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.

scholarly journals EXPERIMENTAL INVESTIGATION OF TOOL WEAR AND INDUCED VIBRATION IN TURNING HIGH HARDNESS AISI52100 STEEL USING CUTTING PARAMETERS AND TOOL ACCELERATION

2020 ◽  
pp. 623
Author(s):  
Nitin Ambhore ◽  
Dinesh Kamble
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Low Cost ◽  
High Hardness ◽  
Cutting Parameters ◽  
Small Scale ◽  
Wear Monitoring ◽  
Artificial Neural Network Ann ◽  
Experimental Values ◽  
Coated Carbide

In machining of high hardness steel, vibration of cutting tool increases tool wear which reduces its life. Tool wear is catastrophic in nature and hence investigation of its assessment is important. This study investigates experimentally induced vibration during turning of hardened AISI52100 steel of hardness 54±2 HRC using coated carbide insert. In this context, cutting tool acceleration is measured and used to develop a novel mathematical model based on acquired real time acceleration signals of cutting tool. The obtained model is validated as R2= 0.93 while its residuals values closely follow the straight line. The predictions are confirmed by conducting conformity test which revealed a close degree of agreement with respect to the experimental values. The Artificial Neural Network (ANN) examination is performed to determine the model regression value. The study shows that the examined reports forecasts of ANN are more exact than regression analysis. The future directon of this investigation is towards developing a low-cost microcontroller-based hardware unit for in-process tool wear monitoring which could be beneficial for small scale industries.

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%.

Highlights of the DARPA Advanced Machining Research Program

1985 ◽  
Vol 107 (4) ◽  
pp. 325-335 ◽  
Author(s):  
R. Komanduri ◽  
D. G. Flom ◽  
M. Lee
Keyword(s):  
Thermal Properties ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Research Program ◽  
High Speed ◽  
Metal Removal ◽  
High Speed Machining ◽  
Advanced Machining ◽  
Nickel Base

Results of a four-year Advanced Machining Research Program (AMRP) to provide a science base for faster metal removal through high-speed machining (HSM), high-throughput machining (HTM) and laser-assisted machining (LAM) are presented. Emphasis was placed on turning and milling of aluminum-, nickel-base-, titanium-, and ferrous alloys. Experimental cutting speeds ranged from 0.0013 smm (0.004 sfpm) to 24,500 smm (80,000 sfpm). Chip formation in HSM is found to be associated with the formation of either a continuous, ribbon-like chip or a segmental (or shear-localized) chip. The former is favored by good thermal properties, low hardness, and fcc/bcc crystal structures, e.g., aluminum alloys and soft carbon steels, while the latter is favored by poor thermal properties, hcp structure, and high hardness, e.g., titanium alloys, nickel base superalloys, and hardened alloy steels. Mathematical models were developed to describe the primary features of chip formation in HSM. At ultra-high speed machining (UHSM) speeds, chip type does not change with speed nor does tool wear. However, at even moderately high speeds, tool wear is still the limiting factor when machining titanium alloys, superalloys, and special steels. Tool life and productivity can be increased significantly for special applications using two novel cutting tool concepts – ledge and rotary. With ledge inserts, titanium alloys can be machined (turning and face milling) five times faster than conventional, with long tool life (~ 30 min) and cost savings up to 78 percent. A stiffened rotary tool has yielded a tool life improvement of twenty times in turning Inconel 718 and about six times when machining titanium 6A1-4V. Significantly increased metal removal rates (up to 50 in.3/min on Inconel 718 and Ti 6A1-4V) have been achieved on a rigid, high-power precision lathe. Continuous wave CO2 LAM, though conceptually feasible, limits the opportunities to manufacture DOD components due to poor adsorption (~ 10 percent) together with high capital equipment and operating costs. Pulse LAM shows greater promise, especially if new laser source concepts such as face pump lasers are considered. Economic modeling has enabled assessment of HSM and LAM developments. Aluminum HSM has been demonstrated in a production environment and substantial payoffs are indicated in airframe applications.

The Ledge Tool: A New Cutting Tool Insert

1985 ◽  
Vol 107 (2) ◽  
pp. 99-106 ◽  
Author(s):  
R. Komanduri ◽  
M. Lee
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Cutting Tool ◽  
Metal Removal ◽  
Face Milling ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Peripheral Milling ◽  
Cemented Carbide Tool ◽  
Edge Wear

The salient features of a simple, wear-tolerant cemented carbide tool are described. Results are presented for high-speed machining (3 to 5 times the conventional speeds) of titanium alloys in turning and face milling. This tool, termed the ledge cutting tool, has a thin (0.015 to 0.050 in.) ledge which overhangs a small distance (0.015 to 0.060 in.) equal to the depth of cut desired. Such a design permits only a limited amount of flank wear (determined by the thickness of the ledge) but continues to perform for a long period of time as a result of wear-back of the ledge. Under optimum conditions, the wear-back occurs predominantly by microchipping. Because of geometric restrictions, the ledge tool is applicable only to straight cuts in turning, facing, and boring, and to face milling and some peripheral milling. Also, the maximum depth of cut is somewhat limited by the ledge configuration. In turning, cutting time on titanium alloys can be as long as ≈ 30 min. or more, and metal removal of ≈ 60 in.3 can be achieved on a single edge. Wear-back rates in face milling are about 2 to 3 times higher than in straight turning. The higher rates are attributed here to the interrupted nature of cutting in milling. Use of a grade of cemented carbide (e.g., C1 Grade) which is too tough or has too thick a ledge for a given application leads to excessive forces which can cause gross chipping of the ledge (rapid wear) and/or excessive deflection of the cutting tool with reduced depth of cut. Selection of a proper grade of carbide (e.g., Grades C2, C3, C4) for a given application results in uniform, low wear-back caused by microchipping. Because of the end cutting edge angle (though small, ≈ 1 deg) used, the ledge tool can generate a slight taper on very long parts; hence an N.C. tool offset may be necessary to compensate for wear-back. The ledge tool is found to give excellent finish (1 to 3 μm) in both turning and face milling. In general, conventional tooling with slight modifications can be used for ledge machining. The ledge tool can also be used for machining cast iron at very high speeds.

scholarly journals A Review on Diffusion Bonding between Titanium Alloys and Stainless Steels

2018 ◽  
Vol 2018 ◽  
pp. 1-15 ◽  
Author(s):  
De-feng Mo ◽  
Ting-feng Song ◽  
Yong-jian Fang ◽  
Xiao-song Jiang ◽  
Charles Q. Luo ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Titanium Alloy ◽  
Titanium Alloys ◽  
Stainless Steels ◽  
Diffusion Bonding ◽  
Low Cost ◽  
Phase Interface ◽  
Intermetallic Phases ◽  
Voids Growth

High-quality joints between titanium alloys and stainless steels have found applications for nuclear, petrochemical, cryogenic, and aerospace industries due to their relatively low cost, lightweight, high corrosion resistance, and appreciable mechanical properties. This article reviews diffusion bonding between titanium alloys and stainless steels with or without interlayers. For diffusion bonding of a titanium alloy and a stainless steel without an interlayer, the optimized temperature is in the range of 800–950°C for a period of 60–120 min. Sound joint can be obtained, but brittle FeTi and Fe-Cr-Ti phases are formed at the interface. The development process of a joint mainly includes three steps: matching surface closure, growth of brittle intermetallic compounds, and formation of the Kirkendall voids. Growth kinetics of interfacial phases needs further clarification in terms of growth velocity of the reacting layer, moving speed of the phase interface, and the order for a new phase appears. The influence of Cu, Ni (or nickel alloy), and Ag interlayers on the microstructures and mechanical properties of the joints is systematically summarized. The content of FeTi and Fe-Cr-Ti phases at the interface can be declined significantly by the addition of an interlayer. Application of multi-interlayer well prevents the formation of intermetallic phases by forming solid solution at the interface, and parameters can be predicted by using a parabolic diffusion law. The selection of multi-interlayer was done based on two principles: no formation of brittle intermetallic phases and transitional physical properties between titanium alloy and stainless steel.

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.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

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 An overview of conventional and non-conventional techniques for machining of titanium alloys

2020 ◽  
Vol 7 ◽  
pp. 34 ◽  
Author(s):  
Samuel Ranti Oke ◽  
Gabriel Seun Ogunwande ◽  
Moshood Onifade ◽  
Emmanuel Aikulola ◽  
Esther Dolapo Adewale ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Metal Removal ◽  
Removal Rate ◽  
High Volume ◽  
Future Research ◽  
Tool Wear Rate ◽  
The Common

Machining is one of the major contributors to the high cost of titanium-based components. This is as a result of severe tool wear and high volume of waste generated from the workpiece. Research efforts seeking to reduce the cost of titanium alloys have explored the possibility of either eliminating machining as a processing step or optimising parameters for machining titanium alloys. Since the former is still at the infant stage, this article provides a review on the common machining techniques that were used for processing titanium-based components. These techniques are classified into two major categories based on the type of contact between the titanium workpiece and the tool. The two categories were dubbed conventional and non-conventional machining techniques. Most of the parameters that are associated with these techniques and their corresponding machinability indicators were presented. The common machinability indicators that are covered in this review include surface roughness, cutting forces, tool wear rate, chip formation and material removal rate. However, surface roughness, tool wear rate and metal removal rate were emphasised. The critical or optimum combination of parameters for achieving improved machinability was also highlighted. Some recommendations on future research directions are made.

Machinability of Heat-Resistant Titanium Alloys during Turning

2021 ◽  
Vol 1022 ◽  
pp. 62-70
Author(s):  
Tatyana Larionova ◽  
Sergei A. Lyubomudrov ◽  
Evgeniy Larionov
Keyword(s):  
Mathematical Model ◽  
Titanium Alloy ◽  
Titanium Alloys ◽  
Experimental Research ◽  
Cutting Tool ◽  
Technological System ◽  
Elastic Deformations ◽  
Heat Resistant ◽  
Processing Modes ◽  
Mechanical And Service Properties

The article discusses the properties and features of heat-resistant titanium alloys. The microstructure of a new titanium alloy VT41, its mechanical and service properties after various processing modes are presented. The main problems in the machining of difficult-to-machine titanium alloys are considered. The developed mathematical model of the formation of errors in turning titanium alloys, taking into account thermal deformations and dimensional wear of the cutting tool, elastic deformations of the technological system, is described. The paper presents the results of experimental research on turning of heat-resistant titanium alloy VT41 on a multi-parameter stand.

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