scholarly journals Investigation of Tool Wear and Chip Morphology in Dry Trochoidal Milling of Titanium Alloy Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (12) ◽  
pp. 1937 ◽  
Author(s):  
Dongsheng Liu ◽  
Ying Zhang ◽  
Ming Luo ◽  
Dinghua Zhang
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
High Efficiency ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Trochoidal Milling ◽  
Radial Depth

Titanium alloys are widely used in the manufacture of aircraft and aeroengine components. However, tool wear is a serious concern in milling titanium alloys, which are known as hard-to-cut materials. Trochoidal milling is a promising technology for the high-efficiency machining of hard-to-cut materials. Aiming to realize green machining titanium alloy, this paper investigates the effects of undeformed chip thickness on tool wear and chip morphology in the dry trochoidal milling of titanium alloy Ti–6Al–4V. A tool wear model related to the radial depth of cut based on the volume of material removed (VMR) is established for trochoidal milling, and optimized cutting parameters in terms of cutting speed and axial depth of cut are selected to improve machining efficiency through reduced tool wear. The investigation enables the environmentally clean rough machining of Ti–6Al–4V.

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.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

Experimental Investigation of Tool Wear and Chip Morphology in Turning Titanium Alloy Ti6Al4V

2014 ◽  
Vol 800-801 ◽  
pp. 81-86
Author(s):  
Zhen Li ◽  
Er Liang Liu ◽  
Teng Da Wang ◽  
Jiao Li ◽  
Yong Chun Zheng
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Adhesion Wear ◽  
On Chip ◽  
Titanium Alloy Ti6al4v ◽  
Cutting Experiments

The various feed rate and cutting speed have an important influence on cutting force, tool wear and chip morphology in machining titanium alloy. Cutting experiments are carried out analyzing the titanium alloy Ti6Al4V under different cutting speed and feed rate, the cutting force values are obtained. The analysis results show that the dominant wear pattern is adhesion wear and chipping. And the tool wear also has an influence on chip morphology.

The Study of Tool Wear Performance on Pocket Milling Strategy

2014 ◽  
Vol 699 ◽  
pp. 64-69 ◽  
Author(s):  
A.B. Mohd Hadzley ◽  
A. Siti Sarah ◽  
R. Izamshah ◽  
M.R. Nurul Fatin
Keyword(s):  
Tool Wear ◽  
Tool Path ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Wear Performance ◽  
Pocket Milling ◽  
Cnc Milling Machine ◽  
Radial Depth ◽  
Wet Condition

The increasing productivity demand in machining industry has lead for fast material removal machining technique of pocket milling using different tool path strategies. This project aims to study about the effect of different tool path strategies on tool wear when machining aluminium alloy 7076. Five milling strategies were evaluated outward helical, inward helical, back and forth, offset on part one-way and offset on part zigzag. CATIA V5R19 was used to setup milling path and the machining experiments were carried out on a HAAS’ 3 axis CNC milling machine. The machining was held under wet condition with 2500 rpm cutting speed, 800 mm/min feed rate, 2 mm radial depth of cut and 2 mm axial depth of cut. The results showed that the best tool path strategies are inward helical and offset on part one-way, while the worst tool path strategy is outward helical. Failure to evacuate chip during pocket milling is the main reason to cause rapid tool wear due to temperature rise and higher contact time and area of cutting tool with the chip. Results from this experiment help to guide the machinist to perform pocket milling effectively.

Microscale Drilling of Bulk Metallic Glass

2013 ◽  
Vol 1 (4) ◽  
Author(s):  
James Zhu ◽  
Hyun Jin Kim ◽  
Shiv G. Kapoor
Keyword(s):  
Metallic Glass ◽  
Tool Wear ◽  
Bulk Metallic Glass ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Acoustic Emissions ◽  
Chip Morphology ◽  
High Rate ◽  
Burr Height ◽  
Drilling Performance

The microscale drilling performance of a Zr-based bulk metallic glass (BMG) is investigated in this paper. Crystallization, drill temperature, axial force, spindle load (SL), acoustic emissions (AE), chip morphology, hole diameter, and entry burr height are measured and analyzed with varying cutting speed and chip load. The progression of tool wear is assessed using stereo-microscopy techniques. At small chip loads, minimum chip thickness (MCT) is observed to shift cutting mechanics from a shear-dominated to a ploughing-dominated regime. Consequently, evidence of drill instability and larger burr height are observed. As drilling temperatures rise above the glass transition temperature, the BMG thermally softens due to the transition to a super-cooled liquid state and begins to exhibit viscous characteristics. In the tool wear study using tungsten carbide microdrills, rake wear is found to dominate compared to flank wear. This is attributed to a combination of a high rate of diffusion wear on the rake face as well as lower abrasion on the flank due to the decreased hardness from thermal softening-induced viscous flow of BMG.

Performance of Brazed Carbide End Mill Tool for Machining of Ti6Al4V

2014 ◽  
Vol 541-542 ◽  
pp. 363-367 ◽  
Author(s):  
Saad Nawaz ◽  
Li Xiao Xing ◽  
Zhou Chai
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Thermal Stresses ◽  
Elevated Temperatures ◽  
Aerospace Industry ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
End Mill

Titanium alloys are attractive materials for aerospace industry due to their exceptional strength to weight ratio that is maintained at elevated temperatures and their good corrosion resistance. Major applications of Titanium alloys were military aerospace industry, but since last decade the trend has now shifted towards commercial industry. On the other hand Titanium alloys are notorious for being poor thermal conductor that leads to them being difficult materials for machining. In this experimental study brazed carbide end mill of grade 5 is used for rough down milling of Ti6Al4V for large depth of cut under different combinations of parameters and application of high pressure coolant. The machining performance was evaluated in terms of tool wear, tool life, thermal crack and tool breaking. The tool wear was mostly observed at the tool tip and at bottom part of tool thermal cracks were observed which propagated with respect to time. Flank wear due to scratching of the cutting chips and diffusion wear because of high thermal stresses were observed specially at the bottom of the cutting tool. At cutting speed of 38m/min tool wear couldnt be observed due to tool failure because of fracture under high thermal stresses. It was found that maximum tool life is obtained at the speed of 25m/min, feed rate of 150mm/min and depth of cut of 10mm. In the end it was concluded that machining of Ti6Al4V is a thermally dominant process which leads to high thermal stresses in machining zone that results in increasing tool wear rate and fracture propagation.

An Experimental Study on Rough Ball-End Milling of T10A Steel

2011 ◽  
Vol 188 ◽  
pp. 78-83
Author(s):  
Xin Qiang Zhuang ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Bin Zou ◽  
H.L. Liu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Main Tool ◽  
Depth Of Cut ◽  
Tool Wear Mechanisms ◽  
Radial Depth ◽  
Coated Cemented Carbide

The milling experiments of the annealed T10A steel were carried out in the various cutting conditions using the coated cemented carbide tool. The cutting parameters were designed by the multi-factor orthogonal experiment method, and the effects of cutting speed, feed, axial depth of cut and radial depth of cut on the cutting force and tool wear were investigated. The tool wear mechanisms were also discussed. Adhesion, abrasion, diffusion and oxidation were the main tool wear mechanisms. According to these investigations, the optimizing cutting parameter was recommended.

scholarly journals On the Machinability Evolution in Asymmetric Milling of TC25 Ti Alloy Aiming at High Performance Machining

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7306
Author(s):  
Xueli Song ◽  
Hongshan Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
High Performance ◽  
High Efficiency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Balanced Development ◽  
Radial Depth ◽  
The Asymmetry

In this paper, the evolutions of cutting force, cutting temperature, and surface roughness, and the corresponding machinability in asymmetric up-milling of TC25 alloy are investigated. The results indicated that radial depth of cut generated opposite influence on the cutting force/cutting temperature versus surface roughness. The reason can be accounted as the intertwining of feed marks at low radial depth of cut, and the mechanism of hard cutting at a high radial depth of cut. Moreover, the asymmetry has a significant effect on the machinability in asymmetry up-milling TC25 alloy. Changing the asymmetry, i.e., the radial depth of cut, can alter the machinability while maintain the balanced development of various indexes. The machinability reaches the best when the radial depth of cut is ae = 8 mm. The axial depth of cut and feed per tooth should be selected as large as possible to avoid work hardening and to improve machining efficiency in asymmetric up-milling TC25 alloy. The cutting speed should be controlled within Vc = 100–120 m/min to obtain better machinability. On the basis of this research, it is expected to find optimized milling parameters to realize high efficiency milling of TC25 alloy.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

An Experimental Investigation of Cutting Forces in Hard Milling of H13 Steel under Different Cooling/Lubrication Conditions

2013 ◽  
Vol 589-590 ◽  
pp. 13-18 ◽  
Author(s):  
Song Zhang ◽  
Jian Feng Li ◽  
Hong Gang Lv ◽  
Wei Dong Chen
Keyword(s):  
Cutting Forces ◽  
Essential Feature ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Depth Of Cut ◽  
H13 Steel ◽  
Hard Milling ◽  
Minimum Quantity ◽  
Radial Depth ◽  
Coated Carbide

In the present research, an attempt has been made to experimentally investigate the cutting forces in hard milling of H13 steel with coated carbide tools under dry, MQL (minimum quantity lubrication) and MQCL (minimum quantity cooling lubrication) cutting conditions. Based on Taguchis method, four-factor (cutting speed, feed per tooth, radial depth of cut, and axial depth of cut) four-level orthogonal experiments were employed. It is found that the periodical fluctuation of the cutting forces caused by the variation of the undeformed chip thickness with the entry/exit of the cutting edge is an essential feature of the hard milling process. The empirical models for cutting forces are established, and ANOVA (analysis of variance) indicates that the quadratic models can well express the relationship between cutting forces and cutting parameters.

Sign in / Sign up

Export Citation Format

Share Document