Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 1: Effect of gradual tool wear evolution

2015 ◽  
Vol 231 (9) ◽  
pp. 1559-1574 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machined Surface ◽  
Segmented Chip ◽  
Gradual Development ◽  
Geometric Variables ◽  
On Chip

Geometric features of the segmented chip have been investigated along with the volume of material removed at a cutting speed at which tool wear is characterized by the gradual development of flank wear when cutting Ti-6Al-4V alloy. The chip geometric variables varied with an increase in the volume of material removed as the combined effect of change in tool’s geometry and increase in cutting temperature. Plastic deformation dimples were observed as periodical regions on the machined surface, a row on each undeformed surface and region on the top of the slipping surface of the segmented chip when cutting with new tool; these dimples on the undeformed surface and machined surface are elongated in the direction of chip flow. All these dimples became less with an increase in the volume of material removed and almost disappeared when the chip was removed with the worn tool at the end of its life. A model of segmented chip formation process has been proposed to satisfactorily explain the formation of the plastic deformation dimples on the undeformed surface and machined surface of the segmented chip produced with a new cutting tool and the transition of chip geometry with the evolution of tool wear.

Study on Effect of Ultrasonic Vibration in Machining of Alumina Ceramic

2012 ◽  
Vol 516 ◽  
pp. 311-316 ◽  
Author(s):  
Kyung Hee Park ◽  
Kyeong Tae Kim ◽  
Yun Hyuck Hong ◽  
Hon Jong Choi ◽  
Young Jae Choi
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Ultrasonic Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Combination Technique

Ultrasonic machining can be applied for the machining of difficult-to-cut materials using ultrasonical oscillation in an axial direction on top of tool rotation, which can cause reduction of cutting temperature and tool wear. In this study, the experiments were performed on a DMG ULTRASONIC 20 linear machine tool using diamond tools in both conventional and ultrasonic vibration assisted machining. The machining performance was evaluated and compared for both cases in terms of cutting forces, machined surface roughness and tool wear. And the combination technique of 3D surface topography measurement and image processing was applied for the tool wear progress. Overall, the experimental results showed that ultrasonic machining had less tool wear and lower cutting forces at low cutting speed compared to conventional machining. Also surface roughness was slightly lower in ultrasonic machining than that without ultrasonic vibration.

Research Status of Subsequent Machining of Laser Cladding Layers

2020 ◽  
Vol 15 ◽  
Author(s):  
Lei Li ◽  
Yujun Cai ◽  
Guohe Li ◽  
Meng Liu
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Laser Cladding ◽  
Wear Surface ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Cladding Layer ◽  
Cladding Layers

Background: As an important method of remanufacturing, laser cladding can be used to obtain the parts with specific shapes by stacking materials layer by layer. The formation mechanism of laser cladding determines the “Staircase effect”, which makes the surface quality can hardly meet the dimensional accuracy of the parts. Therefore, the subsequent machining must be performed to improve the dimensional accuracy and surface quality of cladding parts. Methods: In this paper, chip formation, cutting force, cutting temperature, tool wear, surface quality, and optimization of cutting parameters in the subsequent cutting of laser cladding layer are analyzed. Scholars have expounded and studied these five aspects but the cutting mechanism of laser cladding need further research. Results: The characteristics of cladding layer are similar to that of difficult to machine materials, and the change of parameters has a significant impact on the cutting performance. Conclusion: The research status of subsequent machining of cladding layers is summarized, mainly from the aspects of chip formation, cutting force, cutting temperature, tool wear, surface quality, and cutting parameters optimization. Besides, the existing problems and further developments of subsequent machining of cladding layers are pointed out. The efforts are helpful to promote the development and application of laser cladding remanufacturing technology.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

Study of the Effect of Tool Wear on Cutting Ti6Al4V Process

2013 ◽  
Vol 690-693 ◽  
pp. 2030-2035
Author(s):  
Shu Bao Yang ◽  
Hong Chao Ni ◽  
Guo Hui Zhu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Key Factors ◽  
Serrated Chip ◽  
Comprehensive Properties ◽  
Commercial Applications ◽  
On Chip ◽  
Rapid Tool

Ti6Al4V alloy is widely used in the aircraft industry, marine and the commercial applications due to its excellent comprehensive properties. However, its poor machinability prevents it from application widely, and the rapid tool wear is one of the key factors. The FEM models of cutting titanium alloy are established. The effect of tool wear on chip morphology, cutting temperature and cutting force are studied. The simulation results show that: the cutting force and cutting temperature will rise with the increase of tool wear. Furthermore, the degree of chip deformation will improve, but the frequency of serrated chip tooth occurred will decrease.

Experimental Investigation of Mechanical-Thermal Characteristics in High Efficiency Turning Titanium Alloy Ti6Al4V

2016 ◽  
Vol 836-837 ◽  
pp. 20-28
Author(s):  
Li Min Shi ◽  
Cheng Yang ◽  
Qi Jun Li
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Efficiency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Thermal Characteristics ◽  
Tool Failure ◽  
Minimal Quantity Lubrication ◽  
Titanium Alloy Ti6al4v

Titanium alloy Ti6Al4V has poor machinability, which leads to high unit cutting force and cutting temperature, rapid tool failure. In this study, the effect of the cutting speed, feed rate and cooling condition on cutting force and cutting temperature is critically analysed by turning experiment. At the same time, the relationship is established among tool wear, cutting force and cutting temperature. This investigation has shown that cutting speed is the decisive factor which increasing cutting force and cutting temperature. In the process of turning, tool wear results in high amounts of heat and mechanical stress, which leads to serious tool wear. The Minimal Quantity Lubrication reduces the frictional condition at the chip-tool, decreases cutting force and cutting temperature, and delays the tool failure.

Effect of Temperature on Tool Wear During Milling of Ti64

2021 ◽  
Vol 143 (7) ◽  
Author(s):  
Q. Lagarde ◽  
V. Wagner ◽  
G. Dessein ◽  
M. Harzallah
Keyword(s):  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Effect Of Temperature ◽  
Fundamental Parameter ◽  
Ir Camera ◽  
Radial Depth ◽  
Higher Temperature ◽  
Two Parameters ◽  
Machining Productivity

Abstract In recent years, the development of new, increasingly resistant materials limit machining productivity. This observation is especially true for titanium alloys. The state-of-the-art shows that one of the phenomena responsible for tool wear is temperature. The high temperature is explained by the low thermal conductivity of the alloy and its high mechanical properties. Consequently, high temperatures generated when cutting speeds are increasing lead to very rapid wear phenomena. However in milling, the period during which the insert is not in contact with the material may allow it to cool but its effect is not clearly established. In order to correlate tool wear and cutting temperatures in milling, an experimental bench has been developed. In turning and therefore with a fixed tool, the milling conditions are recreated and allow to measure the temperatures on the cutting face. Two parameters were tested: (i) radial depth, which influences the tooth stress time, and (ii) the cutting speed, which is the fundamental parameter of the cutting temperature. Experimentally, it appears that increasing radial engagement and cutting speed reduces tool life and increases temperatures. However, the phenomenological analysis is not immediate. The relationship between these phenomena is based on a heat balance of the cutting process. The use of an infrared (IR) camera in this problem and a specific analysis method allow observing the temperature gradients on the cutting face making the analysis more robust compared to the thermocouple technic. It thus appears that the increase in radial engagement leads to a higher tool temperature, but the analyses show above all a higher temperature within the insert and therefore more difficult to evacuate.

Effect of Cutting Temperature on Phase Transformation in Cutting of NiTi Alloy

2020 ◽  
Author(s):  
Hao Yang ◽  
Katsuhiko Sakai ◽  
Hiroo Shizuka ◽  
Kunio Hayakawa ◽  
Tetsuo Nagare
Keyword(s):  
Phase Transformation ◽  
Phase State ◽  
Niti Alloy ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Process ◽  
Maximum Temperature ◽  
Machined Surface ◽  
Speed Condition ◽  
Work Material

Abstract In this study, the effect of cutting temperature on phase transformation in cutting of room temperature austenitic NiTi alloy was investigated by X-ray diffraction (XRD) and temperature measurements. Results from XRD reveals that after cutting process, the phase state of work material near the machined surface transformed from austenite to martensite at relatively low cutting speed conditions while the phase state of work material did not undergo any form of transformation at the highest cutting speed condition. Temperature measurement results measured with temperature indicating paint showed that the maximum temperature of work material near the machined surface in cutting process exceeded the Md temperature at the highest cutting speed condition. However, there was no phase transformation observed in cutting chips after cutting at all cutting speed conditions as the temperature of cutting chips was much higher than the Md temperature under all cutting speed conditions.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Influence of Cutting Speed on Surface Plastic Deformation and White Layer Formation of FGH95

2013 ◽  
Vol 589-590 ◽  
pp. 70-75 ◽  
Author(s):  
Jin Du ◽  
Zhan Qiang Liu
Keyword(s):  
Plastic Deformation ◽  
Surface Integrity ◽  
White Layer ◽  
High Reliability ◽  
Cutting Speed ◽  
Surface Plastic Deformation ◽  
Surface Plastic ◽  
Layer Formation ◽  
Machined Surface ◽  
White Layer Formation

The superalloy parts in the aeronautical field demand high reliability, which is largely related to surface integrity. Surface integrity generally includes three parameters, such as geometric parameter, mechanical parameter and metallurgical parameter. The paper presents the influence of cutting speed on surface plastic deformation and white layer formation through orthogonal milling of FGH95 superally material. The influence of cutting speed on grain refinement of machined surface is also investigated. It is found that cutting speed has significantly effect on the surface metallurgical characteristic microstructure. The increasing of cutting speed creates severer plastic deformation. Surface plastic shear strain increases with the increasing of cutting speed, while the depth of plastic deformation decreases on contrary. White layer thickness is increased with the increasing of cutting speed. Through statistical analysis for grains number, it can be drawn that the higher the cutting speed, the more serious grains refinement.

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