Effect of High Pressure Coolant on Tool Wear Phenomenon during Machining of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 826 ◽  
pp. 93-98 ◽  
Author(s):  
Pravin Pawar ◽  
Sandip Patil ◽  
Swapnil Kekade ◽  
Swapnil Pawar ◽  
Rajkumar Singh
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Machining Process ◽  
Tool Wear Mechanism ◽  
Flank Face ◽  
Titanium Alloy Ti6al4v ◽  
High Pressure Coolant

Titanium alloys are referred to difficult-to-cut materials because of its some inferior properties like low thermal conductivity and high chemical reactivity. To improve machinability of these alloys one way is to use cutting fluids which removes the heat generated at the chip tool interface during the machining process. But coolant with low pressure and improper delivery is not able to break the vapor barrier created by high cutting temperature. The present work investigates the effect of using high pressure coolant system (50 Bar) on machinability of Ti6Al4V. The machinability was measured in terms of tool wear. The dominant tool wear mechanism was investigated by using scanning electron microscopy and energy dispersive X-ray analysis of worn out cutting tool surfaces. Abrasion wear on flank face and crater wear on the rake face was observed as a dominant tool wear mechanism. Along with this diffusion of titanium from the work surface to tool face is also confirmed.

Effect of Coolant Pressure on Machinability of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 826 ◽  
pp. 82-87 ◽  
Author(s):  
Sandip Patil ◽  
Swapnil Kekade ◽  
Pravin Pawar ◽  
Swapnil Pawar ◽  
Rajkumar Singh
Keyword(s):  
Titanium Alloy ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Machining Process ◽  
Mechanism Analysis ◽  
Band Formation ◽  
Titanium Alloy Ti6al4v ◽  
High Pressure Coolant ◽  
Coolant System

Titanium alloy Ti6Al4V comes with several desirable and undesirable properties. Its low thermal conductivity and high chemical reactivity makes it difficult for machining producing high cutting temperature and adhesion tendency. Cutting fluids are used to remove the heat generated at the chip tool interface during the machining process. The coolant with low pressure and improper delivery is not able to break the vapor barrier created by high cutting temperature. The current research investigates the effect of using high pressure coolant system (60 Bar) on the machinability of Ti6Al4V. The machinability was measured in terms of chip breaking, chip thickness, surface finish, tool wear, etc. A detailed statistical and chip mechanism analysis was performed emphasizing the phenomenon of shear band formation, crack formation, chip thickness, chip serration frequency, etc.

scholarly journals Coolant boiling and cavitation wear – a new tool wear mechanism on WC tools in machining Alloy 718 with high-pressure coolant

Wear ◽  
2020 ◽  
Vol 452-453 ◽  
pp. 203284 ◽  
Author(s):  
Nageswaran Tamil Alagan ◽  
Philipp Hoier ◽  
Tomas Beno ◽  
Uta Klement ◽  
Anders Wretland
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Alloy 718 ◽  
Tool Wear Mechanism ◽  
Cavitation Wear ◽  
High Pressure Coolant

Evaluation of Thermal Effects in Turning Processes: Numerical and Experimental Approach

2019 ◽  
Author(s):  
Aruna Prabha Kolluri ◽  
Srinivasa Prasad Balla ◽  
Satya Prasad Paruchuru
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Tool Material ◽  
Maximum Error ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Abstract The 3D Finite element method (FEM) is an efficient tool to predict the variables in the cutting process, which is otherwise challenging to obtain with the experimental methods alone. The present study combines both experimental findings and finite element simulation outcomes to investigate the effect of tool material on output process variables, such as vibrations, cutting temperature distribution and tool wear mechanism. Machining of popular aerospace materials like Ti-6Al-4V and Al7075 turned with coated and uncoated tools are part of the investigation. The authors choose the orthogonal test, measured vibrations and cutting temperatures and used FE simulations to carry out the subsequent validations. This study includes the influence of the predicted heat flux and temperature distribution on the tool wear mechanism. The main aim of this study is to investigate the performance quality of uncoated and coated carbide tools along with its thermal aspects. Comparison of experiment and simulation outcomes shows good agreement with a maximum error of 9.02%. It has been noted that the increase of cutting temperature is proportional to its cutting speed. As the cutting speed increases, it is observed that vibration parameter and flank wear value also increases. Overall, coated carbide turning insert tool is the best method for metal turning with higher rotational speeds of the spindle.

scholarly journals Effects of high-pressure cooling in the flank and rake faces of WC tool on the tool wear mechanism and process conditions in turning of alloy 718

Wear ◽  
2019 ◽  
Vol 434-435 ◽  
pp. 102922 ◽  
Author(s):  
Nageswaran Tamil Alagan ◽  
Philipp Hoier ◽  
Pavel Zeman ◽  
Uta Klement ◽  
Tomas Beno ◽  
...  
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Process Conditions ◽  
Alloy 718 ◽  
Tool Wear Mechanism

scholarly journals EFFECT OF HIGH PRESSURE COOLANT JET ON CUTTING TEMPERATURE, TOOL WEAR AND SURFACE FINISH IN TURNING HARDENED (HRC 48) STEEL

2015 ◽  
Vol 45 (1) ◽  
pp. 1-6 ◽  
Author(s):  
Mozammel Mia ◽  
Nikhil Ranjan Dhar
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Cutting Forces ◽  
High Speed ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Beneficial Effects ◽  
Coated Carbide ◽  
High Pressure Coolant

Hard turning of harder material differs from conventional turning because of its larger specific cutting forces requirements. The beneficial effects of hard turning can be offset by excessive temperature generation which causes rapid tool wear or premature tool failure if the brittle cutting tools required for hard turning are not used properly. Under these considerations, the concept of high-pressure coolant (HPC) presents itself as a possible solution for high speed machining in achieving slow tool wear while maintaining cutting forces at reasonable levels, if the high pressure cooling parameters can be strategically tuned. This paper deals with an experimental investigation of some aspects of the turning process applied on hardened steel (HRC48) using coated carbide tool under high-pressure coolant, comparing it with dry cut. The results indicate that the use of high-pressure coolant leads to reduced surface roughness, delayed tool flank wear, and lower cutting temperature, while also having a minimal effect on the cutting forces.

scholarly journals Tool Wear Investigation in Dry and High Pressure Coolant Assisted Machining of Titanium Alloy Ti6Al4V with Variable α and β Volume Fraction

2016 ◽  
Vol 6 ◽  
pp. 154-159 ◽  
Author(s):  
Kamlesh Phapale ◽  
Sandip Patil ◽  
Swapnil Kekade ◽  
Shital Jadhav ◽  
Amit Powar ◽  
...  
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Volume Fraction ◽  
Titanium Alloy Ti6al4v ◽  
High Pressure Coolant

scholarly journals The Research of Tool Wear Mechanism for High-Speed Milling ADC12 Aluminum Alloy Considering the Cutting Force Effect

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1054
Author(s):  
Xinxin Meng ◽  
Youxi Lin ◽  
Shaowei Mi
Keyword(s):  
Aluminum Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Wear Mechanism ◽  
High Speed ◽  
Adhesive Wear ◽  
Cutting Parameters ◽  
High Speed Milling ◽  
Tool Wear Mechanism ◽  
Flank Face

Tool wear is a major cause of accelerated tool failure during the milling of aluminum alloy. The periodically cutting force directly affect the cutting heat and tool wear due to the intermittent cutting characteristics of the milling process. The focus of this paper is to analyze the influence of the variation of cutting force on tool wear behavior. The change law of cutting force by cutting parameters was analyzed firstly. Secondly, the variation of the wear land width (VB) of tool flank face by the milling length was analyzed. Thirdly, the wear morphology and the energy dispersive spectrometer (EDS) results of tool rake face and flank face in different cutting parameters were observed by tungsten filament scanning electron microscope. Finally, considering the cutting force effect, the tool wear mechanism during high-speed milling of Aluminum-Alloy Die Castings 12 (ADC12, 12 means aluminum number 12) was analyzed. The cutting force in tangential direction is predominant during high-speed milling aluminum alloy, which decreases gradually with the increase of cutting speed but increases gradually with the feed rising. The adhesion-oxidation wear was main wear mechanism of tool rake face during high-speed milling. While adhesive wear was the main wear mechanism of the tool flank face during high-speed milling. It is found that the formation of adhesive wear is the process from particle adhesion to melting until the formation of adhesive layer, which related to the change of cutting force.

scholarly journals The effect of applying high-pressure coolant (HPC) jet in machining of 42CrMo4 steel by uncoated carbide inserts

1970 ◽  
Vol 39 (2) ◽  
pp. 71-77 ◽  
Author(s):  
M Kamruzzaman ◽  
NR Dhar
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Product Quality ◽  
Alloy Steel ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dimensional Deviation ◽  
42Crmo4 Steel ◽  
Carbide Inserts ◽  
High Pressure Coolant

To avoid surface distortion and to improve tool life, machining of alloy steel and other hard materials under high speed-feed condition requires instant heat transfer from the work-tool interface where the intensity of cutting temperature is the maximum. Conventional cooling is completely unable and other special techniques like MQL and cryogenic cooling are not suitable in context of product quality and cost effectiveness. Supply of high-pressure coolant (HPC) with high velocity may provide the best control to reduce cutting temperature and tool wear as well as increase tool life. This paper deals with an experimental investigation on the effect of high-pressure coolant on temperature, tool wear, surface roughness and dimensional deviation in turning 42CrMo4 steel by uncoated carbide inserts and comparing it with dry condition. It is observed that the cutting temperature and tool wear is reduced, tool life is increased, surface finish is improved, and dimensional deviation is decreased with the use of high-pressure coolant. Keywords: High-pressure coolant (HPC), Alloy steel, Temperature, Wear and Product quality. doi:10.3329/jme.v39i2.1849 Journal of Mechanical Engineering, Vol. ME39, No. 2, Dec. 2008 71-77

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