Influence of Cutting Parameters and Tool Geometric Angles on TC4 Titanium Alloy Chip Shape

2012 ◽  
Vol 490-495 ◽  
pp. 3912-3915 ◽  
Author(s):  
Wei Hua Wu ◽  
Wen Min Chen ◽  
Xue Hui Wang ◽  
Can Zhao
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Cutting Parameters ◽  
Helix Angle ◽  
Rake Angle ◽  
Serrated Chip ◽  
Tc4 Titanium Alloy ◽  
Chip Shape ◽  
Radial Depth ◽  
Geometric Angles

To select reasonable cutting parameters, improve the processing surface quality, and extend the tool life, this paper uses four solid carbide end milling tools to process TC4 titanium alloy, and analyses the influence of the difference cutting parameters and the geometric angles to chip shape. The experiment results indicate that the degree of serrated chip shape is increased by increasing the feed rate under the condition of certain spindle speed. But the degree of serrated chip shape may be decreased by the adoption of small axial and radial depth, or bigger rake angle and smaller helix angle. Select larger rake angle, cutting edge is sharp, the metal deformation of cutting layer is small, which can reduce the friction force when chip flowing through the tool rake face, so that the cutting force and cutting temperature decreases accordingly.The greater the helix angle is, the worse the chip removal conditions is, and the degree of serrated chip becomes larger, the blade is more sharp, easily crack, and the tool life decreases. So relatively small helix angle is better. The choice of angles is interrelated with each other, the selection of some angle separately cannot get the desired reasonable value.

Physical Simulation of the Cutting Process Induced by Tool Geometric Angle and Cutting Parameters

2012 ◽  
Vol 430-432 ◽  
pp. 715-718 ◽  
Author(s):  
Xue Hui Wang ◽  
Ping Zhou ◽  
Ya Wen Liu ◽  
Ming Jun Dai
Keyword(s):  
Physical Simulation ◽  
Cutting Parameters ◽  
Simulation Method ◽  
Helix Angle ◽  
Rake Angle ◽  
Milling Process ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Solid Carbide

The tool geometric angle and cutting parameters have a significant influence on the titanium alloy milling process by the usage of solid carbide end mills.The physical simulation method was applied to predict the cutting force and temperature by using two comparative sets of simulation data such as the different tool gemetric angle as tool rake angle, helix angle and different cutting parameters such as spindle speed, axial depth of cut, radial depth of cut. Thus are the commonly used methods to simulate and predict the cutting process before the actual production, which can reduce product cost and time.

TC4 Titanium Alloy Surface Crack Detection and Analysis

2014 ◽  
Vol 941-944 ◽  
pp. 1922-1927
Author(s):  
Zhen Ya Chen ◽  
Xing Quan Shen ◽  
Zhi Jie Xin
Keyword(s):  
Titanium Alloy ◽  
Surface Crack ◽  
Crack Detection ◽  
Cutting Parameters ◽  
Surface Cracks ◽  
Cutting Depth ◽  
Depth Of Penetration ◽  
Penetration Testing ◽  
Tc4 Titanium Alloy ◽  
Generate Surface

The mechanism of surface cracks penetration testing are studied, as well as, the cracks’ width and depth of penetration testing formulas are given in the paper, which provide the basis for TC4 titanium alloy structure's penetration testing. The process of fluorescent penetrating testing is analyzed, and the result that detection experiments of TC4 titanium alloy structure's surface crack indicating the changes in the curvature is larger the structure is easier to produce surface cracks. The reason that the surface cracks of structure of TC4 titanium alloy is theoretical analyzed and experimental studied. In process of machining TC4 titanium, cutting parameters are important factors causing stress concentration, particularly, the larger cutting depth will generate surface cracks.

FEA Simulation of the Influence of Cutting Parameters on Serrated Chip Formation in Machining Titanium Alloy Ti-6Al-4V

2012 ◽  
Vol 500 ◽  
pp. 152-156
Author(s):  
Zeng Hui Jiang ◽  
Ji Lu Feng ◽  
Xiao Ye Deng
Keyword(s):  
Titanium Alloy ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Serrated Chip ◽  
Wide Range ◽  
Serrated Chip Formation ◽  
Fea Simulation

A finite element model of a two dimensional orthogonal cutting process is developed. The simulation uses standard finite software is able to solve complex thermo-mechanical problems. A thermo-visco-plastic model for the machined material and a rigid cutting tool were assumed. One of the main characteristic of titanium alloy is serrated shape for a wide range of cutting conditions. In order to understand the influence of cutting parameters on the chip formation when machining titanium alloy Ti-6Al-4V. The influence of the cutting speed,the cutting depth and the feed on the chip shape giving rise to segmented chips by strain localisation is respectively discussed.

Machinability Improvement for Stainless Steel AISI 304 in Turning by Applying Magnetically Damped Cutting

2013 ◽  
Vol 393 ◽  
pp. 177-182
Author(s):  
Ummu Atiqah Khairiyah B. Mohammad ◽  
A.K.M. Nurul Amin ◽  
Muammer D. Arif ◽  
Asan Gani Bin Abdul Muthalif
Keyword(s):  
Tool Life ◽  
Construction Material ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Surgical Instruments ◽  
Depth Of Cut ◽  
Serrated Chip ◽  
Vibration Data ◽  
Amplitude Data ◽  
Serrated Chip Formation

Stainless steels resistance to corrosion and staining, low maintenance and familiar luster make it an ideal material for many applications. The alloy is used in cookware, cutlery, household hardware, surgical instruments, major appliances, industrial equipment (for example, in sugar refineries) and as an automotive and aerospace structural alloy and construction material in large buildings. However, machining of this material is difficult due to high cutting force, lower tool life and high intensity of chatter related to its serrated chip formation behavior. An attempt to reduce chatter and thereby increase the tool life and surface finish by employing magnetic field during turning of the material has been made. A special fixture was designed and used to mount the permanent magnet with high power of 4500 Gauss at the bottom of the cutting tool. An accelerometer was attached at the bottom of the tool holder of 120 mm overhang and connected to the vibration data acquisition system. The vibration amplitude data were recorded at in the frequency range of 0 to 5 kHz. The recorded vibration signals were analyzed using DasyLab software (version 6). Response surface methodology (RSM) was employed in developing the chatter acceleration amplitude models in relation to primary cutting parameters: cutting speed, feed, and depth of cut. Design-expert software was applied to develop the second-order models for the two peak amplitudes observed at approximately at 1 kHz and 5 kHz and to develop the contours. The adequacy of the predictive models was verified using analysis of variance (ANOVA) at 95% confidence level.

Experimental Study on Tool Wear in Cutting Titanium Alloy Ti6Al4V

2011 ◽  
Vol 239-242 ◽  
pp. 2011-2014
Author(s):  
Yue Feng Yuan ◽  
Wu Yi Chen ◽  
Wen Ying Zhang
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Linear Regression Analysis ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Aged Condition ◽  
Cutting Depth ◽  
Solution Treated ◽  
Titanium Alloy Ti6al4v

Tool wear experiments in turning titanium alloy Ti6Al4V in the solution-treated and aged condition were carried out; the influence rules of cutting parameters such as cutting speed, feed rate and cutting depth on the tool life were obtained. Experimental formula of tool wear was regressed based on multi-variable linear regression analysis, it could predict tool life under certain conditions.

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.

Tool Life in High Speed Turning with Negative Rake Angle

2011 ◽  
Vol 264-265 ◽  
pp. 1009-1014 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz H.F. Al Hazza
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
High Speed Cutting ◽  
Life Estimation ◽  
High Speed Turning

The present work studies some aspects of turning process applied on mild steel using cermets tools at high speed cutting (1000mm/min) by using negative rake angle (0 to-12). The influence of increasing the cutting speed and negative rake angle on flank tool wear, cutting forces, feeding forces and tool temperature were analyzed. The research studies and concentrates on the tool life estimation and the effect of the negative rake angle and higher cutting speed on tool life. It was found that the maximum tool life is obtained in (-6) rake angle for the cutting parameters.

Experimental Study on Ultrasonic Vibration Drilling of Titanium Alloy Micro-Hole

2012 ◽  
Vol 588-589 ◽  
pp. 1877-1880 ◽  
Author(s):  
Zhan Feng Liu ◽  
Huan Chang Zhang
Keyword(s):  
Titanium Alloy ◽  
Ultrasonic Vibration ◽  
Cutting Parameters ◽  
Hole Drilling ◽  
Drilling Process ◽  
Basic Principles ◽  
Actual Structure ◽  
Tc4 Titanium Alloy ◽  
Micro Hole ◽  
Vibration Drilling

Through the analysis of the basic principles of vibration drilling and vibration drilling process, in the drilling device and the cutting parameter sides , combined with the actual structure of the workpiece as well as the ultrasonic vibration drilling processing methods to elaborate, using the ultrasonic vibration drilling device to carry out the TC4 titanium alloy micro-hole drilling test. The test prove that selecting reasonable cutting parameters can solve the problem of drillingTC4 titanium alloy micro-hole that size is Φ1.5mm × 12mm , fully reflects the superiority of the ultrasonic vibration drilling. A new method was afforded for titanium alloy micro-hole drilling.

Investigation of the Impact of Cutting Parameters on Surface Integrity in the End Milling of Inconel 625

2019 ◽  
Vol 969 ◽  
pp. 762-767 ◽  
Author(s):  
Ramesh Rajguru ◽  
Hari Vasudevan
Keyword(s):  
Residual Stresses ◽  
Surface Integrity ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Inconel 625 ◽  
Micro Hardness ◽  
Machined Surface ◽  
Radial Rake Angle ◽  
Radial Depth ◽  
The Impact

Nickel based super alloys, such as Inconel 625 is amongst the most difficult to machine, due to its low thermal conductivity and high strength at higher temperature. Although, they are used in aerospace exhaust systems and other applications, the strain hardening that results during the machining operation, which adversely affects surface integrity of machined surface of such materials especially in extensive applications, is a cause for concern. In this context, this study was carried out, involving the milling operation, using solid carbide tools coated with TiAlSiN, under specifically developed conditions for dry machining of the difficult to cut materials. The cutting parameters were 4 in number, namely radial rake angle, feed per tooth, cutting speed and radial depth of cut and the response parameters included surface integrity characteristics, such as residual stresses, surface roughness and micro-hardness. Based on the experimental analyses, it was found that the micro-hardness of machined surface was higher. Micro hardness of sub surface decreases with the depth (50,100,150,250μm) due to a reduction in the work hardening of the Inconel 625, underneath the surface layer. The residual stresses were analyzed using main effect plot, and it was seen that the residual stresses were significantly influenced by the radial rake angle, followed by feed per tooth.

scholarly journals An Investigation of Tool Performance in Interrupted Turning of Inconel 718

2018 ◽  
Vol 237 ◽  
pp. 02008
Author(s):  
Tadeusz Chwalczuk ◽  
Martyna Wiciak ◽  
Agata Felusiak ◽  
Piotr Kieruj
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Burr Size ◽  
Tool Performance ◽  
Interrupted Turning

The paper presents the result of an investigation of cemented carbides cutting tools performance in interrupted turning of Inconel 718. The discussion is based on case study revealed from industry experience. The spacing created for operational reasons cause interruption in turning process what has crucial effect on tool life and wear. Furthermore cutting parameters and tool geometry have significant influence on creating burr at the edge of spacing which leads dimensional deviation. The research based on two stages, preliminary and modelling, was introduced. In the first an effect of cutting speed, feed, depth of cut, rake angle and tool major cutting edge angle on wear and burr size was investigated. The second step was a regression based modelling of major parameter influence on various process aspects such as values of forces, tool wear and burr size. It was found that the consequential effect on plastic deformation of edge and tool performance have depth of cut. It also has been proven that higher cutting speed, lower values of angles provides better quality of machined element. The paper gives recommendations for turning parameters selection to acceptable burr forms, tool life and process performance.

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