scholarly journals Simulation Analysis and Experimental Validation of Cathode Tool in Electrochemical Mill-Grinding of Ti6Al4V

2020 ◽  
Vol 10 (6) ◽  
pp. 1941 ◽  
Author(s):  
Jie Li ◽  
Hansong Li ◽  
Xiaoyun Hu ◽  
Shen Niu ◽  
Guoliang Xu
Keyword(s):  
Titanium Alloy ◽  
Rough Surface ◽  
Experimental Validation ◽  
Simulation Analysis ◽  
Machining Parameters ◽  
Rough Machining ◽  
Cutting Depth ◽  
Machined Surface ◽  
Structural Parts ◽  
Micro Morphology

Electrochemical mill-grinding (ECMG) is an ideal technical means to achieve an efficient and precise machining of titanium alloy monolithic structural parts. In the rough ECMG process, the selection of a reasonable cutting depth can improve the machining efficiency of the rough machining. Adopting a reasonable cathode tool structure can achieve a higher precision in the formation of the rough surface, reduce the finishing allowance and tool wear of subsequent finishing. With this aim, the present research proposed a cathode tool with a reasonable structure. Simulation results showed that the designed cathode tool presented a good uniformity of the flow field in the machining gap, which resulted in a higher precision in the formation of the rough surface. For experimental validation, a larger cutting depth and a designed cathode tool was employed to carry out the rough and finish machining experiments on a Ti6Al4V titanium alloy. The experimental results show that a good flatness of the sidewall of the rough-machining groove was obtained by this scheme. Furthermore, the machining surface exhibited no flow marks, and rough machining accounted for 92.37% of total removal. Moreover, measurement of the micro-morphology, roughness and elemental composition of the machined surface, and the effects of different machining parameters on the surface quality of titanium alloys, were studied.

Machining Finish of Titanium Alloy Prepared by Additive Manufacturing

2017 ◽  
Vol 872 ◽  
pp. 43-48 ◽  
Author(s):  
Xin Huang ◽  
Qian Bai ◽  
Yong Tao Li ◽  
Bi Zhang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Additive Manufacturing ◽  
Surface Finish ◽  
Functional Performance ◽  
Critical Role ◽  
Lower Surface ◽  
Machining Parameters ◽  
Machined Surface ◽  
Slot Milling

Surface finish plays a critical role in functional performance of machined components. This study investigates machining finish of Ti-6Al-4V alloy prepared by Additive Manufacturing (AM) with a series of slot-milling experiments. The study compares the machined AMed part with that made of the conventional wrought Ti-6Al-4V. The microstructure of AMed parts is acicular α and Widmanstatten α lath structures compared to lamellar α structure of that in the wrought parts. Due to the unique microstructure from AM process, the AMed parts present higher strength and lower ductility. Therefore, a lower surface roughness is obtained in the milling of AMed parts compared to its counterpart of wrought parts. In addition, the machined surface of AMed parts possesses a topography of discontinued ridges. It is believed that the topography is due to low ductility of AMed part. The results show that the machined AMed part presents better surface finish. The study provides a guidance to optimization of machining parameters for AMed Ti-6Al-4V alloys.

Study on Residual Stress for High-Speed Cutting Titanium Alloy Based on Finite Element Method

2011 ◽  
Vol 188 ◽  
pp. 216-219 ◽  
Author(s):  
M.H. Wang ◽  
Zhong Hai Liu ◽  
Hu Jun Wang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Titanium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Simulation Method ◽  
Residual Tensile Stress ◽  
Cutting Depth ◽  
Machined Surface ◽  
High Speed Cutting

In order to improve machined surface quality and reduce the deformation, the residual stress involved in cutting titanium alloy was studied under different cutting speed and cutting depth by finite element simulation method. The results indicate that the increase of cutting speed and cutting depth are helpful to the surface residual compressive stress generating. However the increase of cutting speed also leads to the increase of surface residual tensile stress, the effect degree is relatively small. It is required to select higher cutting speed and smaller cutting depth to improve the surface stress state and reduce the unexpected distortion.

FRACTAL-BASED ANALYSIS OF THE EFFECT OF MACHINING PARAMETERS ON SURFACE FINISH OF WORKPIECE IN TURNING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (04) ◽  
pp. 1950043 ◽  
Author(s):  
GEEVIN JITHMAL PATHIRANAGAMA ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Quality ◽  
Surface Finish ◽  
Feed Rate ◽  
Fractal Theory ◽  
Complex Structure ◽  
Spindle Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
Machined Surface ◽  
Turning Operation

Analysis of workpiece surface quality is one of the major issues in manufacturing engineering. Turning operation is a famous machining operation that is widely used in machining of materials. In this research, we investigate the surface finish of machined workpiece from turning operation. For this purpose, we employ fractal theory to study the complex structure of machined workpiece’s surface in different conditions. The applied parameters include the variations of cutting depth, feed rate and spindle speed in wet and dry machining conditions. Based on the obtained results, we found the correlation between the increment of fractal dimension of machined surface and the increment of cutting depth, feed rate and spindle speed in wet machining condition. The obtained results will be discussed in relation with the complexity of machined surface. The employed method of analysis in this research can be widely applied to the analysis of the effect of different machining parameters and conditions on the surface quality of machined workpiece in case of different machining operations.

Research on Anti-Burnt Method during Machining Complex Titanium Alloy Aircraft Structural Parts

2013 ◽  
Vol 589-590 ◽  
pp. 299-303
Author(s):  
Shao Chun Sui ◽  
Cheng Li Du ◽  
Li Min Tang
Keyword(s):  
Titanium Alloy ◽  
Machining Process ◽  
Machining Parameters ◽  
Structural Parts

With the development of modern aircraft, complex titanium alloy aircraft structural parts are widely used. As a kind of difficult machining material, it’s easy to burn the tools and the parts during machining the titanium alloy structural parts because of the gathering heat. The article studies the technology to prevent burning the titanium structural parts during the machining process. The burnt problem can be effectively solved by using proper tools, proper machining parameters and fully cooling environment.

scholarly journals Large Cutting Depth and Layered Milling of Titanium Alloy Thin-Walled Parts

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1499
Author(s):  
Jun Zha ◽  
Jianxin Liang ◽  
Yipeng Li ◽  
Huijie Zhang ◽  
Yaolong Chen
Keyword(s):  
Titanium Alloy ◽  
Milling Process ◽  
Machining Accuracy ◽  
Rough Machining ◽  
Cutting Depth ◽  
Optical Scanner ◽  
Measurement Results ◽  
Milling Method ◽  
Thin Walled ◽  
Coated Cemented Carbide

Deformation of thin-walled titanium alloys can occur during the milling process due to the cutting force and chatter vibration, which can influence the precision of the finished parts. In this research, a new milling method without auxiliary support for machining of thin-walled parts was proposed. A large cutting depth and layered milling technology were used during rough machining, with a different machining allowance for each subsequent remaining layer. In the finishing stage, the surface of the previous layer needed to be dressed before processing the next layer. A TiAlSiN-coated, cemented carbide milling cutter was used to machine titanium alloy thin-walled parts, which are characterized by continuous multilayers of unequal thickness. The processing path was simulated using HyperMILL software, and the machining accuracy was detected by the 3D optical scanner. The measurement results indicated that the surface contour accuracy of the parts was ±0.21 mm, within a range of ±0.30 mm. The machining efficiency was increased by 40%, while guaranteeing machining accuracy.

Energy Mapping and Optimization in Rough Machining of Impellers

2016 ◽  
Author(s):  
Zhenhua Wu ◽  
Marthony Hobgood ◽  
Mathias Wolf
Keyword(s):  
Energy Consumption ◽  
Specific Energy ◽  
Ball Mill ◽  
Removal Rate ◽  
Specific Energy Consumption ◽  
Critical Factor ◽  
Machining Parameters ◽  
Rough Machining ◽  
Cutting Depth ◽  
Energy Mapping

In this paper, energy mapping and optimization in rough machining of impellers was investigated. Experiments were first designed based on the response surface methodology (RSM) to minimize operation specific energy consumption in machining through selection of machining parameters (spindle speed, cutting depth, and feed rate) in the Siemens NX computer aided manufacturing (CAM) simulation. With the simulated machining solution and G-code, experiments were conducted on the CNC lathe and mill to cut Al 6061 impellers. The machine energy consumption was measured using a power meter. The operation specific energy was analyzed in analysis of variance (ANOVA), regression models, and desirability functions. The minimum specific energy in the rough and semi-finish turning process is 0.16 J/mm3 and 0.23 J/mm3 respectively. The minimum specific energy in the blades milling process with 6mm ball mill or 3mm ball mill is 0.08 J/mm3 and 0.42 J/mm3 respectively. In the experiment settings, it identified that cutting depth is the most critical factor to affect the specific energy consumption in impeller machining. The empirical equations between the specific energy and material removal rate (MRR) concluded that specific energy is proportional to the inverse of MRR. From the study, it would suggest that in order to minimize the specific energy in machining of impellers, it should selected the MRR as large as possible.

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.

On-line selection of rough machining parameters

2004 ◽  
Vol 149 (1-3) ◽  
pp. 256-262 ◽  
Author(s):  
Joško Valentinčič ◽  
Mihael Junkar
Keyword(s):  
Machining Parameters ◽  
Rough Machining ◽  
On Line ◽  
Line Selection ◽  
Selection Of

An Experimental Study of Cutting Force on Large Cutting Depth Turning Titanium Alloy with CBN Tool

2014 ◽  
Vol 800-801 ◽  
pp. 237-240
Author(s):  
Li Fu Xu ◽  
Ze Liang Wang ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Cbn Tool ◽  
Cutting Experiment ◽  
Rough Turning

In this paper, the cutting experiment was used to study the influence of various cutting parameters on cutting force when rough turning titanium alloy (TC4) with the whole CBN tool. The results indicate that among the cutting speed, feed rate and cutting depth, the influence of the cutting depth is the most significant on cutting force; the next is the feed rate and the cutting speed is at least.

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