Investigation on Deep Hole Trepanning of TC10 Titanium Alloy

2019 ◽  
Author(s):  
Xiaolan Han ◽  
Zhanfeng Liu
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Process Parameters ◽  
Thrust Force ◽  
Large Diameter ◽  
Manufacturing Cost ◽  
Deep Hole ◽  
Technical Problems ◽  
Material Utilization

Abstract Titanium alloy is a typical hard-to-machine material, and has a relatively expensive material price. For deep-hole tubes made of titanium alloys, the material utilization rate of direct deep-hole drilling is relatively low, especially for large diameter holes. Deep-hole trepanning provides an effective method that reduces manufacturing cost and improves the material utilization which is used on larger diameter bars. In this paper, deep-hole trepanning tests are carried out on the TC10 titanium alloys to resolve the key technical problems. The thrust force and torque, tool wear, and chip morphology are analyzed based on the different process parameters. The results show that appropriate process parameters can remove the chips easily and reduce the thrust force and tool wear. The titanium alloy deep-hole trepanning has a good drilling effect and solves the problem of drilling deep, large diameter holes in titanium alloy tubes, which has practical significance for reducing production cost and improving material utilization.

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

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%.

scholarly journals An experimental research on the machinability of a high temperature titanium alloy BTi-6431S in turning process

2018 ◽  
Vol 5 ◽  
pp. 12
Author(s):  
Yanfeng Gao ◽  
Yongbo Wu ◽  
Jianhua Xiao ◽  
Dong Lu
Keyword(s):  
Titanium Alloy ◽  
High Temperature ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Cutting Forces ◽  
Shear Bands ◽  
Cutting Parameters ◽  
Aircraft Manufacturing ◽  
Mechanical And Physical Properties ◽  
Alpha Titanium

Titanium alloys are extensively applied in the aircraft manufacturing due to their excellent mechanical and physical properties. At present, the α + β alloy Ti6Al4V is the most commonly used titanium alloy in the industry. However, the highest temperature that it can be used only up to 300 °C. BTi-6431S is one of the latest developed high temperature titanium alloys, which belongs to the near-α alloy group and has considerably high tensile strength at 650 °C. This paper investigates the machinability of BTi-6431S in the terms of cutting forces, chip formation and tool wear. The experiments are carried out in a range of cutting parameters and the results had been investigated and analyzed. The investigation shows that: (1) the specific cutting forces in the machining of BTi-6431S alloy are higher than in the machining of Ti6Al4V alloy; (2) the regular saw-tooth chips more easily formed and the shear bands are narrower in the machining of BTi-6431S; (3) SEM and EDS observations of the worn tools indicate that more cobalt elements diffuse into the workpiece from tool inserts during machining of BTi-6431S alloy, which significantly aggravates tool wear rate. The experimental results indicate that the machinability of BTi-6431S near alpha titanium alloy is significantly lower than Ti-6Al-4V alloy.

Experimental research on the deep-hole boring of pure niobium tube

2020 ◽  
Vol 234 (8) ◽  
pp. 1124-1132
Author(s):  
Xiaolan Han ◽  
Zhanfeng Liu ◽  
Yazhou Feng
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Experimental Research ◽  
Process Parameters ◽  
Cutting Tool ◽  
Geometric Parameters ◽  
Deep Hole ◽  
High Quality ◽  
Pure Niobium ◽  
Hole Axis

In the deep-hole boring process on pure niobium tube, there exist some problems including serious tool wear, tough chips, and poor surface quality. In order to bore high-quality deep holes on rolled niobium tube, the cutting tool structure and boring process parameters suitable for machining rolled niobium tube were designed and two experimental schemes were proposed. The results showed that the geometric parameters of the cutting tool and process parameters have important influences on the tool wear, chip morphologies, hole-axis deflection, and hole surface roughness. By adjusting the geometric parameters of the cutting tool and boring process parameters, reasonable geometric parameters of the cutting tool and boring process parameters were obtained.

3D Numerical Investigation of Effect of Milling Process Parameters on High Speed Milling of Ti-Al6-V4

2012 ◽  
Author(s):  
J. Ma ◽  
Shuting Lei ◽  
Huaqi Lu
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Numerical Investigation ◽  
Process Parameters ◽  
High Speed ◽  
Chemical Reactivity ◽  
Milling Process ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Axial Depth

Titanium alloys are widely used in aerospace industry owing to excellent mechanical properties. While because of high chemical reactivity and low thermal conductivity, titanium alloys are classified as hard-to-cut materials. In this paper, Finite Element Method (FEM) is employed to conduct numerical investigation in the effects of milling process parameters (milling speeds, feed per tooth, and axial depth of cut) on three-dimensional (3D) high speed milling of Titanium alloy (Ti-6Al-4V). The tool material used is Carbide and Johnson-Cook plastic model is employed to model the workpiece due to its capability of modeling large strains, high strain rates, and temperature dependent visco-plasticity. Different milling speeds, feed per tooth, and axial depth of cut are used to explore the effects of the milling process parameters on the cutting temperature, cutting forces, and power required for machining. This model provides fundamental understanding of cutting mechanics of the 3D high speed milling of Titanium alloy (Ti-6Al-4V).

scholarly journals A low-cost machinability approach to accelerate titanium alloy development

2020 ◽  
pp. 095440542093786
Author(s):  
Chris Dredge ◽  
Rachid M’Saoubi ◽  
Ben Thomas ◽  
Oliver Hatt ◽  
Meurig Thomas ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Cutting Tool ◽  
Metal Removal ◽  
Low Cost ◽  
Small Scale ◽  
Alloy Development ◽  
Process Step ◽  
Machining Properties

Machining is often the most expensive manufacturing process step when producing titanium alloy components. With a move towards higher metal removal rates to meet aircraft orders, it is important to develop rapid, low-cost methods that assess the machinability of titanium alloys and cutting tool combinations. A cost-effective, small-scale methodology has been developed and validated on the industrial scale using high-speed turning to inform on the machining characteristics of commercial and emerging titanium alloys to aid companies in future developments of new titanium alloys and cutting tool materials. The article demonstrates, using the titanium alloys Ti-6Al-4V (Ti-64) and TIMETAL 407® (Ti-407), that a series of early stage, small-scale methods can identify key machinability characteristics including chip form, tool wear, cutting force and surface damage. It can be concluded using these low-cost machinability assessment methods that Ti-407 exhibits better machining properties to Ti-64 for the aspects of machinability focused on cutting forces and tool wear, whereas the contrary is found for subsurface microstructural features and chip control.

A Study on Titanium Alloys Deep-Hole Drilling Technique

2006 ◽  
Vol 532-533 ◽  
pp. 945-948 ◽  
Author(s):  
Lin Zhu ◽  
Jiang Ping Wang
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Hole Drilling ◽  
Geometrical Parameters ◽  
Deep Hole ◽  
Carbide Tool ◽  
Deep Hole Drilling ◽  
Tool Materials ◽  
Drilling Technique ◽  
Cemented Carbide Tool

Focusing on the difficult-to-cut characteristic of titanium alloy, this paper selects several cemented carbide tool materials in the tests of machining the titanium alloy workpieces. Different sets of geometrical parameters of the drilling bits are grouped, chosen and optimized, and then deep-hole drilling tests are carried out. The suitable cutter materials and the optimum geometrical parameters of the cutter for drilling deep holes in titanium alloy have been determined through the analysis of tested results.

scholarly journals Optimization of process parameters for turning of titanium alloy (Grade II) in MQL environment using multi-CI algorithm

2021 ◽  
Vol 3 (2) ◽  
Author(s):  
Apoorva Shastri ◽  
Aniket Nargundkar ◽  
Anand J. Kulkarni ◽  
Luigi Benedicenti
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Process Parameters ◽  
Optimization Algorithm ◽  
Materials Science ◽  
Industrial Applications ◽  
Contact Length ◽  
Grade Ii

AbstractThe advancement of materials science during the last few decades has led to the development of many hard-to-machine materials, such as titanium, stainless steel, high-strength temperature-resistant alloys, ceramics, refractories, fibre-reinforced composites, and superalloys. Titanium is a prominent material and widely used for several industrial applications. However, it has poor machinability and hence efficient machining is critical. Machining of titanium alloy (Grade II) in minimum quantity lubrication (MQL) environment is one of the recent approaches towards sustainable manufacturing. This problem has been solved using various approaches such as experimental investigation, desirability, and with optimization algorithms. In the group of socio-inspired optimization algorithm, an artificial intelligence (AI)-based methodology referred to as Cohort Intelligence (CI) has been developed. In this paper, CI algorithm and Multi-CI algorithm have been applied for optimizing process parameters associated with turning of titanium alloy (Grade II) in MQL environment. The performance of these algorithms is exceedingly better as compared with particle swarm optimization algorithm, experimental and desirability approaches. The analysis regarding the convergence and run time of all the algorithms is also discussed. It is important to mention that for turning of titanium alloy in MQL environment, Multi-CI achieved 8% minimization of cutting force, 42% minimization of tool wear, 38% minimization of tool-chip contact length, and 15% minimization of surface roughness when compared with PSO. For desirability and experimental approaches, 12% and 8% minimization of cutting force, 42% and 47% minimization of tool wear, 53% and 40% minimization of tool-chip contact length, and 15% and 20% minimization of surface roughness were attained, respectively.

Rotary Ultrasonic Machining of Titanium Alloy: A Feasibility Study

2005 ◽  
Author(s):  
N. J. Churi ◽  
Z. C. Li ◽  
Z. J. Pei ◽  
C. Treadwell
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Aerospace Industry ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Conventional Machining

Due to their unique properties, titanium alloys are attractive for some unique applications especially in the aerospace industry. However, it is very difficult to machine these materials cost-effectively. Although many conventional and non-conventional machining methods have been reported for machining them, no reports can be found in the literature on rotary ultrasonic machining of titanium alloys. This paper presents an experimental study on rotary ultrasonic machining of a titanium alloy. The tool wear, cutting force, and surface roughness when rotary ultrasonic machining of the titanium alloy have been investigated using different tool designs and machining conditions. The results are compared with those when machining the same material with diamond grinding.

Optimization of Process Parameters in Micro-EDM of Ti-6Al-4V Alloy

2016 ◽  
Vol 16 (1) ◽  
pp. 41-49
Author(s):  
V. Krishnaraj
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Performance Criteria ◽  
Machining Parameters ◽  
Micro Edm ◽  
Micro Holes ◽  
Pulse On Time

AbstractTitanium alloys are categorized as light weight materials posse greater strength and toughness and are usually known to create major challenges during conventional and non-conventional machining. In general, these alloys are referred as difficult to machine materials. Titanium alloy (Ti-6Al-4V) suffers poor machinability for most cutting processes, especially the generation of micro-holes using traditional machining methods. Electrical Discharge Machining (EDM) is suitable for machining titanium alloys, although selection of machining parameters for higher machining rate and accuracy is a challenging task in machining micro-holes. Discharge current, pulse ON time and Flushing pressure were considered as the major influencing machining parameters and Material Removal Rate (MRR), Tool Wear Rate (TWR) and Hole Taper were considered as the performance criteria. It is observed that machining performances are affected mostly by the peak current and pulse-on time during micro-electro discharge machining of titanium alloy. Mathematical models have been developed using multiple regression analysis, to establish the relationship between various significant process parameters and micro-EDM performance criteria. Also, studies have been made to examine the influence of various process parameters on the quality of the machined micro-hole.

scholarly journals The effect of Titanium Alloy Composition and Tool Coating on Drilling Machinability

2020 ◽  
Vol 321 ◽  
pp. 13002
Author(s):  
Alex Graves ◽  
Maria Teike ◽  
Susanne Norgr ◽  
Pete Crawforth ◽  
Marun Jackson
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Force Feedback ◽  
Alloy Composition ◽  
High Strength ◽  
Wear Behaviour ◽  
Work Piece ◽  
Novel Approach ◽  
Tool Coating

Excessive tool wear and poor machinability is observed in the machining of high strength, near-β titanium alloys when compared to α + β titanium alloys such as Ti-64. Tooling suppliers want to better understand drilling machinability in terms of (1) why alloy composition influences tool wear behaviour, (2) how this impacts part integrity and (3) the effectiveness of tool coating. This paper presents a novel approach to investigating the mechanisms by which tool wear and microstructural deformation occur in a range of titanium alloys, through the manipulation of the force experienced by the tool and work piece. The investigation compares and contrasts the drilling machinability of three important aerospace titanium alloys. Force feedback, tool wear and microstructural damage results highlight key differences when drilling different titanium alloys. Such findings will contribute to tool design, providing a better understanding of wear and machinability in near-β titanium alloy drilling.

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