the tool wear surface and chip is increased with the improvement of cutting speed. This work investigates the fractal characteristics of chip morphology and tool wear morphology. The fractal dimension changes regularly with the change of tool wear, which plays an important role in predicting this tool wear. It is also provides some guidance for the efficient processing of an iron-based super alloy.

Effect of Machining Parameters and MQL Liquids on Surface Integrity of High Speed Drilling Ti-6Al-4V

2010 ◽  
Vol 447-448 ◽  
pp. 816-820 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Surface Roughness ◽  
Palm Oil ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Subsurface Deformation ◽  
High Speed Drilling ◽  
Coated Carbide

Surface integrity is particularly important for the aerospace industry components in order to permit longer service life and maximized its reliability. This present work compares the performance of palm oil and synthetic ester on surface roughness, surface defect, microhardness and subsurface deformation when high speed drilling of Ti-6Al-4V under MQL condition. The drilling tests were conducted with AlTiN coated carbide tool. The surface roughness decreased with increasing in cutting speed and thicker subsurface deformation was formed underneath the machined surface. Grooves, cavities, pit holes, microcracks and material smearing were the dominant surface damages thus deteriorated the machined surface. For both lubricants, the machined surface experienced from thermal softening and work hardening effect thus gave a variation in microhardness values. The results indicated the substantial benefit of MQL by palm oil on surface integrity.

Surface Integrity of Magnesum-Calcium Orthopedic Biomaterial Procesed by Dry High-Speed Face Milling

2010 ◽  
Author(s):  
M. Salahshoor ◽  
Y. B. Guo
Keyword(s):  
Surface Integrity ◽  
Human Body ◽  
High Speed ◽  
Mechanical Load ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Orthopedic Implants ◽  
Face Milling ◽  
Depth Of Cut ◽  
Machining Parameter

Biodegradable magnesium-calcium (Mg-Ca) implants have the ability to gradually dissolve and absorb into the human body after implantation. The critical issue that hinders the application of Mg-Ca implants is its poor corrosion resistance to human body fluids. A promising approach to tackle this issue is tailoring the surface integrity characteristics of the orthopedic implants to get an appropriate corrosion kinetic. High speed face milling of biodegradable Mg-Ca alloy is used in this study as a possible way to achieve that goal. Polycrystalline diamond inserts are used to avoid material adhesion and likely fire hazards. All the cutting tests are performed without using coolant to keep the manufacturing process ecological. High cutting speed of 40 m/s and 200 μm depth of cut are applied in a broad range of feed values to cover finish and rough cutting regimes. The effect of feed as a key machining parameter which defines the amount and duration of thermo-mechanical load and ultimately provides higher chances for surface integrity changes are investigated.

Surface Integrity of Die Material in High Speed Hard Machining, Part 1: Micrographical Analysis

1999 ◽  
Vol 122 (4) ◽  
pp. 620-631 ◽  
Author(s):  
T. I. El-Wardany ◽  
H. A. Kishawy ◽  
M. A. Elbestawi
Keyword(s):  
Tool Wear ◽  
Residual Stresses ◽  
Tool Steel ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Conditions ◽  
Metallographic Analysis ◽  
Tool Geometry ◽  
Machined Surface ◽  
Geometrical Defects

The effects of cutting conditions and tool wear on chip morphology and surface integrity during high speed machining of D2 tool steel (60–62 Hrc) are investigated experimentally and analytically in this paper. Polycrystalline Cubic Boron Nitride (PCBN) tools are used in this investigation. The chips and the subsurface of the workpiece are examined using optical and scanning electron microscopy. Microhardness measurements are performed on the surface and subsurface of the workpiece. The X-ray diffraction technique is used to measure the residual stresses induced in the machined surface. The paper is divided into two parts. Part 1 presents the results obtained from the micrographical analysis of the chips and the surfaces produced. Part 2 deals with microhardness and residual stresses of the machined surface. The micrographical analysis of the chips produced shows that different mechanisms of chip formation exist depending on the magnitude of the cutting pressure and tool wear. Saw toothed chips are produced during the machining of D2 tool steel if the cutting pressure exceeds approximately 4000 MPa. The metallographic analysis of the surface produced illustrates the damaged surface region that contains geometrical defects and changes in the subsurface metallurgical structure. The types of surface damage are dependent on the cutting conditions, tool geometry and the magnitude of the wear lands. [S1087-1357(00)00104-0]

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Machinability of the EBM Ti6Al4V in Cryogenic Turning

2015 ◽  
Vol 651-653 ◽  
pp. 1183-1188 ◽  
Author(s):  
Stefano Sartori ◽  
Alberto Bordin ◽  
Stefania Bruschi ◽  
Andrea Ghiotti
Keyword(s):  
Tool Wear ◽  
Liquid Nitrogen ◽  
Surface Integrity ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Fluid ◽  
Cobalt Chromium ◽  
Machined Surface ◽  
Surgical Implants ◽  
Cutting Zone

In machining operations, the adoption of a cutting fluid is necessary to mitigate the effects of the high temperatures generated on the cutting zone, and, therefore, to avoid severe detrimental effects on the tool wear and surface integrity. In the biomedical field, the traditional processes to manufacture surgical implants made of Titanium and Cobalt Chromium Molybdenum alloys involve turning and milling operations. To cool the cutting tool with standard oil emulsions leaves contaminants on the machined surfaces, which require further cleaning steps that are expensive in terms of time and costs. Currently, this limitation is marginally overcome by machining without the coolant; however, as a consequence, severe tool wear and poor surface integrity take place. In the last years, many studies have been conducted on the application of Liquid Nitrogen as a coolant in machining difficult-to-cut materials such as Ti6Al4V. Thanks to its properties to evaporate immediately when getting in contact with the cutting zone, thus living the workpiece and chips dry and clean other than its ability to lower the cutting temperature. The adoption of Liquid Nitrogen as a cooling mean in machining surgical implants may represent an optimum solution enhancing the benefits of dry machining. This work is aimed at evaluating the performances of the Liquid Nitrogen as a coolant in semi-finishing turning of Ti6Al4V produced by Electron Beam Melting, a comparison with dry turning is presented. The alloy machinability in such conditions is evaluated in terms of tool wear, machined surface integrity and chip morphology.

Surface Integrity and Fatigue Property of a High Speed Milled Titanium Alloy

2008 ◽  
Vol 53-54 ◽  
pp. 305-310 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
Machined Surface ◽  
Metallurgical Structure

Surface integrity has a great effect on the fatigue property of titanium alloy. The surface integrity and fatigue property of a high speed milled Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy were investigated in this research. The main objective of this paper is to study the influence of milling speed on the surface integraty and fatigue property of the machined part. The surface roughness, work hardening, metallurgical structure and residual stress of the machined surface were studied in a cutting speed range of from 50m/min to 300m/min. To verify the relationship between cutting speed and the surface integrity of machined surface, the fatigue property of titanium alloy specimens milled at four different cutting speeds ranging from 50 to 200m/min were compared at two stress levels. This research shows that the cutting speed has little effect on the work hardening, metallurgical structure and residual stress, but the surface roughness decreases with the increasing cutting speed. Therefore, increasing milling speed has a positive effect on the surface integrity and fatigue property of the machined surface.

Study on High-Speed Drilling of SUS304 Based on FEA

2011 ◽  
Vol 188 ◽  
pp. 529-534 ◽  
Author(s):  
M.P. Yan ◽  
H. Shao
Keyword(s):  
Finite Element Analysis ◽  
Tool Wear ◽  
Machine Tools ◽  
High Speed ◽  
Cutting Speed ◽  
Formation Processes ◽  
Element Analysis ◽  
High Speed Drilling ◽  
Tool Wear Mechanism ◽  
Drilling Conditions

Experimental explorations for optimal cutting conditions on high speed drilling processes could be expensive and risky both to machine tools and operators. In this study, high-speed drilling of SUS304 stainless steel with a TiN-coated drill was simulated for optimized drilling conditions. Tool wear mechanism as well as chip formation processes was also explored based on finite element analysis (FEA). It was found with the simulations that higher cutting speed came up with smaller tool wear.

Cutting Force Experiment and Simulation by Hard Turning GCr15 Bearing Steel with High Speed Considering Cutting Edge Preparation

2006 ◽  
Vol 532-533 ◽  
pp. 845-848
Author(s):  
Yu Wang ◽  
Fu Gang Yan ◽  
Jing Shu Hu ◽  
Tao Chen ◽  
Zhen Chang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Hard Turning ◽  
Cutting Speed ◽  
Bearing Steel ◽  
Machined Surface ◽  
Element Analysis ◽  
Gcr15 Bearing Steel

In this study, hard turning GCr15 bearing steel with high cutting speed is experimental investigated the influence of the CB7015WH insert with chamfer edge and Safe-Lock and the CB7015 insert with a combination of hone radius and a chamfer edge on cutting forces and surface roughness of machined surface. Experimental results show that the cutting forces of the chamfer edge and Safe-Lock is smaller than that of the combination of hone radius and a chamfer edge. Moreover, surface roughness of machined surface with the CB7015WH insert is better. A coupled thermo-mechanical 2D finite element model with general finite element analysis software Deform 2D.8.1 is developed for the influence of two kinds of inserts on cutting forces and effective stress. The simulation results are compared with experimental data and found to be in good agreement.

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