Analytical modeling of tool failure boundary map in milling titanium alloy

2021 ◽  
pp. 095440542110439
Author(s):  
Yan-jie Du ◽  
Cai-xu Yue ◽  
Xiao-chen Li ◽  
Xian-li Liu ◽  
Steven Y. Liang
Keyword(s):  
Titanium Alloy ◽  
Cutting Parameters ◽  
Milling Process ◽  
Machine Material ◽  
Tool Failure ◽  
Prediction Time ◽  
Boundary Map ◽  
The Stability ◽  
Titanium Alloy Ti6al4v ◽  
Cemented Carbide Tools

As a typical aerospace difficult-to-machine material, tool failure in milling titanium alloy Ti6Al4V will reduce the stability of the milling process and affect the surface quality of the workpiece. Aiming at the fact that cemented carbide tools are prone to wear failure and breakage failure in milling titanium alloy, a safe tool failure boundary map is provided to ensure that the tools will not occur failure with the cutting parameters selected in the safe area during the prediction time. Based on the processing characteristics of Ti6Al4V, the failure boundary map mainly considers three forms of tool failure: flank wear, rake wear, and cutting edge breakage. By revealing the three failure mechanisms, the failure analytical model is established and the failure boundary map is obtained. Compared with the experimental results, it has good consistency, and the research results can provide a reference for the field of titanium alloy cutting process.

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.

Investigations on the Machinability of Titanium Alloy TC25

2014 ◽  
Vol 800-801 ◽  
pp. 92-96
Author(s):  
Hong Shan Zhang ◽  
Xing Ai ◽  
Zhan Qiang Liu ◽  
Ji Gang Liu ◽  
Zhao Lin Zhong
Keyword(s):  
Thermal Stability ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Service Life ◽  
Heat Resistance ◽  
Cutting Forces ◽  
Cutting Parameters ◽  
Aircraft Industry ◽  
Excellent Thermal Stability ◽  
Cemented Carbide Tools

Titanium alloy TC25 has been widely used in aircraft industry due to its excellent thermal stability, heat resistance and longer service life. In this paper, cemented carbide tools were applied to carry out orthogonal milling experiments for both titanium alloy TC25 and TC4 with identical cutting conditions. Cutting forces, cutting temperatures and surface roughness were measured to assess the machinability for TC25 and TC4. From the experimental results, the cutting parameters can be optimized to guide efficient machining processing of TC25.

scholarly journals Machining Performance of TiAlN-Coated Cemented Carbide Tools with Chip Groove in Machining Titanium Alloy Ti-6Al-0.6Cr-0.4Fe-0.4Si-0.01B

Metals ◽  
2018 ◽  
Vol 8 (10) ◽  
pp. 850 ◽  
Author(s):  
Zhaojun Ren ◽  
Shengguan Qu ◽  
Yalong Zhang ◽  
Xiaoqiang Li ◽  
Chao Yang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Machining Performance ◽  
Cemented Carbide Tools ◽  
Optimal Cutting Parameters ◽  
Coated Cemented Carbide

In this paper, TiAlN-coated cemented carbide tools with chip groove were used to machine titanium alloy Ti-6Al-0.6Cr-0.4Fe-0.4Si-0.01B under dry conditions in order to investigate the machining performance of this cutting tool. Wear mechanisms of TiAlN-coated cemented carbide tools with chip groove were studied and compared to the uncoated cemented carbide tools (K20) with a scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). The effects of the cutting parameters (cutting speed, feed rate and depth of cut) on tool life and workpiece surface roughness of TiAlN-coated cemented carbide tools with chip groove were studied with a 3D super-depth-of-field instrument and a surface profile instrument, respectively. The results showed that the TiAlN-coated cemented carbide tools with chip groove were more suitable for machining TC7. The adhesive wear, diffusion wear, crater wear, and stripping occurred during machining, and the large built-up edge formed on the rake face. The optimal cutting parameters of TiAlN-coated cemented carbide tools were acquired. The surface roughness Ra decreased with the increase of the cutting speed, while it increased with the increase of the feed rate.

Experimental Study on Tool Wear in Cutting Titanium Alloy Ti6Al4V

2011 ◽  
Vol 239-242 ◽  
pp. 2011-2014
Author(s):  
Yue Feng Yuan ◽  
Wu Yi Chen ◽  
Wen Ying Zhang
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Linear Regression Analysis ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Aged Condition ◽  
Cutting Depth ◽  
Solution Treated ◽  
Titanium Alloy Ti6al4v

Tool wear experiments in turning titanium alloy Ti6Al4V in the solution-treated and aged condition were carried out; the influence rules of cutting parameters such as cutting speed, feed rate and cutting depth on the tool life were obtained. Experimental formula of tool wear was regressed based on multi-variable linear regression analysis, it could predict tool life under certain conditions.

Influence of Cutter Geometric Parameters on the Stability of Milling Process of Thin-Walled Blades

2012 ◽  
Vol 443-444 ◽  
pp. 21-26 ◽  
Author(s):  
Wei Wei Liu ◽  
Xiao Juan Gao ◽  
Chen Wei Shan ◽  
Wei Jun Tian
Keyword(s):  
High Performance ◽  
Cutting Parameters ◽  
Milling Process ◽  
Chatter Vibration ◽  
Clamping System ◽  
Cutting Deformation ◽  
Thin Walled ◽  
Simulation Results ◽  
The Stability ◽  
New System

In this paper, a new experiment procedure is proposed to study the influence of cutter parameters and clamping methods on the stability of the milling process of thin-walled blade. A dedicated fixture is designed to carry out the experiment. Simulation results show that the new clamping system can enhance the rigidity of thin-walled blade to reduce cutting deformation and chatter vibration phenomenon. Then, cutter and cutting parameters can be optimized properly to make the system obtain high rigidity and high performance stable milling process. Industrial application indicates that the new system can improve the cutting performance and ensure the cutting quality.

scholarly journals The influence of tool diameter on wear during milling of titanium alloy Ti6Al4V

Mechanik ◽  
2017 ◽  
Vol 90 (3) ◽  
pp. 198-200
Author(s):  
Józef Kuczmaszewski ◽  
Kazimierz Zaleski ◽  
Jakub Matuszak ◽  
Tomasz Pałka ◽  
Rafał Garwacki
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Milling Process ◽  
Production Costs ◽  
High Durability ◽  
Titanium Alloy Ti6al4v ◽  
Wear Tool ◽  
Tool Diameter ◽  
The Impact ◽  
Large Coefficient

One of the main problems associated with machining of difficult-to-cut materials is tool wear. Tool wear may comprise a large proportion of production costs. Titanium alloys due to its properties – low thermal conductivity, high durability and a large coefficient of friction belong to difficult-to-cut materials. The paper presents the results of research on the impact of cutter diameter on tool wear during the milling process of titanium alloy Ti6Al4V.

Effect of Cutting Conditions on the Stability Lobes for End Milling Process

2010 ◽  
Vol 139-141 ◽  
pp. 748-751
Author(s):  
Min Wan ◽  
Yi Ting Wang ◽  
Wei Hong Zhang ◽  
Jian Wei Dang
Keyword(s):  
End Milling ◽  
Cutting Parameters ◽  
Helix Angle ◽  
Milling Process ◽  
Cutting Condition ◽  
Multiple Delays ◽  
Cutter Runout ◽  
Stability Lobes ◽  
The Stability ◽  
New Phenomena

Milling process will be dominated by multiple delays due to the effect of the cutter runout or the pitch angles of the cutter. In this paper, research efforts are focused on the dynamic behavior of milling processes under different cutting condition parameters such as different radial immersions, feed directions, feeds per tooth and helix angles. To improve the prediction accuracy of stability lobe, the combined influences of feed rate and cutter runout on the stability lobes are also taken into account. The basic principle of the method presented in one existing work is applied to examine the asymptotic stability trends for both down milling and up milling. Some new phenomena for certain combinations of cutting parameters are shown and explained in detail. It is found that as cutter runout occurs, feed per tooth, feed direction and cutter helix angle have great effects on the stability lobes.

scholarly journals Study on the Cutting Performance of Micro Textured Tools on Cutting Ti-6Al-4V Titanium Alloy

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 137 ◽  
Author(s):  
Kairui Zheng ◽  
Fazhan Yang ◽  
Na Zhang ◽  
Qingyu Liu ◽  
Fulin Jiang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Feed Force ◽  
Cemented Carbide Tools

Titanium alloys are widely used in various fields, but their machinability is poor because the chip would easily adhere to the tool surface during cutting, causing poor surface quality and tool wear. To improve the cutting performance of titanium alloy Ti-6Al-4V, experiments were conducted to investigate the effect of micro textured tool on the cutting performances. The cemented carbide tools whose rake faces were machined with line, rhombic, and sinusoidal groove textures with 10% area occupancy rates were adopted as the cutting tools. The effects of cutting depth and cutting speed on feed force and main cutting force were discussed based on experimental results. The results show that the cutting force produced by textured tools is less than that produced by non-textured tools. Under different cutting parameters, the best cutting performance can be obtained by using sinusoidal textured tools among the four types of tools. The wear of micro textured tools is significantly lower than that of non-textured tools, due to a continuous lubrication film between the chip and the rake face of the tool that can be produced because the micro texture can store and replenish lubricant. The surface roughness obtained using the textured tool is better than that using the non-textured tool. The surface roughness Ra can be reduced by 35.89% when using sinusoidal textured tools. This study is helpful for further improving the cutting performance of cemented carbide tools on titanium alloy and prolonging tool life.

Tool stiffness influence on the chosen physical parameters of the milling process

2012 ◽  
Vol 60 (3) ◽  
pp. 597-604 ◽  
Author(s):  
W. Zębala
Keyword(s):  
Titanium Alloy ◽  
Aluminium Alloy ◽  
Chip Formation ◽  
Cutting Forces ◽  
Contact Point ◽  
Milling Process ◽  
Cutting Process ◽  
Physical Parameters ◽  
Titanium Alloy Ti6al4v ◽  
The Impact

Abstract This article presents our own model researches, relating to the down milling process of Aluminium alloy (Al6061) and Titanium alloy (Ti6Al4V), with a tool made of sintered carbides. These investigations pay the special attention to the impact of the tool rigidity on the process of chip formation. The simulation calculations have been carried out for two cases of the cutting process: case 1 - assuming an ideally rigid construction of a milling cutter (length of tool does not impact its deflection under the cutting forces); case 2 - it is possible that the tool can be subjected to deflection under the cutting forces (length of a tool part is counted from the holder end to the contact point of a cutting edge with the machining material).

Cutting Temperature in High Speed Milling of a Near Alpha Titanium Alloy

2006 ◽  
Vol 315-316 ◽  
pp. 145-149 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu ◽  
Yu Can Fu ◽  
Y.F. Ge ◽  
C. Su
Keyword(s):  
Titanium Alloy ◽  
High Speed ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Machining Accuracy ◽  
High Speed Milling ◽  
Thermocouple Method ◽  
Alpha Titanium ◽  
Cemented Carbide Tools

Cutting temperature has direct effects on tool wear and tool life, as well as machining accuracy and machining quality. Titanium alloys, however, are generally machined at lower cutting speeds with cemented carbide tools due to its low thermal conductivity and high chemical reactivity with cutting tool materials. This paper deals with cutting temperature in high-speed milling of a near alpha titanium alloy. The measuring principle of cutting temperature by the workpiece-constantan thermocouple method was illustrated and the physical meaning of the electromotive force (EMF) signals was described in the paper. The effects of cutting parameters and wear status on cutting temperature were studied, and the temperature distribution along the cutting edge was investigated.

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