scholarly journals Experimental Investigation on Machinability of Titanium Alloy by Laser-Assisted End Milling

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1552
Author(s):  
Dong-Hyeon Kim ◽  
Choon-Man Lee
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Titanium Alloy ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Cutting Tool ◽  
End Milling ◽  
Chemical Reactivity ◽  
Depth Of Cut ◽  
Laser Assisted Machining

The Machining of titanium alloys is challenging because of their high strength, low thermal conductivity, high chemical reactivity, and high stresses at the cutting tool edges. Laser-assisted machining is an effective way to improve the machinability of titanium alloys. This paper presents an experimental investigation of the machinability of cutting force and surface roughness in laser-assisted end milling of titanium alloy Ti-6Al-4V. The absorptivity of Ti-6Al-4V was determined by conducting preheating experiments using a high-power diode laser with a wavelength of 940–980 nm. A thermal analysis was performed using the finite element method to predict temperature distribution. The depth of cut was determined where tensile strength decreased sharply, and the predicted surface temperature is presented in the analysis results. The experiments were performed with conventional machining and laser-assisted machining. Surface roughness, tool wear, and cutting force were evaluated. In contrast to the results of conventional end milling, laser-assisted end milling improved surface roughness. Moreover, laser-assisted end milling proved more effective than conventional end milling in terms of cutting tool damage. Our results proved that heat assistance significantly influenced the magnitude of the cutting forces—while the actual reduction in forces varied slightly depending on the force component, cutting tool, and cutting conditions, force components showed a reduction of roughly 13–46%.

Study on Cutting Forces and Surface Finish During End Milling of Titanium Alloy

2014 ◽  
Author(s):  
Krishnaraj Vijayan ◽  
Samsudeen Sadham ◽  
Saikumar Sangeetha ◽  
Kuppan Palaniyandi ◽  
Redouane Zitoune
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Cutting Speeds

This paper investigates numerical and experimental study of end milling of titanium alloy Ti–6% Al–4% V using carbide insert based cutting tool. The experiments were carried out under dry cutting conditions. The cutting speeds selected for the experiments are 20,30,40,50 mmin–1. The feed rates used in the experiment were 0.02, 0.04, 0.06 and 0.08 mmrev–1, while depth of cut is kept constant at 1.0 mm. For conducting the experiments single insert based cutting tool is based. For a range of cutting speeds and feeds measurements of cutting force, surface roughness and cutting temperature have been recorded. From the experimental study it can be seen that cutting speed has the significant effect on temperature when compared to feed/tooth. Further it is also found that cutting speed of 30 m min−1 and feed rate of 0.02 mm rev−1 could be used for machining Ti alloy. Moreover the experimental and numerical cutting force values are compared.

Improvement of Surface Roughness in End Milling of Ti6Al4V by Coupling RSM with Genetic Algorithm

2011 ◽  
Vol 264-265 ◽  
pp. 1154-1159
Author(s):  
Anayet Ullah Patwari ◽  
A.K.M. Nurul Amin ◽  
S. Alam
Keyword(s):  
Genetic Algorithm ◽  
Surface Roughness ◽  
Titanium Alloys ◽  
End Milling ◽  
Fitness Function ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Resistance Surface

Titanium alloys are being widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. Surface roughness is one of the most important requirements in machining of Titanium alloys. This paper describes mathematically the effect of cutting parameters on Surface roughness in end milling of Ti6Al4V. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The developed RSM is coupled as a fitness function with genetic algorithm to predict the optimum cutting conditions leading to the least surface roughness value. MATLAB 7.0 toolbox for GA is used to develop GA program. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to achieve the minimum surface roughness value.

Surface integrity in laser-assisted machining of Ti6Al4V

2020 ◽  
pp. 095440622097825
Author(s):  
O Kalantari ◽  
MM Fallah ◽  
F Jafarian ◽  
SR Hamzeloo
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Laser Source ◽  
Depth Of Cut ◽  
Thermal Source ◽  
Laser Assisted Machining

In laser-assisted machining (LAM), the laser source is focused on the workpiece as a thermal source and locally increases the workpiece temperature and makes the material soft ahead of the cutting tool so using this method, the machining forces are reduced, which causes improving the surface quality and cutting tool life. Machinability of advanced hard materials is significantly low and conventional methods do not work effectively. Therefore, utilizing an advanced method is inevitable. The product life and performance of complex parts of the leading industry depends on surface integrity. In this work, the surface integrity features including microhardness, grain size and surface roughness (Ra) and also the maximum cutting temperature were investigated experimentally in LAM of Ti-6Al-4V. According to the results, cutting speed has inverse effect on the effectiveness of LAM process because with increasing speed (15 to 63 m/min), temperature decreases (524 °C to 359 °C) and surface roughness increases (0.57 to 0.71 μm). Enhancing depth of cut and feed has direct effect on the process temperature, grain size, microhardness and surface roughness.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

scholarly journals A Study on the Laser-Assisted Machining of Carbon Fiber Reinforced Silicon Carbide

Materials ◽  
2019 ◽  
Vol 12 (13) ◽  
pp. 2061 ◽  
Author(s):  
Khulan Erdenechimeg ◽  
Ho-In Jeong ◽  
Choon-Man Lee
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Carbon Fiber ◽  
Cutting Force ◽  
Ceramic Composites ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Fiber Reinforced ◽  
Laser Assisted Machining ◽  
Carbon Fiber Reinforced

In recent years, as replacements for traditional manufacturing materials, monolithic ceramics and carbon fiber reinforced silicon carbide (C/SiC) ceramic matrix composites have seen significantly increased usage due to their superior characteristics of relatively low density, lightweight, and good high temperature mechanical properties. Demand for difficult-to-cut materials is increasing in a variety of area such as the automotive and aerospace industries, but these materials are inherently difficult to process because of their high hardness and brittleness. When difficult-to-cut materials are processed by conventional machining, tool life and quality are reduced due to the high cutting force and temperatures. Laser-assisted machining (LAM) is a method of cutting a workpiece by preheating with a laser heat source and lowering the strength of the material. LAM has been studied by many researchers, but studies on LAM of carbon–ceramic composites have been carried out by only a few researchers. This paper focuses on deducing the optimal machining parameters in the LAM of C/SiC. In this study, the Taguchi method is used to obtain the major parameters for the analysis of cutting force and surface roughness under various machining conditions. Before machining experiments, finite element analysis is performed to determine the effective depth of the cut. The cutting parameters for the LAM operation are the depth of cut, preheating temperature, feed rate, and spindle speed. The signal to noise (S/N) ratio and variance analysis (ANOVA) of the cutting force and surface roughness are analyzed, and the response optimization method is used to suggest the optimal machining parameters.

3D Numerical Investigation of Effect of Milling Process Parameters on High Speed Milling of Ti-Al6-V4

2012 ◽  
Author(s):  
J. Ma ◽  
Shuting Lei ◽  
Huaqi Lu
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Numerical Investigation ◽  
Process Parameters ◽  
High Speed ◽  
Chemical Reactivity ◽  
Milling Process ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Axial Depth

Titanium alloys are widely used in aerospace industry owing to excellent mechanical properties. While because of high chemical reactivity and low thermal conductivity, titanium alloys are classified as hard-to-cut materials. In this paper, Finite Element Method (FEM) is employed to conduct numerical investigation in the effects of milling process parameters (milling speeds, feed per tooth, and axial depth of cut) on three-dimensional (3D) high speed milling of Titanium alloy (Ti-6Al-4V). The tool material used is Carbide and Johnson-Cook plastic model is employed to model the workpiece due to its capability of modeling large strains, high strain rates, and temperature dependent visco-plasticity. Different milling speeds, feed per tooth, and axial depth of cut are used to explore the effects of the milling process parameters on the cutting temperature, cutting forces, and power required for machining. This model provides fundamental understanding of cutting mechanics of the 3D high speed milling of Titanium alloy (Ti-6Al-4V).

Monitoring of Surface Roughness Based on Cutting Force and Cutting Temperature in Ball-End Milling Process by Utilizing Response Surface Analysis

2015 ◽  
Vol 799-800 ◽  
pp. 324-328
Author(s):  
Panrawee Yaisuk ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Process ◽  
Depth Of Cut ◽  
Tool Diameter ◽  
End Milling Process

The surface roughness is monitored using the cutting force and the cutting temperature in the ball-end milling process by utilizing the response surface analysis with the Box-Behnken design. The optimum cutting condition is obtained referring to the minimum surface roughness, which is the spindle speed, the feed rate, the depth of cut, and the tool diameter. The models of cutting force ratio and the cutting temperature are proposed and developed based on the experimental results. It is understood that the surface roughness is improved with an increase in spindle speed, feed rate and depth of cut. The cutting temperature decreases with an increase in tool diameter. The model verification has showed that the experimentally obtained surface roughness model is reliable and accurate to estimate the surface roughness.

Experimental Investigation and Estimation of Surface Roughness using ANN, GMDH & MRA models in High Speed Micro End Milling of Titanium Alloy (Grade-5)

2017 ◽  
Vol 4 (2) ◽  
pp. 1019-1028 ◽  
Author(s):  
Chakradhar Bandapalli ◽  
Bharatkumar Mohanbhai Sutaria ◽  
Dhananjay Vishnuprasad Bhatt ◽  
Kundan Kumar Singh
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Titanium Alloy ◽  
High Speed ◽  
End Milling ◽  
Grade 5 ◽  
Micro End Milling
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