Cutting Performance of Fiber Laser Textured Tools in Face Milling of Titanium Alloys

Textured self-lubricating tools were fabricated by fiber laser machining. Dry milling of titanium alloys was carried out with these textured tools and conventional one for comparison. The cutting forces, cutting temperature, surface roughness of processed workpiece and tool flank wear were measured. Results show that the textured tools can reduce the cutting forces, cutting temperature and surface roughness of workpiece, as a result, present superior wear-resistance compared to the untextured tool.

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Study of Cutting Forces and Surface Roughness in Milling of Carbon Fibre Composite (CFC) With Conventional and and Pressurized CO2 Cutting Fluids

Volume 2B: Advanced Manufacturing ◽

10.1115/imece2015-50419 ◽

2015 ◽

Author(s):

Aishah Najiah Dahnel ◽

Christopher Kibbler ◽

Stuart Barnes ◽

Helen Ascroft

Keyword(s):

Surface Roughness ◽

Carbon Fibre ◽

Cutting Forces ◽

Cutting Temperature ◽

Cutting Fluid ◽

Depth Of Cut ◽

Cutting Fluids ◽

Dry Milling ◽

Carbon Fibre Composites ◽

Cutting Speeds

Carbon Fibre Composites (CFC) are commonly used in aerospace, automotive and civil industries to manufacture high performance products which require high strength with low weight. They are usually produced to near net shape, however machining such as milling is frequently performed to achieve dimensional accuracy. This paper presents the effect of using conventional (water-based) and carbon dioxide (CO2) cutting fluids during milling of CFC on cutting forces, temperature and surface roughness in comparison to dry milling. Milling experiments were conducted using uncoated tungsten carbide milling routers at a constant feed rate and depth of cut of 0.025 mm/rev and 5 mm, respectively. Cutting speeds used were 100, 150 and 200 m/min. Cutting forces were measured using a dynamometer, temperatures during milling were measured at the workpiece by thermocouples and surface roughness (Ra) of the milled surfaces were measured using a surface profilometer. Milling with conventional and CO2 cutting fluids resulted in higher cutting forces than dry milling at all cutting speeds used. This was attributed to cooling of the CFC, which retained the strength of polymer matrix during machining. Cutting temperatures were the highest and reached beyond 100°C during dry milling. The use of conventional cutting fluid during milling provided significant cooling to the workpiece, in which cutting temperatures were maintained below 30°C at all cutting speeds used. Cooling the workpiece during milling with CO2 cutting fluid resulted in cutting temperatures within the range of 65–86°C. Even though the application of cutting fluids during milling generated higher cutting forces than dry milling, it produced favourable results in terms of surface finish. The use of cutting fluid during machining CFC is shown to be highly effective in sustaining the strength of CFC materials as a result of low cutting temperature.

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Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.382 ◽

2010 ◽

Vol 443 ◽

pp. 382-387 ◽

Cited By ~ 6

Author(s):

Somkiat Tangjitsitcharoen ◽

Suthas Ratanakuakangwan

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Cutting Forces ◽

Cutting Temperature ◽

Cutting Conditions ◽

Cutting Condition ◽

Nose Radius ◽

Dry Cutting ◽

Cnc Turning ◽

Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

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Treatment of Titanium Alloys Based on Preliminary Plastic Impact

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.836.63 ◽

2020 ◽

Vol 836 ◽

pp. 63-70

Author(s):

Vyacheslav V. Maksarov ◽

Alexander E. Efimov ◽

Taras S. Golikov

Keyword(s):

Surface Roughness ◽

Plastic Deformation ◽

Oxide Film ◽

Titanium Alloys ◽

High Temperatures ◽

Cutting Forces ◽

The Self ◽

Heterogeneous Structure ◽

Adsorption Phenomenon ◽

Tool Cutting

This paper proposed a new method for processing titanium alloys based on preliminary plastic impact. The reasons for the deterioration of the surface roughness of titanium alloys during machining are considered. This problem lies in the formation of outgrowths on tool cutting wedge, which leads to the cutting process taking place as in the titanium-titanium pair. The adsorption phenomenon leads to the fact that the outgrowth is saturated with gases from the environment, and a thick oxide film is formed. As a result, high temperatures arise during machining from 1100 to 1200°C, increasing the cutting forces P and friction Q, which introduce the technological system into an unstable self-oscillating process. The problem posed eliminated by the method of preliminary plastic deformation, which forms a local inhomogeneous structure. At the stage of processing the titanium billet, the cutting edge enters the region with a heterogeneous structure, destroying the chips and growth with an oxide film. Since most of the temperature, about 80% takes away with the chips, the amplitude of the self-oscillating process decreases, which reduces the surface roughness of the processed titanium alloys.

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Acoustic Emission Sensing of Tool Wear in Face Milling

Journal of Engineering for Industry ◽

10.1115/1.3187124 ◽

1987 ◽

Vol 109 (3) ◽

pp. 234-240 ◽

Cited By ~ 56

Author(s):

E. N. Diei ◽

D. A. Dornfeld

Keyword(s):

Acoustic Emission ◽

Tool Wear ◽

Cutting Forces ◽

Flank Wear ◽

Face Milling ◽

Processing Scheme ◽

Acoustic Emission Sensing ◽

Vertical Milling Machine ◽

Time Domain Averaging ◽

Ae Signals

Acoustic Emission (AE) signal analysis was applied to on-line sensing of tool wear in face milling. Cutting tests were conducted on a vertical milling machine. AE signals, feed and normal components of cutting force and flank wear were measured and compared. A signal processing scheme for intermittent cutting forces and AE signals, based on the concept of time domain averaging (TDA) is proposed. The results indicate that both AE and cutting forces have parameters that correlate closely with flank wear.

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The influence of cooling techniques on cutting forces and surface roughness during cryogenic machining of titanium alloys

Archives of Mechanical Technology and Materials ◽

10.1515/amtm-2016-0003 ◽

2016 ◽

Vol 36 (1) ◽

pp. 12-17 ◽

Cited By ~ 4

Author(s):

Iwona Wstawska ◽

Krzysztof Ślimak

Keyword(s):

Surface Roughness ◽

Titanium Alloys ◽

Cutting Forces ◽

Positive Influence ◽

Cryogenic Machining ◽

Specific Strength ◽

Titanium Machining ◽

Starting Point ◽

The Cost ◽

Parameter Values

Abstract Titanium alloys are one of the materials extensively used in the aerospace industry due to its excellent properties of high specific strength and corrosion resistance. On the other hand, they also present problems wherein titanium alloys are extremely difficult materials to machine. In addition, the cost associated with titanium machining is also high due to lower cutting velocities and shorter tool life. The main objective of this work is a comparison of different cooling techniques during cryogenic machining of titanium alloys. The analysis revealed that applied cooling technique has a significant influence on cutting force and surface roughness (Ra parameter) values. Furthermore, in all cases observed a positive influence of cryogenic machining on selected aspects after turning and milling of titanium alloys. This work can be also the starting point to the further research, related to the analysis of cutting forces and surface roughness during cryogenic machining of titanium alloys.

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